DAT 475 Module Three Project One_Miguel_Ortiz_Paonessa
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475
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Industrial Engineering
Date
Apr 3, 2024
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docx
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Uploaded by MajorClover12242
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Miguel Ortiz Paonessa
DAT 475
Module Three: Project One
Instructor: Lee E. Edwards, MS
Sunday, January 28, 2024
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In Tijuana, Mexico, a manufacturing company specializing in electronic boards is grappling with quality challenges amidst rising product demand. Their production process, consisting of component placement, wave soldering, and thorough quality inspections, has been blemished by an increase in various welding defects. These defects, ranging from solder bridges to component misalignments, have significantly impacted the post-assembly quality of the boards. To adhere to the stringent IPC-A-610E quality standards and address the escalating cost concerns of post-production corrections, the company is compelled to tackle these defects head-
on.
The company's strategic response involves two key objectives: achieving a 20% reduction in welding defects and enhancing the capacity of their production lines by 20% without exacerbating the defect rates. This dual approach underscores the imperative to not only enhance production efficiency but also to ensure the consistent quality of the electronic boards. The resolution of these manufacturing issues is critical for the company to meet its quality standards and maintain its operational efficiency in the face of increasing demand.
I will provide 2 key findings. The first findings will be done through Pareto Chart Insights
: The analysis will reveal that specific defects, including component misalignment, billboarding, and bad modules, dominate the defect spectrum. These defects are critical focal points for improvement strategies.
The second key finding will be set as Root Cause Analysis
: A fishbone diagram pinpointing potential causes across six domains: Materials, Methods, Machines, Manpower, Measurement, and Environmental Factors
. Each domain offers insight into underlying issues and guides targeted improvement measures.
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Figure 1: Pareto Chart - Number of Defects based on Defect Types - Model 595310-001-00
The dominant defect on this chart is 'Excessive Solder', followed by 'Solder Bridge', and 'Damaged Component'. These top three defects account for a substantial portion of the total, with
'Excessive Solder' alone constituting a significant percentage. This suggests that issues in solder application and component handling are critical areas for improvement in this model.
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Figure 2: Pareto Chart - Number of Defects based on Defect Types - Model 595481-00x-00
Similar to the first chart, 'Solder Bridge' and 'Missing Component' are among the top defects, with 'Excessive Solder' again being the most frequent. The persistence of 'Excessive Solder' across models indicates a systemic problem in the soldering process.
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Figure 3: Pareto Chart - Number of Defects based on Defect Types - Model 595407-xxx-00
In this chart, 'Solder Bridge' is the most common defect, followed closely by 'Missing Component' and 'Lifted Component'. The shift in the most frequent defect type might point to model-specific issues or variances in the assembly or inspection process.
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Figure 4: Pareto Chart - Number of defects based on defect types - Entire Facility
When looking at the facility as a whole, 'Excessive Solder' and 'Solder Bridge' remain the
top issues, reinforcing the need for a process-wide evaluation of soldering techniques and quality
control measures.
Analyzing the four Pareto charts, they display the frequency and cumulative impact of different defect types found in the manufacturing process for three specific model numbers and the entire facility. Common across the charts is the prominence of defects such as 'Excessive Solder,' 'Solder Bridge,' and 'Missing Component,' which are prevalent and therefore key areas to
focus on for quality improvement.
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The defects follow a similar distribution pattern across the different model numbers, with 'Excessive Solder' being the most frequent defect. The similarity suggests systemic issues in the manufacturing process that are consistent across different product lines. The entire facility chart confirms the trend and implies that the problems are widespread, not isolated to specific models.
In line with the case study's objectives, addressing the top defects can significantly reduce the overall defect rate by following the Pareto principle (80/20 rule), which suggests that most problems (80%) are often due to a small number of causes (20%). Focusing on these top defects aligns with the company's goal of reducing defects by 20% and increasing capacity without a corresponding increase in defect rates.
In conclusion, the analysis suggests that focusing corrective actions on soldering practices and component handling could lead to significant improvements in quality. These findings should guide targeted process improvements and training efforts to reduce defects and meet the project's
goals.
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Figure 5: Fishbone diagram
In the fishbone diagram, each category's relationship to welding defects and potential solutions is more deeply explored:
Methods
: This includes the procedures and techniques used in soldering. For instance, improper soldering technique can lead to 'Excessive Solder' or 'Solder Bridges'. Refining these methods through updated training or revising SOPs can directly reduce these defects.
Manpower
: The skill and attention of the workforce directly influence defect rates. Lack of training or fatigue from overwork can result in mistakes. Enhancing training programs, ensuring adequate rest, and providing ongoing skill development can significantly improve quality.
Machines
: Faulty or poorly calibrated equipment can cause consistent defects. For example, a soldering machine that applies too much solder or operates at incorrect temperatures can lead to 'Excessive Solder'. Regular maintenance and calibration of machines are key solutions.
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Materials
: The quality of solder and components used in production directly affects the final product. Low-quality solder might not adhere properly, leading to defects. Implementing stricter quality control measures for materials can ensure higher product quality.
Measurements
: The accuracy of quality control measures determines how well defects are identified and addressed. Inadequate measurement tools might miss 'Solder Bridges'. Investing in
more precise measurement tools and refining quality metrics can improve defect detection.
Environment
: Conditions like temperature and humidity can affect soldering quality. An environment that's too humid, for instance, can impact soldering processes. Controlling these environmental factors more effectively can reduce related defects.
By analyzing these categories, specific interventions can be designed to target and reduce
the most frequent welding defects, leading to overall process improvement.
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Resources:
Fishbone diagram
. Fishbone Diagram - MN Dept. of Health. (2022, October 26). https://www.health.state.mn.us/communities/practice/resources/phqitoolbox/fishbone.html
DAT 475 Project Case Study