www8538rcom:QE&OTD Improvement Action REPORT130310_图文

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ENTECH GROUP

Entech QE&OTD Improvement Action Report

2013.03.11

目標 Targets
ENTECH GROUP

Targets for 2013:

- Quality Evaluation (QE): > 53 - On Time Delivery (OTD): > 76

品质現狀說明 QE Status Show
ENTECH GROUP

Entech 2012 QE score is: - Quality Evaluation (QE): 44

2012年验货的不良缺陷分类 The inspection defects classification for 2012 外观不良 装配不良 功能不良

Function Assembly defect 装配不良 功能不良defect 1% 11%

Cosmetic 外观不良 defect 88%

品质原因分析 Defects Causes Analysis
ENTECH GROUP

? ? ?

?
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前言:主要問題點皆為外觀不良 Majority defects were Cosmetic 自主檢驗系統未落實– Self-inspection System Needs improvements 品質判定基準不够严格—Quality Inspection Not

Strict Enough
生产管理系统不够完善—Production

Management System needs improvements

ENTECH GROUP

改善对策1 Countermeasure 1 強化自主檢驗系統 Strengthening Self-inspection System

? ?

檢驗流程方式改善 Improvement Inspection Flow
? ? ? ? ? ? ? ? ? ? ? ? 要求由作業員自我檢驗及加重其责任感 Request workers to inspect by themselves and increase their responsibility QC再次確認,如此QC自主檢驗方式才能一致性 QC to inspect again to confirm P/R時全程執行 During Pilot run, execute the above for the whole process 量產時執行於首末件 During Mass production, execute the above for the first piece & the last piece 若客訴時再執行1批, 直到客訴點消失為止 If there is customer complaint , carry out the above till the issue resolved. 若有設计變時一執行1批 If any design change, carry out the above for another lot。

ENTECH GROUP

改善对策2 Countermeasure 2 提升自我检验标准 Raise Self-inspection Level

? According to the chart, Major and Minor accounts for 50% respectively. We'll raise the level of Major and Minor to Critical and Major respectively as internal inspection standards. This way we can ensure a higher pass rate in the pre-shipment inspection. ? 根据QE值计算公式:主缺数量和次缺数量各占50分,可 将内部验货标准提升至主缺为零缺陷,保证QE分值能处 于大于50分水平。

ENTECH GROUP

改善对策3 Countermeasure 3 強化生产管理方法 Strengthening Production Management

?

To implement the Cell Manufacturing practice so as to make production planning and production management easier. 实行生产线单元式管理更便于生产安排及人员管理。 Train workers for multi-tasks

?

The aim is to train more operation staff in production/quality etc. area. 培训 多能型操作员
? Strengthening Staff Appraisal – The aim is to reward and punish impartially We‘ll retain only the skilled workers. More benefits will go to the skilled workers. 绩效管理,奖罚分明,提供工作士气。 Establish a task force and focus on the issues that occur often. PE and QE has a chart of the issues. 建立专项小组追踪客诉问题点 Set up a defects database for training and tracking the problems.建立问题点数据以作 跟进及后期培训。

? ?

QE总结 QE Conclusion
ENTECH GROUP

As shown in defects classification, without the cosmetic defects, QE score can increase to 53 or above in 2013. Improving cosmetics management has a great impact on the performance of the cosmetic defect (88% in 2012). This information proved very useful to production line managers to better understand the greatest improvements could be gained by allocating resources to focus on cosmetic checking, and in particular, the incoming quality of housings. Since these parts were experiencing more significant problems with quality improvement.

ENTECH GROUP

出货現狀說明1 OTD Status Show1 Entech delivery performance chart
Kenwood Delivery Performance Chart Time Period: Jan' 2012 - Dec' 2012 by ETD

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

M ay

ar

r

Au g

O ct

n

Fe b

Se p

ov

l

Ap

Ja

Ju

M

Ju

N

Early % <5days

On Time % = ± 5days

5days < one week % ≤11days

two weeks% + >11days

Main delay issue summary: Jan to Feb. .: manpower shortage due to CNY, but we have prepare well in 2013, manpower issue is not so serious to impact shipment performance. Mar. to Apr.: late heating element for JKP250 series, had requested Kenwood to place order on/before Dec. 2012. and Entech will prepare some buffer stock base on Kenwood’s forecast. May. /Sep./ Oct. Less leadtime Jun. to Jul. late ECSI/late LC from end customer Dec. no shipment allowed by Kenwood in last two weeks of Dec. 2012

D

ec

n.

ENTECH GROUP

出货現狀說明2 OTD Status Show 2 Entech leadtime performance chart

Kenwood Leadtime Performance Chart Time Period: Jan'2012 - Dec' 2012 by ETD

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
Jan. Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

less lead time

enough lead time

over lead time

Total 142 Pos of 2012,40 Pos less lead time.Average 26days less lead time. The standard lead time had been provide In Jul. 2013, please try best to issue the PO upon that. It will help us to improve OTD in 2013.

ENTECH GROUP

出货現狀說明3 OTD Status Show 3 Entech Top 5 sales group performance chart
TOP 5 GROUP ON TIME CHART Time Period: Jan' 2012 - Dec' 2012 by ETD

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

10 *

03 *

JK P2

JK P2

Early %

On Time %

SK M

one week %

two weeks% +

TT M

SJ M

32 *

5*

4*

ENTECH GROUP

出货現狀說明4 OTD Status Show 4 Entech sales volum by group chart

Kenwood shipment volum by group chart Time Period: Jan'2012 - Dec' 2012 by ETD
35.00% 30.00% 25.00% 20.00% 16.03% 15.00% 10.00% 5.00% 0.00% JKP24* JKP25* SJM10* SJM11* SKM03* TTM10* TTM11* TTM12* TTM13* TTM32* TTM33* TTM83* TTM92* TTM93* 4.97% 3.01% 0.38% 2.53% 1.37% 2.98% 0.77% 0.75% 1.79% 13.56% 11.39% 8.54% 31.92%

JKP25*: 74582pcs SJM10*: 37604pcs SKM03*: 31796pcs JKP24*: 26712pcs TTM32*: 20024pcs

延迟原因分析 Delay Cause Analysis
ENTECH GROUP

Kenwood shipment delay issues analysis chart Time Period: Jan'2012 - Dec' 2012 by ETD
40.00% 35.00% 30.00% 25.00% 20.00% 15.00% 10.00% 5.00% 0.00% customer issue material quality labor operation

37.29% 23.73% 10.17%

22.03%

6.78%

Customer issues: 13 orders, late consign power cord for JKP240J/ Late ECSI for new market(Finland/Nigeria)/ Late LC for (Korea market)/low volum and need to consolidate shipment Material issues: 22orders, Entech will prepare some buffer stock base on Kenwood’s forecast for the component which crop up frequently. Labor issue: 14 orders, Entech had foresee manpower shortage due to CNY and prepare well in 2013, it won’t be a serious issue to impact shipment performance in 2013.

改善对策 Countermeasure
ENTECH GROUP

? ?

Customer issues - Strength communication with Customer on ECSI/PO/international standard issues. Material issues - Entech will prepare some buffer stock base on Kenwood’s forecast for the component which crop up frequently. Labor issues - To dispense reward and punishment impartially and more benefits will go to the skilled workers, in order retain the skilled workers. Operation issues - To improve Abnormal Feedback Effectiveness ? Add IQC Function in the engineer stage ? 依棧板進行抽驗AQL0.40%,重點著重於搭配性功能與外觀 ? According to pallet have select inspect AQL0.40%,the focal point is collocation function and cosmetic ? IQC批退時,立即開單並知會該產線之課級幹部與QE,決定重工流程 ? While IQC reject the incoming goods, They should fill in the list and inform the manager of product line and QE immediately and to determine rework flow

?

?

改善对策 Countermeasure Abnormal Feedback flow chart
ENTECH GROUP

作業員 Operater

PQC,班長 10分鐘內可決定 對策 PQC,Monitor make a countermeasure in 10 minute

執行 Carry out

PQC Affirm

QE,班長 20分鐘內可決定 對策QE,Monitor make
a countermeasure in 20 minute

執行 Carry out

PQC,QE Affirm

生产经理 召集相關人員 Manager summon member

執行 Carry out

生产经理,PQC,QE確認
Manager ,PQC,QE Affirm

OTD总结 OTD Conclusion
ENTECH GROUP

As shown in above charts if we solve the customer issue and operation issue, OTD score can be increased to 76 or above in 2013. Improving late material issue (37.29% in 2012) has a great impact on the OTD. This information proved very useful to purchasing and PMC managers to better understand the greatest improvements could be gained by coordination between material and production plan, and in particular, the incoming quality of heating element for water kettle and guard net for toaster. Since these parts were experiencing more significant problems with OTD improvement.

ENTECH GROUP

Thank you!


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