BỘ GIÁO DỤC VÀ ĐÀO TẠO TRƯỜNG ĐẠI HỌC SƯ PHẠM KỸ THUẬT THÀNH PHỐ HỒ CHÍ MINH ĐỒ ÁN TỐT NGHIỆP NGÀNH QUẢN LÝ CÔNG NGHIỆP APPLYING DMAIC METHOD TO REDUCE SETUP TIME of M8326 PRODUCT in MEDICAL LINE at II-VI VIETNAM CO,.LTD GVHD: NGUYEN THI MAI TRAM SVTH: NGUYEN THI KIM PHUNG MSSV: 16124056 SKL 0 0 7 0 0 9 Tp. Hồ Chí Minh, 2020 do an MINISTRY OF EDUCATION AND TRAINING HO CHI MINH UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF HIGH QUALITY TRAINING GRADUATE THESIS APPLYING DMAIC METHOD TO REDUCE SETUP TIME of M8326 PRODUCT in MEDICAL LINE at II-VI VIETNAM CO,.LTD Student’s name : Nguyen Thi Kim Phung Student code : 16124056 Grade : 2016 Major : Industrial Management Instructor : MI. Nguyen Thi Mai Tram Ho Chi Minh – 2020 do an Supervisor: Nguyen Thi Mai Tram SUPERVISOR ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- Ho Chi Minh,……………………………………. Supervisor do an Supervisor: Nguyen Thi Mai Tram do an Supervisor: Nguyen Thi Mai Tram REVIEWER ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- Ho Chi Minh,…………………………………….
Reviewer do an Supervisor: Nguyen Thi Mai Tram ACKNOWLEDGEMENT It was my fortune to have an internship in II-VI Vietnam as well as great chance for learning and professional development in II-VI Vietnam. Being a part of company, I experienced and worked with many professional and kindly people who led me though this internship period with many lessons. I also have hearty thanks for Ms. Nguyen Thi Mai Tram to support placing my thesis on good grade for her careful and precious guidance in graduate thesis which were extremely valuable for my study both theoretically and practically.
I express my deepest thanks to Mr. Ha Hai Hung – CI manager, Mr.Huynh Anh Tuan - manager of System for taking part in useful decision, giving necessary advices and guidance and arranged all facilities to make project easier. I choose this moment to acknowledge his contribution gratefully. Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks to the my mentor Mr.Van Quoc Tien – Production Engineer who in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my project at their esteemed organization and extending during the training.
I also appreciate the supporting from engineers, line leaders and operators in System to finish the project. I perceive as this opportunity as a big milestone in my career development in Industrial Engineering. I will strive to use gained skills and knowledge in the best possible way, and I will continue to work on their improvement, in order to attain desired career objectives. Hope to continue cooperation with all of you in the future.
Sincerely, Nguyen Thi Kim Phung Ho Chi Minh May 5th 2020 Nguyen Thi Kim Phung - 16124056 i do an Supervisor: Nguyen Thi Mai Tram LIST OF ABBREVIATIONS ABBREVIATIONS DESCRIPTION PROJECT The project applying DMAIC to reduce setup time of M8326 in System SU time Set-up time CO time Change-over time WO Work order number Traveler Instructions that follows a part in a manufacturing process. Medical line Production line with products applied in medical area and have similar procedure. Other line The rest of line in System factory DMAIC The methodology is applied in solving problems in lean six-sigma 5M1E 5M1E Method (Man, Machine, Materials, Method, Measure and Environment) 5W1H The problem statement by What – Why – When – Where – Who and How much or How many Nguyen Thi Kim Phung - 16124056 ii do an Supervisor: Nguyen Thi Mai Tram LIST OF TABLES Table 1 Traveler of Medical products in System .17 Table 2 Traveler of Other products (Introduction of System of II-VI Vietnam) .18 Table 3 Tools applicationin project (Synthesize by author) .29 Table 4 Focused Problem Statement 1 as 5W1H .56 Table 5 Focused Problem Statement 2 as 5W1H .57 Table 6 Focused Problem Statement 3 as 5W1H .57 Table 7 Potential causes for long setup time at FPS1 Assembly stage of M8326 .59 Table 8 Potential causes for long setup time at FPS2 Inspection stage of M8326.59 Table 9 Potential causes for long setup time at FPS3 Preparation stage of M8326.60 Table 10 Improvement idea for root causes summarisation .68 Table 11 Prioritisation Matrix for solutions .70 Table 12 Build Action Plan for reducing setup time M8326 (Source: Synthesize by author) .72 Nguyen Thi Kim Phung - 16124056 iii do an Supervisor: Nguyen Thi Mai Tram LIST OF FIGURES Figure 1 Network of II-VI Incorporated worldwide .3 Figure 2 Periodic Table .4 Figure 3 Group II-VI Logo .5 Figure 4 Logo of II-VI Vietnam Co.7 Figure 5 Products for Automotive .8 Figure 6 Products Thermal-electric Cooler (TEC) (Introduction of System of II-VI Vietnam) .9 Figure 7 Product Select Comfort .9 Figure 8 Gesture Recognition products .10 Figure 9 Product for DNA test .10 Figure 10 Application of Thermal-electric Cooler (TEC).11 Figure 11 General organization chart of II-VI Vietnam Co.11 Figure 12 Production process diagram at II-VI Vietnam Co.14 Figure 13 System Organization of II-VI Vietnam Co.15 Figure 14 Change-over time (Downtime here) .20 Figure 15 Story board of DMAIC project .23 Figure 16 Prioritization Matrix.27 Figure 17 Histrogram chart .29 Figure 18 The Pareto chart illustration .30 Figure 19 Process mapping symbols .34 Figure 20 Setup time per unit by module of Medical line.37 Figure 21 Forecast of quantity for Medical line in 6 months (June – December, 2020) .38 Figure 22 Forecast of setup time for Medical line in next 6 months (June – December,2020) .38 Figure 23 Timer series plot setup time per unit of M8326 by WO (October- December, 2019) (Source: Synthesize by author) .39 Figure 24 Voice of customer and Critical to quality Matrix Diagram .39 Figure 25 Is & Is not Matrix for problem statement .40 Figure 26 Time series plot setup time of target setting .40 Figure 27 Total hour deduction for setup time improvement .42 Figure 28 Timeline for setup time improvement project .42 Figure 29 Project charter of setup time improvement project .44 Nguyen Thi Kim Phung - 16124056 iv do an Supervisor: Nguyen Thi Mai Tram Figure 30 Process mapping of setup operation of M8326 at Preparation (retainer 1) .45 Figure 31 Process mapping of setup operation of M8326 at Preparation (retainer well block) .46 Figure 32 Process mapping of setup operation of M8326 at Preparation (retainer 2) .46 Figure 33 Process mapping of setup operation of M8326 at Assembly (Solder and cleaning) .47 Figure 34 Process mapping of setup operation of M8326 at Assembly (In-Inspection) .47 Figure 35 Process mapping of setup operation of M8326 at Assembly (Assemble heatsink) .48 Figure 36 Process mapping of setup operation of M8326 at Assembly (Assemble board) .48 Figure 37 Process mapping of setup operation of M8326 at Test .49 Figure 38 Process mapping of setup operation of M8326 at Inspection .49 Figure 39 Identify stratification criteria: Criteria 1 Type of Setup .50 Figure 40 Identify stratification criteria: Criteria 2 Setup at Stage .50 Figure 41 Collection data form (used at Final Inspection stage).51 Figure 42 Diagnostic Report (One-Way ANOVA for Types of Setup) .52 Figure 43 Summary Report (One-Way ANOVA for Types of Setup).52 Figure 44 Diagnostic Report (One-Way ANOVA for Setup at Stage) .53 Figure 45 Summary Report (One-Way ANOVA for Setup at Stage) .53 Figure 46 Setup time per unit of M8326 by Stage .53 Figure 47 Process of capability of Setup at Stage of M8326 .54 Figure 48 New specification control for Setup at stage .55 Figure 49 Complexity for each priority issue .55 Figure 50 Tree diagram to achieve target .56 Figure 51 Potential causes for long setup time at Assembly stage of M8326.61 Figure 52 Potential causes for long setup time at Inspection stage of M8326 .61 Figure 53 Potential causes for long setup time at Preparation stage of M8326 .61 Figure 54 Prioritization Matrix of potential causes for setup time of M8326 .63 Figure 55 5Whys for root causes of preparing cleaning tools .63 Figure 56 5Whys for root causes of calibration .64 Figure 57 5Whys for root causes of unpacking wraps of materials .64 Figure 58 5Whys for root causes of carrying materials from pass box to production position .65 Nguyen Thi Kim Phung - 16124056 v do an Supervisor: Nguyen Thi Mai Tram Figure 59 5Whys for root causes of opening BOM report .65 Figure 60 5Whys for root causes of finding code of events .66 Figure 61 5Whys for root causes of getting hand tools .66 Figure 62 Impact – Effort Matrix for priority solutions .71 Figure 63 Time for carrying heatsink at Assembly stage .74 Figure 64 Trolley for transporting heatsink before improvement.75 Figure 65 Trolley for transporting heatsink after improvemnt.75 Figure 66 Time for carying materials per unit at Preparation stage .76 Figure 67 Calibration time series plot at Inspection stage .77 Figure 68 Bar code card before improvement .78 Figure 69 Bar code card after improvement .78 Figure 70 Time series plot of scan labor time per unit .78 Figure 71 Check sheet for ouliers of setup M8326 after improvement.80 Nguyen Thi Kim Phung - 16124056 vi do an Supervisor: Nguyen Thi Mai Tram LIST OF APPENDIX Appendix 1 I-MR Chart of setup time of M8326 for Overall process .85 Appendix 2 Process Capability Report for setup time of M8326 for Overall process .85 Appendix 3 I-MR Chart of setup time of M8326 at Preparation Stage .86 Appendix 4 Process Capability Report for setup time of M8326 at Preparation stage 86 Appendix 5 I-MR Chart of setup time of M8326 at Assembly stage.87 Appendix 6 Process Capability Report for setup time of M8326 at Assembly stage .87 Appendix 7 I-MR Chart of setup time of M8326 at Inspection stage.88 Appendix 8 Process Capability Report for setup time of M8326 at Inspection stage.88 Nguyen Thi Kim Phung - 16124056 vii do an Supervisor: Nguyen Thi Mai Tram TABLE OF CONTENTS SUPERVISOR. i LIST OF ABBREVIATIONS.
ii LIST OF TABLES. iii LIST OF FIGURES. iv TABLE OF CONTENTS. Research Objectives and Scope.
Organization of thesis .4 INTRODUCTION OF II-VI INCORPORATED .1 Introduction of II-VI Incorporated.2 The company name.4 Quality mission statement.2 Introduction of II-VI Vietnam .1 History of company II-VI Vietnam.2 Logo II-VI Vietnam.3 Vision, Mission, The Core Value, Quality policy .3 The core value.4 Areas of Activities and Products .1 Areas of activity.5 The Organization of II-VI Viet Nam.6 Production process at company.14 Nguyen Thi Kim Phung - 16124056 viii do an Supervisor: Nguyen Thi Mai Tram 1.7 Introduction of System Factory .1 Overview of the system department .2 Functional department in System. Production process in System. Production process in Medical line. Production process in Other lines .1 Background of Setup .1 Set-up time: .2 Change-over time definition .3 Reducing non-valued time .3 Tools in DMAIC .5 Is & Is not.35 DEFINING, MEASURING AND ANALYSING .1 Scope and Problems Definition .2 Current Situation and Target setting (VOC, CTQ.3 Initial Financial benefit Evaluation .1 Detailed Process Mapping .2 Identify stratification criteria .51 Nguyen Thi Kim Phung - 16124056 ix do an Supervisor: Nguyen Thi Mai Tram 3.5 Stability and Capability Study .6 Complexity for each priority issue .7 Tree diagram to achieve target .8 Focused Problem Statement .9 Confirm specific target for each FPS .1 List potential causes .2 Group similar causes .3 Prioritization of potential cause .4 Root cause verification plan.63 IMPROVING AND CONTROLLING SUGGESTIONS .1 Root cause verification plan .2 Priorities and select solutions.3 Build Action Plan .5 Verify Target Achievement .2 Training the teams.85 Nguyen Thi Kim Phung - 16124056 x do an Supervisor: Nguyen Thi Mai Tram INTRODUCTION 1.