General Micro Electronics (GME) Inc

8/12/2019 General Micro Electronics (GME) Inc

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Introduction

A new wire bonding machine was purchased

and installed in January.

The company has marketed their product as

better than military standards.

The company top management are very

insistent on quality which is a good sign.


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Problems

The machine has started to behave erratically.

If this continues it will fail to deliver.

No proper initial analysis done by Regan.


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Problems continued

Quality problems cropping up in customer

side.

They cannot increase capacity of their entire

operation this plant is needed to ensure that

they can deliver to customers.


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GME standards

The company has maintained good quality.

That is when the Military only requires 4grams of break force they continue to produce

with 7 grams of break force.

Fewer than 10 ppm fail.


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Situation in quality checks

GME quality checks are manual they are not

automated.

The management reasons that it is done in all

other companies of their size.


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CAN THEY DO IT?


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Capability

They can produce quality goods.

They can meet their own quality standards.

Although their quality standards are much

more than required.


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Findings

However in the sample observation that was

conducted 80 of 1008 wire connections failed

the test.

Although most are spread in 5 particular

Samples it is still a matter of concern.


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The real problem

Their machines seems to give products they

are not uniform in nature even the ones close

to each other seem to be far apart.

The standard deviation in each sample is too

high and this is posing a great threat to the

quality of the product.


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0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

1 4 710

13

16

19

22

25

28

31

34

37

40

43

46

49

52

55

58

61

64

67

70

73

76

79

82

85

88

91

94

97

100

103

106

109

112

115

118

121

124

Std Deviation of Observation of each sample

Std Deviation


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Some of the worst cases


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Why was it bad?

The red ones point to some of the most erratic

behaviour in the same sample.

The yellow ones represent the worst as a

sample.


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What is it that we want?

We want high averages and low standard

deviation.

To do this we need Design of Experiments.


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4 Factors

Temperature.

Force.

Time.

Power.


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The effects


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What did we see?

Temperature was the most influential of all

the factors.

Followed by force.


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Recommendations


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Why?

They offer high average and low standard

deviation.

In fact combination 6 is the best by far

offering lowest standard deviation with high

average but it takes twice the amount of time

as combination 2 does.


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Conclusion

Choose Combination 2.

Verify it by increasing number of quality checksfor the next 2 months.

Maintain log of the settings used from here on forall the machines and maintain statistical data onall machines even if they are running well.

If possible repeat this with at least 3 options in

each factor to get a better idea on the wholeproblem and consider this for future problems as

well.


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THANK YOU

General Micro Electronics (GME) Inc

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