Cycle time Reduction

Define

FLOW DIAGRAM OF ORIGIN

Team Charter

Project Title: Cycle time in Origin Lines to be reduced from 2.65 to 2.4 secBusiness CaseOpportunity StatementThis Project Support the corporate strategic objectives of fulfilling & enhancing customer satisfaction by Delivery of Product on time with low cost, which directly impacting the business volumes and hence our market share.Pain:- Currently Avg. cycle time of three months is March- May 09 is 2.65 secs.Opportunity :- there is an opportunity to reduce this cycle time from 2.65 sec. To 2.4 secs.Gain:- This Project Benefit to company approximately 1.6 million INR (Realized)Goal statement Project scope Metric Current levelGoal / TargetTarget date Process under improvement::Origin Lines 16X+/- R Process of plant-01 & 02 of Greater Noida (U.P)Starts with: Dried PC from Piovan Ends with Receiver table Cycle time 2.65sec 2.4 sec / productivity above ABP 25th Jan-10Project Schedule Team SelectionPhaseStart EndRemarks Define01/06/0920/06/09 CompletedChampion: Dr. J.S. Bist(HOD Process Engg. Cell)Measure21/06/0918/07/09 CompletedGB : Pankaj Kumar Analyze 20/07/0915/08/09CompletedMember: B.C. Bhatt ,R.A. Churasia (Maint.) Amit Shrivastava , Hemant Sharma,Bijendra Kumar(Production),Ashif (IMM)B.K Agarwal(maint.),Ganesh sati (Quality),Biswas (IMM Maint.)Improve 16/08/0917/09/09Completed

Control 19/09/0925.01.2010Completed

Mechanical parameterMechanical parameterMechanical parameterElectrical parameterDown grading trend of electrical & mechanical parametersBeforeAfterBeforeBeforeBeforeAfterAfterAfter

Critical to Quality and Critical to Process Chart

Voice of business Business issuesCritical business requirementCritical to process

Timely Delivery of Product With Low cost price Low CRDDProductivity should meet ABP targetCycle time

Business Opportunity

Project Title: Cycle time in Origin Lines to be reduced from 2.65 sec to 2.4 sec

Opportunity Customer ImpactBusiness impact Monthly production lagging behind ABP target (Origin Lines).

Increase in Customer satisfaction by timely delivery of productHigh ProductivityImprovement in CRDDIncrease in Market shareEfficient utilization of Man & machineLow CRDDLoyalty will improveCost saving: Rs 1.6 million INR

Project Benefit: Initial estimate / COPQ: INRINTANGIBLE BENEFIT :Customer satisfaction will increased as their requirements will be meet on time.

TANGIBLE BENEFIT :

SIPOC DIAGRAMDVDR Manufacturing (Optical Media Group)Starting point: Dried PC from PiovanEnd point: Receiver table

SupplierInputsProcessOutputsCustomersPiovanPoly Carbonate (Bayer &.Panlite Dried PC from Piovan

DVD-R 16X + / -R

ProductionStore MBILStamperIMMMask & TargetCoolingBonding GlueDye CoatingEdge washingDye LabDye (16X TFP based)PrintingMethyl LactateAnnealingQC1 scanningSputteringBonding & U.V. CuringQC2 scanningReceiver table

Top Down chart for Process

Starting point: Dried PC from Piovan(Poly Carbonate treatment 124 deg cent/4hrs)End point: Receiver table MANUFACTURE DVDR (16X+/-R) DISCS IMM Cooling Dye Coating Edge washing

C

*

Top Down chart for Process MANUFACTURE DVDR (16X+/-R) DISCS Printer Annealing Qc1 Scanner Metallizer

CC

*

Top Down chart for Process MANUFACTURE DVDR (16X+/-R) DISCS Bonding&U.V. curing QC2 scannerFinal disc to Receiver

C

*

Functional Deployment Chart

Functional Deployment Chart

Sheet1

Sub process/Deptt.Production/Process/IMM Maint.Quality

Project chater

ParticularsValueUnit

ABP production Target from sep - 09 to mar -10204.07Nos

Estimated production After completion from sep-09 to mar 10 (32 Lines)219.13Nos

projected Increased in prodution on 32 origin lines15.07Nos

projected Annual saving in production on 32 Origin lines with reference to ABP target39.17INR

ApprovalsNameSignature

Project Leader NameAshif Akhtar

Date06.08.09

Champion NameDr. J.S Bist

Date06.08.09

Finance Namesanjeev/panda

Date06.08.09

costing

Cycle Time project in Origin Lines from 2.65 sec to 2.4 sec.

30313031312831

Apr-09May-09Jun-09Jul-09Aug-09Sep-09Oct-09Nov-09Dec-09Jan-10Feb-10Mar-10

Cycle time as per ABP2.652.642.622.612.602.582.572.552.542.532.512.50

OEE as per ABP89.00%89.09%89.18%89.27%89.36%89.45%89.55%89.64%89.73%89.82%89.91%90.00%

Production/Line as per ABP Plan29017291972937929563297482967529809299443002173022173035530494

Production/Line as per Project benefit32204322363226932302323353236732400

Variance/per day/line2529242823252222211720121906

Gain with 32 Lines /month2427918240818622321822204044210054418029091890635

ABP in Min28.4929.5728.7529.8429.9827.230.25

Projected Prodn.30.9231.9830.9832.0432.082932.14

Total gain in million15.07

gain in terms of saving39.17

Qualitative analysisProject Title: Cycle time in Origin Lines to be reduced from 2.65 sec to 2.4 sec

Qualitative analysis

Quick winsProject title: Cycle time in Origin Lines to be reduced from 2.65 sec to 2.4 sec

Sheet1

Sheet2

SOURCECONCERN/ISSUEPOTENTIAL QUICKWIN OPPORTUNITY(SOLUTION)EASY TO IMPLEMENTFAST TO IMPLEMENTCHEAP TO IMPLEMENTWITH IN THE TEAM CONTROLEASY REVERSIBLEIMPLEMENT (Y/N)

Funtional DeploymentIMM cycle Time is highTo reduced Robot Kick Rtn. Time from 120 to 90 secs.YYYYYYes

Bonding Time is highTo reduced Dispence Time & Spinning TimeYYYNYNO

To reduced Bonding stage disc travelling timeNYYNYNO

To reduced Feeding robot home positionNYYNNNO

Dye conveyor belt speed/carry arm speed/handler speed/feeding robot speed/cooler I/O put handler speed & dryer I/O handler speed is lowTo reduced Servo motor & Drive speedNYYNYNO

Sheet3

Quick wins implementation Plan

Sheet1

S.NO.Quick winsActivitiesResponsibility PersonStart dateTarget date of completionActual date of completion

1Robot kick Rtn. TimeReduced Robot kick Rtn from 120 to 90 sec.Ashif6/19/096/24/096/27/09

Sheet2

Sheet3

Sheet1

S.NO.Quick winsQuick win implementationResponsibility Personinitial CTGaincycle time after impletionRemarks

1Robot kick Rtn. TimeReduced Robot kick Rtn from 120 to 90 sec.Ashif2.65 sec0.05 sec2.60 secsetting implemented across all lines

S.NO.Quick winsActivitiesResponsibility PersonStart dateTarget date of completionActual date of completionStandardization of completion

1Robot kick Rtn. TimeReduced Robot kick Rtn from 120 to 90 sec.Ashif/sandeep3/19/093/24/093/27/09setting implemented across all lines

Sheet2

Sheet3

MBD00054B1A.xls

Sheet1

S. No.Quick WinsActivitiesResponsibilities personResponsibilities personStart dateTarget date of completionActual date completionStandardization of Completion

1Robot Kick Rtn. Time,Robot entry pos.w.r.t mold gap & mold open/close time.Reduced kick Rtn.time 120msec to 90msec,Reduced gapping between Robot entry pos.w.r.t mold as per m/c & also open/close speed increased from 90% to 99%Ashif/ sandeepSandeep/Ashif19-03-0924-03-0927-03-09setting implented across all lines

2Bonding dispence Time,spinning time & Step time Reduced.Glue dispense time Reduced from 0.9 to 0.75 sec.,New spinning profile design & Bonding step 4 & 7 time reduced from 0.65 sec. To 0.6 sec.& step 10 time reduced from 1.2 to 1.0 sec.AmitAmit/hemant/Bijender20-03-0926-03-0930-03-09Technical Report published

3Bonding stage disc travelling timeTravel time Bottom disc head at bonding stage reduce by reducing effective distt. Between top & bottom head from 24mm to 22mm (providing additional spacer of 2mm thickness)BC Bhatt19-03-0930-03-092/4/09setting implented across all lines

4Feeding robot home positionFeeding robot home position change from center of walking unit to above dummy side walking unit.BC Bhatt19-03-0930-03-092/4/09setting implented across all lines

5speed of servo motors & drive(dye conv.belt speed,carry arm speed,handler speed,feeding robot speed,cooler I/p & o/p handler speed & dryer inlet & outlet arm speed)servo motor/drive motor speed increased.BC Bhatt20-03-0929-03-091/4/09setting implented across all lines

Sheet1 (2)

S. No.Quick WinsQuick Win implementationResponsibilities personResponsibilities personinitial cycle TimeGaincycle time after implementationRemarks

1Robot Kick Rtn. Time,Robot entry pos.w.r.t mold gap & mold open/close time.Reduced kick Rtn.time 120msec to 90msec,Reduced gapping between Robot entry pos.w.r.t mold as per m/c & also open/close speed increased from 90% to 99%Ashif/ sandeepSandeep/Ashif2.65 sec0.05 sec2.60 sec

2Bonding timeGlue dispense time Reduced from 0.9 to 0.75 sec.,New spinning profile design & Bonding step 4 & 7 time reduced from 0.65 sec. To 0.6 sec.& step 10 time reduced from 1.2 to 1.0 sec.AmitAmit/hemant/Bijender2.65 sec0.3 sec2.35 sec

Travel time Bottom disc head at bonding stage reduce by reducing effective distt. Between top & bottom head from 24mm to 22mm (providing additional spacer of 2mm thickness)

Feeding robot home position change from center of walking unit to above dummy side walking unit.

3speed of servo motors & drive(dye conv.belt speed,carry arm speed,handler speed,feeding robot speed,cooler I/p & o/p handler speed & dryer inlet & outlet arm speed)servo motor/drive motor speed increased.BC Bhatt2.65 sec0.3 sec2.35 seccooler & Bonding section Area cycletime Reduced to 2.35 sec

Sheet3

COOLER 2.65SecDYE COATER /EDGE WASHING 2.65SecPRINTERMETALLIZER 2.65SecBONDING 2.65SecQ.C. 2 (Final Scanner)IMM--2.65SecQ. C. 1ANNEALING2.65SecPROCESS FLOW DIAGRAM OF ORIGIN LINE AT 2.65 sec(Before Quick win)

*The Slide Template The company logo should come on the right-hand side of each slide (as per the given format) FONTSTitle- 28 points of Arial/ Verdana/TrebuchetSubtitle - 24 points of chosen fontBody - Text colour-Black: 18 point

Use at least 18 pt. font size. Smaller sizes get too grainy and difficult to read when projectedonto a large screen.

CHARTSUse Times New Roman font for Legends with 12 or 14 points

COOLER 2.65SecDYE COATER /EDGE WASHING 2.65SecPRINTERMETALLIZER 2.65SecBONDING 2.65SecQ.C. 2 (Final Scanner)IMM--2.60SecQ. C. 1ANNEALING2.65SecPROCESS FLOW DIAGRAM OF ORIGIN LINE AT 2.60 sec(After Quick win) IMM Cycle Time gain 0.05 sec. from robot kick Rtn.Time.but couldn't get the out put due to the high ct of down stream .

*The Slide Template The company logo should come on the right-hand side of each slide (as per the given format) FONTSTitle- 28 points of Arial/ Verdana/TrebuchetSubtitle - 24 points of chosen fontBody - Text colour-Black: 18 point

Use at least 18 pt. font size. Smaller sizes get too grainy and difficult to read when projectedonto a large screen.

CHARTSUse Times New Roman font for Legends with 12 or 14 points

Measure

Line Out put Cycle TIMEIMM C.TDye Coating C.TAnnealing C.TMetallizer C.TBonding C.T

High Cycle Time

Annealing

DYE COATER

IMM

Injection time

Cooling Time

Dye coating time

Pick & Place handler speed

Reciever handler speed

Inlet & outlet arm speed

Hold on time

Hold on Pressure

Cooling time

Eject time Robot take out time Drying time

Screw Speed

METALLIZER

Swivel arm speed

Sputtering time

Sputtering thickness

Ramp time

Injection speed

Drying temperature

wait time

Sputter Vacuum Inlet & outlet table movementNo. of Dye CupsEdge washing timeConveyor belt speedI/P & O/P handler speedIshikawa Diagram (Cause and Effect Diagram)

Bonding Bonding spinning TimeBonding Handling TimeDispensing TimeBoth Active & Dummy Bond Time

*

OPERATIONAL DEFINITION FOR Xs1. Cooling time (IMM):This is the time for which Disc is being cooled from end of holding time to finish of cooling time,for molten material solidification . Measured in sec.2. Hold time (IMM) : This is the extra time to hold the back flow of material injected & compensate the shrinkage after injection. Measured in sec.3. Dye coating time: Dye coating time is the time taken of application of dye in groove of Blank substrate & Spun-off(Centrifugal-Process) the dye solution from the Blank substrate for desired Thickness of Dye on Blank substrate,desired Optical density & Evaporation of TFP solution form Dye solvent. It is measured in Sec.

OPERATIONAL DEFINITION FOR Xs4. Drying time: Time required for annealing of a disc in Annealing Oven chamber. It is measured in Sec.5. Sputtering time:Time required for Metallization layer over Active disc for desired thickness. It is measured in Sec.6. Bonding time:Time required for Bond Active with dummy disc for desired Layer. It is measured in Sec.

Data Measurement Plan(Xs)

Sheet1


1Robot kick Rtn. TimeReduced Robot kick Rtn from 120 to 90 sec.Ashif/sandeep2.65 sec0.05 sec2.60 secsetting implemented across all lines



BondingAs defined in operational definitionData logger/ Bonding screen30Hemant1/6/0910 readings/shift/day

Sheet2

Operational definitionData source and locationSample sizeWho will collect the dataWhen will data be collectedHow will data be collected

IMMAs defined in operational definitionData logger/IMM Screen30Ashif1/6/0910 readings/shift/day

Dye coaterData logger/Dye coater screen30Ashif1/6/0910 readings/shift/day

AnnealingData logger/ Annealing screen30B.C Bhatt1/6/0910 readings/shift/day

MetallizerData logger/ Metallizer screen30Amit Shrivastava1/6/0910 readings/shift/day

BondingData logger/ Bonding screen30Hemant1/6/0910 readings/shift/day

process/input(X)Operational definitionData source and locationSample sizeWho will collect the dataWhen will data be collectedHow will data be collected

Cooling time (IMM)As defined in operational definitionData logger/IMM Screen30Ashif1/6/0910 readings/shift/day

Holding Time (IMM)Data logger/IMM Screen30Ashif1/6/0910 readings/shift/day

Dye coating TimeData logger/Dye coater screen30Bijender1/6/0910 readings/shift/day

Drying TimeData logger/ Annealing screen30B.C Bhatt1/6/0910 readings/shift/day

Sputter timeData logger/ Metallizer screen30Amit Shrivastava1/6/0910 readings/shift/day

Bonding timeData logger/ Bonding screen30Hemant1/6/0910 readings/shift/day


Cooling time (IMM)As defined in operational definitionData logger/IMM Screen30Ashif1/6/09Record set value

Holding Time (IMM)Data logger/IMM Screen30Ashif1/6/09Record set value

Dye coating TimeData logger/Dye coater screen30Bijender1/6/09Record set value

Drying TimeData logger/ Annealing screen30B.C Bhatt1/6/09Record set value

Sputter timeData logger/ Metallizer screen30Amit Shrivastava1/6/09Record set value

Bonding timeData logger/ Bonding screen30Hemant1/6/09Record set value

Sheet3

failuar mode-IMM

Process/Products Name:Process/Products Failure Mode Effects & Analysis(FMEA)

Cycle Time Reduction From 2.65 sec. To 2.4 sec in Origin LinePrepaired by :page ; 1 of 5FMEA date(Origin) --22-07-2009(Rev)--------------

Responsible Green BeltAshif Akhtar & Team

Ashif Akhtar

Process FunctionPotential Failure ModePotential Effect of failureS E VPotential causes/Mechanisims of failureOCCCurrent process controlsDETRPNRecomnmended actionResponsibility& Completion DateAction TakenAction Results

S E VO C CD E TR P N

Blank substrate process of mouldingBad TiltDisc shape abnomal5clamping force setting/Mold temp.5offline tilt check per shift as per quality plan/online 100% Check by scanner250New optimized Moulding process window to be displayed w.r.t Low cycle time in all lines & audit will be in daily basis & cycle time Monitoring will be done in shift basisAshif AkhtarAfter published of Technical Report& ISO documents w.r.t TQM Level new Optimized window has been displayed in all lines w.r.t Low cycle time.53230

Cycle Take OutFrequently molding stop5high Packing3M/c will stop34552220

Groove Replication PoorHigh error In Disc5Mold Temp/clamp.setting3Groove geometry check per shift34552220

233052220

Sprue tailhigh visual generate/Down grade5Nozzle/sprue/Back Pressureonline scanner 100% check & L0 by L1

334553230

injection flaw/silver stickshigh visual generate/Down grade5Back pressure/barrel temp/Back pressureonline scanner 100% check & L0 by L1

7

High Cycle TimeLow out put Disc7high Cooling Time7Cycle time check every day62941214

High Holding Time6Cycle time check every day62521214

Robot Take out Time High5Cycle time check every day62101214

123567

failuar mode-Dye coating

Process/Products Failure Mode Effects & Analysis(FMEA)

Process/Products Name:



Ashif Akhtar

DET

Process FunctionPotential Failure ModePotential Effect of failureS E VPotential causes/Mechanisims of failureOCCCurrent process controlsRPNRecomnmended actionResponsibility& Completion DateAction TakenAction Results


Dye coating ProcessHigh/Low optical dencityElectrical signal not better5Dye spinning profile setting5offline OD check per shift /online 100% OD Check by scanner250New optimized Dye Coating process window to be displayed w.r.t Low cycle time in all lines & audit will be in daily basis & cycle time Monitoring will be done in shift basisAshif AkhtarAfter published of Technical Report& ISO documents w.r.t TQM Level new Optimized window has been displayed in all lines w.r.t Low cycle time.53115

Inproper dye coatingDye Related Issue,V-cut,dye at hub5dye spinning Nozzle profile,dye volume,Pressure Setting3online scanner 100% check & L0 by L134552220

Groove Replication PoorHigh error In Disc5Dye spinng/Nozzle profile setting6Online 100% OD check by scanner39053230

High Cycle TimeLow out put Disc7High Dye process Time6Cycle time check every day625272342

23567

failuar mode-Annealing





Ashif Akhtar

DET



Annealing processInsufficient evapuration of TFP solventHigh error in disc5dryer Temperature/Time setting3Thermo Couple Temperature Flactuation345New optimized process window to be displayed w.r.t Low cycle time in all lines & audit will be in daily basis & cycle time Monitoring will be done in shift basisAshif AkhtarAfter published of Technical Report& ISO documents w.r.t TQM Level new Optimized window has been displayed in all lines w.r.t Low cycle time.52330

High Cycle TimeLow out put Disc7Screw Rotation of Dryer time High6Cycle time check every day625273363

123567

failuar mode-Mettalizer



Cycle Time Reduction From 2.65 sec. To 2.4 sec in Origin LinePrepaired by :page ;4 of 5FMEA date(Origin) --22-07-2009(Rev)--------------


Ashif Akhtar

DET



Sputter processLow Air PressureElectrical signal Not good5Aurgon flow not Good3M/c will not Run545New optimized process window to be displayed w.r.t Low cycle time in all lines & cycle time Monitoring will be done in shift basis& New PLC programming to be DesingAshif AkhtarAfter published of Technical Report& ISO documents w.r.t TQM Level new Optimized window has been displayed in all lines w.r.t Low cycle time.& New PLC Programming Design has been done.52330

Poor VaccumeElectrical signal Not good5Pump failure3system will not start23052110

High Cycle TimeLow out put Disc7Wrong Input of process Prameters6Cycle time check every day625273242

1357

failuar mode-Bonding





Ashif Akhtar

DET



Bonding ProcessMissallignment of Bonding ArmBubble,Bonding gape related vasule problem5Teaching Not proper3online scanner 100% check & L0 by L1230New optimized process window to be displayed w.r.t Low cycle time in all lines & audit will be in daily basis & cycle time Monitoring will be done in shift basis& New PLC programming to be DesingAshif AkhtarAfter published of Technical Report& ISO documents w.r.t TQM Level new Optimized window has been displayed in all lines w.r.t Low cycle time..& New PLC Programming Design has been done&V-arm Design has been desing52220

Insuffient curing timeDrop test failure5Low uv energy/process not good5Drop test check on shift basis37553230

Insuffient Rasin glue DispenseBubble,V-cut Related visual problem5Wrong process setting2online scanner 100% check & L0 by L122052110

High Cycle TimeLow out put Disc7Wrong in put of Bonding Parameters6Cycle time check every day625273242

1357

DOE

D.O.EMold Closing Time0.28 sec.

PrametersMin LevelMax. LevelMold Opening Time0.26 sec

Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29

Holding time0.030.10CT = Mold Opening+Injection Time+Holding time+Cooling Time+Mold opening Time+Robot take out

Robot take out time0.200.29

Mold Closing TimeMold Opening TimeInjection TimeCT

StdOrderRunOrderCenterPtBlocksCooling TimeHolding TimeRobot Take Out Time

11111.40.030.20.290.270.132.36

22111.650.030.20.290.270.132.55

33111.40.10.20.290.270.132.43

44111.650.10.20.290.270.132.63

55111.40.030.290.290.270.132.45

66111.650.030.290.290.270.132.65

77111.40.10.290.290.270.132.52

88111.650.10.290.290.270.132.72

StdOrderRunOrderCenterPtBlockscooling Timeholdig TimeRobot take out TimeImm ct

11111.40.030.22.36

22111.650.030.22.55

33111.40.10.22.43

44111.650.10.22.63

55111.40.030.292.45

66111.650.030.292.65

77111.40.10.292.52

88111.650.10.292.72

DOE Final


Min LevelMax. LevelMold Opening Time0.26 sec

Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29





71111.40.10.280.290.270.132.47

42111.650.10.20.290.270.132.64

83111.650.10.280.290.270.132.72

34111.40.10.20.290.270.132.39

15111.40.030.20.290.270.132.32

66111.650.030.280.290.270.132.65

57111.40.030.280.290.270.132.40

28111.650.030.20.290.270.132.57

StdOrderRunOrderCenterPtBlocksCooling TimeHolding TimeRobot Take Out TimeCycle Time

71111.40.10.282.47

42111.650.10.22.64

83111.650.10.282.72

34111.40.10.22.39

15111.40.030.22.32

66111.650.030.282.65

57111.40.030.282.40

28111.650.030.22.57

MBD00054B1A.xls

Sheet1







Sheet1 (2)







Sheet3

Normality Test of IMM cycle time

Stability test for IMM Cycle Time As all data points are with in limits so process is stable

Graphical summary

Normality Test of Dye coating cycle time

Stability test for Dye Coating Cycle Time As all data points are with in limits so process is stable

Graphical summary

Normality Test of Annealing cycle time

Stability test for Annealing Cycle Time As all data points are with in limits so process is stable

Normality Test of Mettalizer cycle time

Stability test for Metallizer Cycle Time As all data points are with in limits so process is stable

Normality Test of Bonding cycle time

Stability test for Bonding Cycle Time As all data points are with in limits so process is stable

Normality Test

Stability testAs all data points are with in limits so process is stable

Data Summarization (Y)Baseline definition For continuous (Y)

Output indicatorNormalityStabilityAverageStandard deviation IMM C.TNoYes2.6.008Dye Coating C.TNo Yes2.65.009Annealing C.TNo Yes2.65.011Metallizer C.TNo Yes2.65.012Bonding C.TNo Yes2.65.011Total Line Cycle timeNOYes2.650.005

Key Xs to be validated

S. No.Xs identified as important from CE Matrix Tool UsedCurrent ValuesProposed values

1Cooling time(IMM)Mann-Whitney1.65 sec1.44 sec2Hold time (IMM)Mann-Whitney0.1 sec0.05 sec3Dye Coating time(Dye coater)Mann-Whitney14 sec12 sec4Drying Time (Annealing ) Mann- Whitney760 sec700 sec5Sputtering time (Metallizer) Mann- Whitney1.83 sec1.45 sec6 Bonding Time Mann-Whitney2.4 sec2.00 sec

Practical statement : Reducing cooling time will reduce cycle time of IMM.Statistical statement: Ho : Average cycle time of IMM with cooling time 1.44 sec. = Average cycle time of IMM with cooling time 1.6 sec Ha : Average cycle time of IMM with cooling time 1.44 sec. < Average cycle time of IMM with cooling time 1.6 sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann Whitney Validation of effect of Cooling time(Moulding) on IMM Cycle time

Test of IndependenceAFTERBeforeAs all four P values are >0.01 so data is Independent.

Test of NormalityAFTERBeforeAs P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in cooling time is significant factor.Validation of effect of Cooling time(Moulding) on IMM Cycle timeMann-Whitney Test and CI: IMM CT at 1.44 , IMM CT at 1.6sec

N MedianIMM CT at 1.44 ( Cooling Time) 30 2.4400IMM CT at 1.6sec (cooling time) 30 2.6000

Point estimate for ETA1-ETA2 is -0.160095.2 Percent CI for ETA1-ETA2 is (-0.1600,-0.1600)W = 465.0Test of ETA1 = ETA2 vs ETA1 < ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)

Practical statement : Reducing holding time will reduce cycle time of IMM.Statistical statement: Ho : Average cycle time of IMM with holding time 0.05 sec. = Average cycle time of IMM with holding time 0.1 sec Ha : Average cycle time of IMM with cooling time 0.05 sec. < Average cycle time of IMM with cooling time 0.1 sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann WhitneyValidation of effect of holding time(Moulding) on IMM Cycle time

Test of NormalityAFTERBefore

As P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in holding time is significant factor.Validation of effect of holding time(Moulding) on IMM Cycle timeMann-Whitney Test and CI: IMM CT at 0.05 , IMM CT at 0.1 se

N MedianIMM CT at 0.05 sec hold time 30 2.4900IMM CT at 0.1 sec hold time 30 2.5400


Practical statement : Reducing dye coater time will reduce cycle time of dye coating. (Cycle time 12 secs. Is for 6 cups.)Statistical statement: Ho : Average cycle time of dye coating with dye coater time 12 sec. = Average cycle time of dye coating with dye coater time 14sec Ha : Average cycle time of dye coating with dye coater time 12 sec. < Average cycle time of dye coating with dye coater time 14sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann WhitneyValidation of effect of dye coater time on dye coating Cycle time


As P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in Dye coating time is significant factor.Validation of effect of dye coater time on dye coating Cycle timeMann-Whitney Test and CI: Dye coater CT at, Dye coater CT at

N MedianDye coater CT at 12 Sec (6 Cup) 30 2.3800Dye coater CT at 14 sec (6Cup) 30 2.6500


Practical statement : Reducing drying time will reduce cycle time of annealing .Statistical statement: Ho : Average cycle time of annealing with drying time 700 sec. = Average cycle time of annealing with drying time 760sec Ha : Average cycle time of annealing with drying time 700 sec. < Average cycle time of annealing with drying time 760sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann WhitneyValidation of effect of drying time on annealing Cycle time


As P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in Annealing time is significant factor.Validation of effect of drying time on annealing Cycle time Mann-Whitney Test and CI: Anealing CT at 7, Anealing CT at 76

N MedianAnealing CT at 700 sec(255 Disc 30 2.4100Anealing CTat 760Sec.(255 Disc) 30 2.6500


Practical statement : Reducing sputtering time will reduce cycle time of metallizer.Statistical statement: Ho : Average cycle time of metallizer with sputtering time 1.45 sec. = Average cycle time of metallizer with sputtering time 1.83sec Ha : Average cycle time of metallizer with sputtering time 1.45 sec. < Average cycle time of metallizer with sputtering time 1.83sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann WhitneyValidation of effect of sputtering time on metallizer Cycle time


As P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in Sputtering processing time is significant factor.Validation of effect of sputtering time on metallizer Cycle timeMann-Whitney Test and CI: Metallizer Ct at 1.45 sec.PT, Metallizer CT at 1.83 P

N MedianMetallizer Ct at 1.45 sec.PT 30 2.4100Metallizer CT at 1.83 PT 30 2.6500


Practical statement : Reducing bonding time will reduce cycle time of bonder.Statistical statement: Ho : Average cycle time of bonder with bonding time 2 sec. = Average cycle time of bonder with bonding time 2.4sec Ha : Average cycle time of bonder with bonding time 2 sec. = Average cycle time of bonder with bonding time 2.4sec

Analysis :Data Collect data for Test time Check Independency and Normality testData Independence:- OKData Normality:- Not OKTool Used :- Mann Whitney TestStat Non Parametric Mann WhitneyValidation of effect of bonding time on bonder Cycle time

Test of NormalityAFTERBeforeAs P value is

Statistical Conclusion:Since P-value < 0.05 then we CAN REJECT Ho.Practical Conclusion : Reduction in bonder processing time is significant factor.Validation of effect of bonding time on bonder Cycle timeMann-Whitney Test and CI: Bonding CT at 2.0 Sec, PT, Bonding CT at 2.4 Sec. PT

N MedianBonding CT at 2.0 Sec, PT 30 2.3800Bonding CT at 2.4 Sec. PT 30 2.6500


Improve

DOE for IMM cycle timeNo. of Factors-3(Cooling time,Holding Time & robot take out time.No. of Levels:- 2No. of Center points:- 1No. of replicates:-1

Sheet1






Sheet2

Performance measure (Ys)Operational definitionData source and locationSample sizeWho will collect the dataWhen will data be collectedHow will data be collected


Dye coaterData logger/Dye coater screen30Sandeep1/6/0910 readings/shift/day






Holding Time (IMM)Data logger/IMM Screen30Sandeep1/6/0910 readings/shift/day







Holding Time (IMM)Data logger/IMM Screen30Sandeep1/6/09Record set value





Sheet3

failuar mode-IMM




Ashif Akhtar






233052220


334553230


7




123567






Ashif Akhtar

DET







23567






Ashif Akhtar

DET





123567






Ashif Akhtar

DET






1357






Ashif Akhtar

DET







1357

DOE



Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29





71111.40.10.280.290.270.132.47

42111.650.10.20.290.270.132.64

83111.650.10.280.290.270.132.72

34111.40.10.20.290.270.132.39

15111.40.030.20.290.270.132.32

66111.650.030.280.290.270.132.65

57111.40.030.280.290.270.132.40

28111.650.030.20.290.270.132.57

DOE Final



Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29





71111.40.10.280.290.270.132.47

42111.650.10.20.290.270.132.64

83111.650.10.280.290.270.132.72

34111.40.10.20.290.270.132.39

15111.40.030.20.290.270.132.32

66111.650.030.280.290.270.132.65

57111.40.030.280.290.270.132.40

28111.650.030.20.290.270.132.57


71111.40.10.282.47

42111.650.10.22.64

83111.650.10.282.72

34111.40.10.22.39

15111.40.030.22.32

66111.650.030.282.65

57111.40.030.282.40

28111.650.030.22.57

MBD00054B1A.xls

Sheet1







Sheet1 (2)







Sheet3

DESIGN OF EXPERIMENT DOE Carried out for IMM Cycle Time:

Sheet1






Sheet2

Operational definitionData source and locationSample sizeWho will collect the dataWhen will data be collectedHow will data be collected


Dye coaterData logger/Dye coater screen30Sandeep1/6/0910 readings/shift/day






Holding Time (IMM)Data logger/IMM Screen30Sandeep1/6/0910 readings/shift/day







Holding Time (IMM)Data logger/IMM Screen30Sandeep1/6/09Record set value





Sheet3

failuar mode-IMM




Ashif Akhtar






233052220


334553230


7




123567






Ashif Akhtar

DET







23567






Ashif Akhtar

DET





123567






Ashif Akhtar

DET






1357






Ashif Akhtar

DET







1357

DOE



Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29





11111.40.030.20.290.270.132.36

22111.650.030.20.290.270.132.55

33111.40.10.20.290.270.132.43

44111.650.10.20.290.270.132.63

55111.40.030.290.290.270.132.45

66111.650.030.290.290.270.132.65

77111.40.10.290.290.270.132.52

88111.650.10.290.290.270.132.72

StdOrderRunOrderCenterPtBlockscooling Timeholdig TimeRobot take out TimeImm ct

11111.40.030.22.36

22111.650.030.22.55

33111.40.10.22.43

44111.650.10.22.63

55111.40.030.292.45

66111.650.030.292.65

77111.40.10.292.52

88111.650.10.292.72

DOE Final



Cooling Time1.401.65CT = 0.26+0.12+0.15+1.8+0.28+.29





71111.40.10.280.290.270.132.47

42111.650.10.20.290.270.132.64

83111.650.10.280.290.270.132.72

34111.40.10.20.290.270.132.39

15111.40.030.20.290.270.132.32

66111.650.030.280.290.270.132.65

57111.40.030.280.290.270.132.40

28111.650.030.20.290.270.132.57


71111.40.10.282.47

42111.650.10.22.64

83111.650.10.282.72

34111.40.10.22.39

15111.40.030.22.32

66111.650.030.282.65

57111.40.030.282.40

28111.650.030.22.57

MBD00054B1A.xls

Sheet1







Sheet1 (2)







Sheet3

DOE Analysis

DESIGN OF EXPERIMENT Conclusion : Cycle time reduces significantly if cooling time , hold time and robot take out time is reduced.

DOE AnalysisFactorial Fit: Cycle Time versus Cooling Time, Holding Time, ...

Estimated Effects and Coefficients for Cycle Time (coded units) SETerm Effect Coef SE Coef T PConstant 2.73375 0.005728 477.24 0.000Cooling time 0.17250 0.08625 0.005728 15.06 0.000Hold time 0.07250 0.03625 0.005728 6.33 0.003Robot Take out time 0.07250 0.03625 0.005728 6.33 0.003

S = 0.0162019 R-Sq = 98.71% R-Sq(adj) = 97.75%Analysis of Variance for Cycle time (coded units)Source DF Seq SS Adj SS Adj MS F PMain Effects 3 0.080537 0.080537 0.0268458 102.27 0.000Residual Error 4 0.001050 0.001050 0.0002625Total 7 0.081587Conclusion : Cooling time , hold time , robot take out time is significant as p value is < 0.05

DESIGN OF EXPERIMENT Conclusion : There is no interaction of three factors

DESIGN OF EXPERIMENT Response Optimizer :Optimum setting to achieve 2.4 cycle time is cooling time 1.44 sec , Hold time 0.05 sec and Robot time 0.24 sec. At robot time less than 0.24 sec problem of disc picking observed .

HiLo0.83412D1Cur

d = 0.83412: 2.40 sec. Cycle timey = 2.4025

0.200.2800.030.11.401.65Hold timRobot TaCooling [1.4394][0.05][0.2602]

Same type of experiments conducted for Bonding ,Sputtering and other sections to optimize Cycle time without affecting quality parameters.

List of Possible Solutions

Sheet2


Funtion DiplomentyIMM cycle TimeRobot Kick Rtn. Time,Robot entry pos.w.r.t mold gapYYYYYYes

Bonding TimeDispence Time & Spinning TimeYYYYYYes

Bonding stage disc travelling timeYYYYYYes

Feeding robot home positionYYYYYYes

Dye conveyor belt speed/carry arm speed/handler speed/feeding robot speed/cooler I/O put handler speed & dryer I/O handler speedServo motor & Drive speedYYYYYYes

Sheet4

S.NO.Quick winsActivitiesResponsibility personStart dateTarget date of completionActual date of completionstandardization of completion

Sheet6

Sheet3

IMM CTDye coatingAnnealingMettalizerBondingIMM CT (cooling time)IMM CT(holding Time)Dye coatingAnnealingMettalizerBonding

12.602.652.652.652.641.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

22.602.652.662.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

32.602.652.672.672.661.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.431.831.450.382.42

42.592.642.672.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.431.831.450.382.40

52.592.642.652.682.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.411.831.450.382.43

62.612.662.662.652.661.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.421.831.450.382.40

72.602.652.652.642.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.39

82.612.662.652.652.641.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.411.831.450.382.40

92.592.642.662.682.671.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.43

102.622.672.682.672.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.441.831.450.382.42

112.602.652.652.652.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

122.592.642.662.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.40

132.602.652.662.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

142.602.652.642.642.681.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.39

152.622.672.652.652.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.411.831.450.382.40

162.612.662.642.642.671.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.401.831.450.382.39

172.592.642.682.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.441.831.450.382.40

182.602.652.652.652.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

192.602.652.642.672.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.42

202.622.672.662.682.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.421.831.450.382.43

212.612.662.652.652.651.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.411.831.450.382.40

222.602.652.682.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.441.831.450.382.40

232.602.652.672.652.661.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.431.831.450.382.40

242.622.672.652.672.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.411.831.450.382.42

252.602.652.662.652.641.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

262.592.642.652.652.641.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.411.831.450.382.40

272.602.652.642.662.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.41

282.602.652.652.682.681.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.43

292.592.642.662.652.671.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.40

302.602.652.642.642.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.39

0.05

12

0.06666666670.05

Sheet1

5B-hall Production(1-to 16)

Line Nos1-Aug2-Aug3-Aug4-Aug5-Aug6-Aug7-Aug8-Aug9-Aug10-Aug11-AugAvg.

540328753425033000325003275024250341252937533250340003325032148

541343753425034250340003300029625341252925031750351253400033068

542211253150029375282502550021625251252887528625318752687527159

543321253237530500311252900025375252503362527625331253300030284

544318753337532750326253237518375328753125033000337503287531375

545253753250032250306252525025750271252762530625315003187529136

546296253187529250302502837522125285002887529875300002850028841

547308753325032500318753312528000303753050031375296253337531352

548307503125029875327503175025250316253137533000318753150031000

Avg

7-Aug8-Aug9-Aug10-Aug11-Aug

3025030500303753025032500

3162533750307503337534000

3000024875230002725020750

2500026000250002375028125

2437521375270002450027250

2437524250252502362523125

2187523750245002212521250

2500026625265002537527000

2425024125250002400026875

Sheet1

0

0

0

0

0

0

0

0

0

540 541 542 543 544 545 546 547 548

Line Nos

No of Disc

5B hall Avg Production(Dt.1-aug to 16 Aug)

Sheet5

Input / process indicatorCycle time final unit(Y)Out put indicator

X"S

IMM(Y1)Dye coating(Y2)Annealing (Y3)Sputter (Y4)Bonding(Y5)Total

1010101010Importance

Holding time9000090

cooling time9000090

Robot take out time9000090

dye coating time0900090

annealing time0090090

Sputter time0009090

Bonding time0000990

Injection time3000030

Ejection time3000030

I/O let arm speed0030030

swivel arm speed000000

ramp time0001010

Inlet & outlet table movement0033060

annealing Screw speed0030030

Edge washing time0300030

No.of disc of dye cups0300030

I/O hander speed0100010

Pick & place hander speed0100010

Reciever hander speed000000

waiting Time0003030

Dryer Temp0010010

sputter vaccume.000000

Bonding dispencing time0000330

Bonding hander Reciver time0000330

Bonding Glue temp.0000110

Sheet8

S. No.Xs validatedPossible solutions

1Molding cycle timeA1 Reduce cooling time from 1.6 to 1.44 sec.

A.2 Reduce holding time from .1 to 0.05 sec.

2Dye coating Cycle timeB.1 Reduce Dye Coating time from 14 to 12sec.

3Annealing Oven cycle timeC.1 Reduce Drying time from 760 sec. To 700 sec.

4Metallizer cycle timeD.1 Reduce Sputtering time from 1.83 to1.45sec.

5Bonding cycle timeE.1 Reduce Bonding Time from2.4to 2 sec.

For compensating Low Cooling time changes have been made in clamp profile for tilt.

Sheet2


Funtion DiplomentyIMM cycle TimeRobot Kick Rtn. Time,Robot entry pos.w.r.t mold gapYYYYYYes

Bonding TimeDispence Time & Spinning TimeYYYYYYes

Bonding stage disc travelling timeYYYYYYes

Feeding robot home positionYYYYYYes

Dye conveyor belt speed/carry arm speed/handler speed/feeding robot speed/cooler I/O put handler speed & dryer I/O handler speedServo motor & Drive speedYYYYYYes

Sheet4

S.NO.Quick winsActivitiesResponsibility personStart dateTarget date of completionActual date of completionstandardization of completion

Sheet6

Sheet3

IMM CTDye coatingAnnealingMettalizerBondingIMM CT (cooling time)IMM CT(holding Time)Dye coatingAnnealingMettalizerBonding

12.602.652.652.652.641.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

22.602.652.662.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

32.602.652.672.672.661.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.431.831.450.382.42

42.592.642.672.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.431.831.450.382.40

52.592.642.652.682.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.411.831.450.382.43

62.612.662.662.652.661.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.421.831.450.382.40

72.602.652.652.642.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.39

82.612.662.652.652.641.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.411.831.450.382.40

92.592.642.662.682.671.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.43

102.622.672.682.672.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.441.831.450.382.42

112.602.652.652.652.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

122.592.642.662.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.40

132.602.652.662.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

142.602.652.642.642.681.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.39

152.622.672.652.652.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.411.831.450.382.40

162.612.662.642.642.671.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.401.831.450.382.39

172.592.642.682.652.651.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.441.831.450.382.40

182.602.652.652.652.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.40

192.602.652.642.672.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.42

202.622.672.662.682.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.421.831.450.382.43

212.612.662.652.652.651.601.440.162.450.100.050.052.56141220.33333333332.38750690600.242.411.831.450.382.40

222.602.652.682.652.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.441.831.450.382.40

232.602.652.672.652.661.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.431.831.450.382.40

242.622.672.652.672.651.601.440.162.460.100.050.052.57141220.33333333332.39750690600.242.411.831.450.382.42

252.602.652.662.652.641.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.421.831.450.382.40

262.592.642.652.652.641.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.411.831.450.382.40

272.602.652.642.662.671.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.41

282.602.652.652.682.681.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.411.831.450.382.43

292.592.642.662.652.671.601.440.162.430.100.050.052.54141220.33333333332.36750690600.242.421.831.450.382.40

302.602.652.642.642.651.601.440.162.440.100.050.052.55141220.33333333332.37750690600.242.401.831.450.382.39

0.05

12

0.06666666670.05

Sheet1

5B-hall Production(1-to 16)

Line Nos1-Aug2-Aug3-Aug4-Aug5-Aug6-Aug7-Aug8-Aug9-Aug10-Aug11-AugAvg.

540328753425033000325003275024250341252937533250340003325032148

541343753425034250340003300029625341252925031750351253400033068

542211253150029375282502550021625251252887528625318752687527159

543321253237530500311252900025375252503362527625331253300030284

544318753337532750326253237518375328753125033000337503287531375

545253753250032250306252525025750271252762530625315003187529136

546296253187529250302502837522125285002887529875300002850028841

547308753325032500318753312528000303753050031375296253337531352

548307503125029875327503175025250316253137533000318753150031000

Avg

7-Aug8-Aug9-Aug10-Aug11-Aug

3025030500303753025032500

3162533750307503337534000

3000024875230002725020750

2500026000250002375028125

2437521375270002450027250

2437524250252502362523125

2187523750245002212521250

2500026625265002537527000

2425024125250002400026875

Sheet1

0

0

0

0

0

0

0

0

0

540 541 542 543 544 545 546 547 548

Line Nos

No of Disc

5B hall Avg Production(Dt.1-aug to 16 Aug)

Sheet5

Input / process indicatorCycle time final unit(Y)Out put indicator

X"S

IMM(Y1)Dye coating(Y2)Annealing (Y3)Sputter (Y4)Bonding(Y5)Total

1010101010Importance

Holding time9000090

cooling time9000090

Robot take out time9000090

dye coating time0900090

annealing time0090090

Sputter time0009090

Bonding time0000990

Injection time3000030

Ejection time3000030

I/O let arm speed0030030

swivel arm speed000000

ramp time0001010

Inlet & outlet table movement0033060

annealing Screw speed0030030

Edge washing time0300030

No.of disc of dye cups0300030

I/O hander speed0100010

Pick & place hander speed0100010

Reciever hander speed000000

waiting Time0003030

Dryer Temp0010010

sputter vaccume.000000

Bonding dispencing time0000330

Bonding hander Reciver time0000330

Bonding Glue temp.0000110

Sheet8

S. No.Xs validatedPossible solutions

1Molding cycle timeA1 Reduce cooling time

A.2 Reduce holding time

2Dye coating Cycle timeB.1 Reduce Dye Coating time

3Annealing Oven cycle timeC.1 Reduce Drying time

4Metallizer cycle timeD.1 Reduce Sputtering time

5Bonding cycle timeE.1

Sheet7

Presentations & Public Speaking

Cycle time Reduction