iSixSigma

Dog Sxxx

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  • #101730

    Dog Sxxx
    Participant

    Oppp..I can still get value added to my pocket. I did suggest to my clients got some low pay operators to do such NVA task, but they declined my suggestion and instead they were willing to pay USD 40 per hour rate for doing such NVA. I am no longer in the inspection line because I can earn more in other jobs.
     

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    #101727

    Dog Sxxx
    Participant

    This is the freedom of speech you people always say people like me from a third world shall follow?

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    #101726

    Dog Sxxx
    Participant

    This is the freedom of speech you people says people like me from a shall follow?

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    #101724

    Dog Sxxx
    Participant

    I forget to tell you that my US clients were a bit lazy to define separate defect category for their separate product line and prefer to use the IPC manual as a full blanket standard to cover their “assholes”.

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    #101723

    Dog Sxxx
    Participant

    The original poster can choose all defects listed in the IPC manual as his/her defect opportunity as wish, but you as an expert shall know that not all defects listed can be found in a specified type of PCBA. As a practioner, go work out a realistic defect opportunity level by talking to your internal and external customers who have profound process and design knowledge on that PCBA.
    May be for some theorists, the goal is getting lowest DPMO as possible and try to impress their management. 
     
     

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    #101722

    Dog Sxxx
    Participant

    My worry is some people make SS something only can be understood by MBB or BB elite. SS is nothing (new) and do not need to be glorified as a new invention such as the gravitivity theory.  These two contradicted statements?
    I have observed this forum for quite some times and stand sidelined all the while. I have one Japanese robust design training manual written by Taguchi in 70s sit in front of my table. This manual was used extensively for Japanese engineer training since 70s. Do you know none of these Japanese engineers got “belts”?  

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    #101720

    Dog Sxxx
    Participant

    Do you think you can buy PCBA without any specificition either internally generated by the buyers or using an industry standard?
    Do you know many types of defects can be found in PCBA without any spec? Answer me first before I answer your silly question?
     

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    #101696

    Dog Sxxx
    Participant

    Kepner-Tregoe website, http://www.kepner-tregoe.com/
    BTW, I always advise people to use Google search engine to find out first.

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    #101692

    Dog Sxxx
    Participant

    If you look into the detail, you will realize KT method covers multi-vari, FMEA, 8D and risk analysis methodolodies. I did apply a potential problem analysis for one 100,000 sq ft new plant setup project for one US MNC.. This project was completed whithin the time frame because all potential problems are predicted in advance and its preventive solutions are planned ahead. This plant is a model plant in Indonesia for all foreign visting VIPs nowadays.
    KT method seems is overlooked by a bunch of companies.

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    #101687

    Dog Sxxx
    Participant

    This public forum is not always can give you the answer you want because this is just another public forum. 
    I know most of the materiasl from USA companies is too expensive for those people from a third world country like me. That is too bad! 
    You can go to http://www.bnet.com to find some free JIT reading materials.

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    #101685

    Dog Sxxx
    Participant

    Yes. I am quite worry Six Sigma will be another ISO9000 certificate program soon. People only wanted to have BB certificate for their marketing purpose, and not using SS as an improvement vehicle.

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    #101684

    Dog Sxxx
    Participant

    It’s simple and straight forward, my US clients wanted all their subcons to follow IPC manual. Anything not mention in the manual means that is not a defect opportunity.

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    #101683

    Dog Sxxx
    Participant

    1—is it a DMAIC methodology?……..i.e if we adopt this approach in the processes then can we say that the specific company following the approach is a six sigma company?
    DMACI is not six sigma, is just a modified Deming cycle. Deming cycle was being used by Japanese long long before Motorola people invented Six Sigma new term.
    2—is it a approach used for reducing defect to 3.4DPMO?…..i.e a company will only be a six sigma company if defects are 3.4dpmo…what are the defects?…say a part has 30 attributes to measure then these can all be defects or there will be only one defect (defective).
    My Japanese customers only interested on zero defect products, there are no interested on 3.4 DPMO.
    3—is it only related to cultural changes?
    Yes, the mindset must change from treating your customers like dog shit to God.
    For example, our staff resently ordered two technical books from a US six sigma consultant, but they sent a wrong book to us. They keep a deaf ear and refuse to send us a correct book. You can talking as loud as you wish in saying your customer first, but your action is more important than what you say.
    4— When can we say that a specific company is operating on six Sigma?….is it must that all requirements as I mentioned in para 1,2 & 3 must be fulfilled?
    The consumers are the final judge to say you are six sigma company or not. And Six Sigma companies also do not need to ask their government to intervene with political muscle and forcing a foreign country to raise their money exchange rate for them to survive in the world market.5— Is six sigma only for large companies who can invest million or billions of dollars per annum on their quality program?… i mean to say that can small companies whose annual profit is not in millions can also adopt six sigma approach
    If you have people like Bob Govin in a small company, I believe these small companies will be as good as Motorola or GE or even performed better. Strong leadership is importnat for either the small or big companies.   6— Can you please guide me to some of the areas of six sigma on which research is underway?Looking forward for ur co operation.
    Motorola University is doing research on future six sigma.
    AM Qureshi

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    #101675

    Dog Sxxx
    Participant

    Don’t believe such 4-5 weeks BB program in the market will transform a person into a real Six Sigma black belt. A BB must have a very good political skill which you cannot learn from elsewhere except you observe it, learn it and practice it in your workplace. 

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    #101674

    Dog Sxxx
    Participant

    KT method is an analytical problem solving and decision making skillset. It has four components; situation analysis, problem analysis, decision analysis and potential problem analysis for the past, present and future problems. It teaches you to break down a complex problem into many small manageable problems with the process thinking approach.
    KT method can be used in all situations, not just limited to SQC. You do not need any MBB title for you to learn this useful technique. First thing I train to engineers is KT method, not those Six Sigma stuff. (a bunch of old techniques copied from TQC!!).
    You can go to KT official website to order a book on this subject.

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    #101673

    Dog Sxxx
    Participant

    Another idiotic and ignorance talking from a so-called MBB trained by Motorola. Only belt holers know the part counting woh!! I was hired by your American MNCs to inspect and qualify thier Asian OEM suppliers for years. I personally check more boards than your number of postings here. 

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    #101639

    Dog Sxxx
    Participant

    Unlikely the poster has zero knowledge on the PCB defects must come from the part and connection. Reread the poster’s question before you give such an advice.

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    #101638

    Dog Sxxx
    Participant

    SS originator (not innovator!!) can be the company itself or in you word is Bill Smith. People with a little bit common sense shall know that late Bill Smith has nothing to do in my posting because he was passed away long time ago.
    I let the readers to judge themselves and I will stop responding to you on this issue.

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    #101636

    Dog Sxxx
    Participant

    It’s better not to drag a passed away person into our “dispute”. You shall be fully aware that I was referring to a SS company in my posting, not to late Bill Smith who is a respected person.
    BTW, I will email you the book titled to in a few days time.

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    #101635

    Dog Sxxx
    Participant

    There is a case study for SS implementation in an apparel company in China, but the article is written in Chinese language. You can search this article from a chinese search engine http://www.baidu.com if you know chinese language.

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    #101633

    Dog Sxxx
    Participant

    I learned some lean stuff from Oliver Wight people many years ago. Those OW people are true experts in their field unlike some people so-called MBB all over the place. Their materials are copyrighted which I cannot share with you. But I recommend you a value for money book on the lean subject written by a US guy. Pls give me your email address. 

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    #101631

    Dog Sxxx
    Participant

    This is a civilized manner from a “MBB” towards a dead person like Mr Bill Smith? Shame on you. 

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    #101614

    Dog Sxxx
    Participant

    Your case is not too strange for me. We have been hired to conduct GB and BB for companies which are being asked by their customer to get a “Six Sigma Certfication”. They treated SS like another ISO9000 certification.
    Your customers do not need any objective evidence from your company, they will feel the end result of “six sigma certification program”. :-)

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    #101613

    Dog Sxxx
    Participant

    I have seen frequently Japanese engineers solved problem without statistically proved as long as they solved the root cause(s). They go to the line and study the problem instead of discussing problem in the meeting room with a bunch of SS toolkits.
    I had statistically proved ok with a hypothesis test for a product quality report to my US counterpart thought I knew in my heart that the result is not ok. I laughed when I received a compliment email from my US counterpart saying I had submitted a good report to them. :-)

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    #101612

    Dog Sxxx
    Participant

    I think you have to get feedback from your process and product people and more importantly from your customers on all defect info before you declare them as your defect opportunities.
    Using an industry standard such as IPC-A-610 to define defect opportunities is an overkilled effort.

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    #101611

    Dog Sxxx
    Participant

    When I first dealing with Six Sigma, you may not heard about it until GE makes SS a new jargon in mid 90s.
    I am not saying I am an expert in SS. (And I will never claim I am a BB master afer a few weeks of training!). Actually I am sick to see people who overused and oversold belts like MBB, BB here and there. Go read a book titled “New Six Sigma” from Motorola people to konw about their comments about the belt holders.
    Japanese people have done all “Sx Sigma” stuff, but without using Six Sigma term as early as 70s. If you think Six Sigma in a new invention by US guy, then you shall take a step back to rethink about it.
    I do not need to advertise myself and my company in this forum. We have clinched a deal with SS originator for lean service. 

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    #101610

    Dog Sxxx
    Participant

    There are two typed of kanbans, one is called product dependent and product independent. You make use of product independent kanban to cater for many mixed products as you want. 

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    #101589

    Dog Sxxx
    Participant

     If you do not understand that distribution location is the difference between Cp and Cpk then you will have a serious problem figuring out anything in the Measure Phase which will seriously impede you effectiveness as any type of belt.
    Sorry, I have no belt thought I had helped a bunch of companies saved money long before so-called belt system was invented. Please bear in mind that sometimes a person does not want to engage any discussion with you does not mean that person know nothing about the subject.  

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    #101582

    Dog Sxxx
    Participant

    I make it short in my reply. Actually, I can’t write a very long essay. :-)
    1. The risk I mean in my context is the possibility of defect.
    2. For me, control and specification limits are conceptually two different things. I am not yet go into mathematic justification to prove and disapprove their relationship. :-)
    3. I don’t think I want to be dragged into the process capability and control discussion as you did to see some subtle and practical relationships for both limits.
     

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    #101581

    Dog Sxxx
    Participant

    Thank both Mike and you. No answer is a good answer until I convince myself with a little own research.

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    #101563

    Dog Sxxx
    Participant

    “The sigma you calculate from the average range will be very close to the standard deviation of the individual measurements if the process is in control.”
    Can you explain this?
    Thx by Dog Shxx
     

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    #101559

    Dog Sxxx
    Participant

    …the risk of occurance of special causes is always there unless there is a perfect system.

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    #101494

    Dog Sxxx
    Participant

    A typo correction, defect shall be detect.
    The control chart purpose is to DETECT any special causes presence in the process and remove it immediately. Everyone shall be aware that control chart is not a tool to prevent defect in any sense.

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    #101493

    Dog Sxxx
    Participant

    “I would run the process to a control chart. You might want to consider the fact that when you are controling a finished dimension you have put a control on a Y variable (SS problem solving equation Y = f(x)). Works better if you control the x’s (feed, speed, etc.) then you don’t have to watch the Y’s. By the time the Y goes bad you may be making defects.”
    Practicality is another issue in controlling X. No doubt that controlling X is more effective, but this part shall be taking care by your process characterization study which is to find out the relationship X and Y.
    If you have 4 major Xs, then you have to ask operator to plot and monitor 4 charts instead of one chart for big Y. A major X can then be influcened by many minor Xs in a machine or equipment.
    The control chart purpose is to defect any special causes presence in the process and remove it immediately. Everyone shall be aware that control chart is not a tool to prevent defect in any sense.
     
     

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    #101446

    Dog Sxxx
    Participant

    You can use pre-control chart or color chart if you want to make use of specification limits.
    The control limit in your chart has nothing to do with specification limit. Both are two different things. Tampering on common causes may increase the variation. 

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    #101418

    Dog Sxxx
    Participant

    People have to understand your writing first before they can contribute their ideas.

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    #101381

    Dog Sxxx
    Participant

    Kaizen is small and continuous or incremental improvements over time. Unlikely Kaizen screwed up Japanese in the last five decades. :-) 
    I am not sure Deming did say only breakthroughts can get things better thought I had read his book, “Out of the crisis” a decade ago.

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    #101376

    Dog Sxxx
    Participant

    Continuous means uninterrupted in time, sequence, substance, or extent.
    Continual is chiefly restricted to what is intermittent or repeated at intervals.
    I prefer “continuous improvement” than “continual improvement” because the improvement activities shall be uninterrupted all the time and not on a repeated cycle or pattern.
    ISO 9000 manual uses “continual” word. May be ISO only wants us to renew ISO certification on yearly basis. :-)

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    #101352

    Dog Sxxx
    Participant

    My field experience with US and Japan companies operating in Asia Pacific reveal that,
    American companies: American engineers prefer to document visual defects with a few thousand words and sketchings. Sometimes you need to teach basic English to local engineers first for them to understand such documents
    Japanese companies: Japanese engineers usually only provide one or two page visual standard with photos displayed and/or actual samples together with graphical work sequences or work instructions. In constrast, American engineers will provide you 10-20 pages (or even more in many cases!) long unreadable work instructions.
    Let use our common sense to judge which approach is more effective and efficient!

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    #101343

    Dog Sxxx
    Participant

    A few questions here
    Shall you pay more to inspector who catch more rejects or who can catch less rejects?
    Do you need another master inspector to gage inspector reliablity performance? So on and so on…
    It’s fair to pay less for an inspector who works in a line which is occupied by “bad” or new operators?
    Why shall I feedback defect problems to line operators if I can get more pays by detecting more defective parts from “bad” line?
    etc…
    I also thought about this kind of pay for inspection performance scheme when I was an engineer many years ago, but I had never implemented it due to such a complicated human factor. :-)
    In order to improve visual inspection efficiency, I suggest you conduct some eyeball correlations or you call it MSA and also provide them with “good” and “bad” visual actual samples for all inspectors and line operators.
     
     

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    #63482

    Dog Sxxx
    Participant

    This article speaks out same dilemma for using Six Sigma in software development.  http://www.adtmag.com/article.asp?id=9491

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    #101261

    Dog Sxxx
    Participant

    I do not think “k” is from Japanese word. I tend to believe that “k” is from a Latin word for coefficient or constant value. k is a common term used in Physics for coefficient value.

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    #101260

    Dog Sxxx
    Participant

    ISO9000 is one of the most stupid thing people shall avoid it. ISO was copying PDCA model from Six Sigma in their latest 2000 version. How many ISO-certified companies got the knowledge and commitment to practise PDCA continual improvement?

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    #101259

    Dog Sxxx
    Participant

    Do you need Six Sigma if you already operating at 5.5 sigma level? Toyota was using their own Toyota Production System (TPS), a production system based on lean enterprise concept. Lean is an idea copied from the US supermarket. PDCA cycle (DMAIC’s grandfather!) is widely used in TPS 
    The trend I see now is more and more American companies are looking at lean enterprise while only few Japanese comapaies are interested on Six Sigma.

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    #101204

    Dog Sxxx
    Participant

    Cpk is never more than Cp.

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    #101203

    Dog Sxxx
    Participant

    Cp and Cpk are measurements for the potential process capability. Obviously p stands for process, C stands for Capabilility or Capability index/ratio/factor. k represents a non-centering factor.
    Hope this answer can meet your expectation. Also check this useful statistics site http://www.http://www.statsoft.com/textbook/stathome.html to verify my answer.

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    #101200

    Dog Sxxx
    Participant

    First, work closely with your supplier to solve your incoming problem. Train their engineers for free if you need to do so. Second, find other better supplier if above effort fails due to lack of commitment from your supplier’s management.
    There is no such thing is called 100% inspection. I always challenge engineers sit in the line and show me that they can detect 100% defects with their eyes. Insofar no one dares to take this small challenge. :-)

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    #58136

    Dog Sxxx
    Participant

    In my opinion, lean concept is more applicable for service industries like banking. Customers are demanding faster trasanction speed from more user friendly and flawless banking processes/products. The priority shall eliminating non-value added waste and improving service quality with some lean and Six Sigma methods.
    All statistical tools can be used in the banking industry. For instance, a simple statistical tool like t- test can be used to tell those data collected from an improvd process has any significant different with the old process or not.  More advanced tool like Taguchi DOE can be used to determine what are the main input factors for a banking (new) product to satisfy customers. In the nutshell, what tools to be selected are all depending on the purpose of a study.

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    #101101

    Dog Sxxx
    Participant

    One of them is our client. Main problem in China is job hopping is a too common thing for BB. About 60-70% of BB trainees from our client left the company in within one year and looking for a greener pasture at somewhere else. This is a probable cause you cannot find any six sigma related public information from them. :-)
    Good and bad news for us and other consultants as well ! Good one is BB candidates trained by us are recognized by Chinese market while bad one is this company is quite hesitate to train more BBs in the future.
     
     

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    #101022

    Dog Sxxx
    Participant

    Look at the problem from two perspectives  1. Macro level 2. Micro level
    Macro level: Map the process with value stream technique. Identify non-value added processess and think some feasible and practical ways to eliminate or reduce them with IE improvement methods like elimination, simplification, combination etc. Also using six sigma method to further reduce value added process cycle time and improve process robustness.
    What we did are: For examples, redesigned floor layout after a comprehensive time and motion study to reduce wasted motions.  Introduced a single piece flow U-shaped cellular manufacturing line with 95% and above line balancing factor and implemented a simple kanban production control system to control WIP. Also forced QA to eliminate many non-value added visual inspections.
    Keep line pacing and takt time in mind when you are conducting time and motio study. 
    Micro Level: Study operators’ motions to design ergonomic work methods. For example, changed the screw typed to one-step spring typed clamping method and redesigned fixture/tooling to make it easy to be used by operators, not by tooling desginers who have never seen real production lines. Actually more than 20 improvement items were running simultaneously at any one time for the first six months of this project.
    An IBM auditor admitted that our plant is a first plant with paperless production system without a penny IT investment seen in her auditing life.
    Ideas for improvement are unlimited and people only need to use their innovative brain power to find them. (not with degree qualification or six sigma black belt certificate!)
    As far as I know, Motorola, TI and many other American MNCs are re-discovered lean enterprise usefulness after ignoring this simple technique for too long.
     

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