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TQM tool

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  • #48982

    Roberto
    Member

    An electronic plant is experiencing soldering rejects on printed circuit   boards (PCB). Develop a comprehensive list of all the factors in the soldering process of a PCB, that could cause the effect of solder defects and have an impact on defect rate.    Illustrate with appropriate TQM tool/s   to organize the random list to show relationships and help management make intelligent choices.
    can u tell me which tqm tool is to use for this analysis and what report formate should i choose.please if any one can tell me in detail. i m really new to understand.

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    #166530

    Fake Harry Alert
    Participant

    Process Mapping,Root causation,5 Whys,R&R,Pareto,Scatter D.,
    Histogram,SPC (control charts,Range  Charts),etc.
    Use  one by  one (logical-wise),good  luck 

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    #166531

    Roberto
    Member

    thanks harry to let me know all tqm tools.
    but can u o me one favour? can u guie me what tools shoul i use in my perticular case( as i mentioned earlier) and what approach should i have before using that tool. i mean what should i know? why m doing this an why m i using it?
    thanks in advance,waiting for your reply.
     

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    #166532

    Roberto
    Member

    but i dont have any data.so i cant make any chart.
    in this perticular case wht approach shud i attemp?
    and what tools can i use , if i ont have any data, but still have to examine cause of problem.

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    #166533

    Fake Harry Alert
    Participant

    Process mapping,brainstorming,C&E Diagram,Roots Cuasation,5Whys,Identify VAS/NVA,Scatter D.,Histogram,Control Chart,Range Chart,Counter Measures to  rectify  faults ,observe improvements (before  and  after),etc.
    What else  you want  to  know?
    Start working,don’t  waste  time
    Apply R&R (and  Accuracy) to  ensure proper  data.
    Good Luck

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    #166534

    Deanb
    Participant

    If you have known defects, then you have potential data. You just need to start capturing and harnessing it. Suggest you start with inspection check sheets which document the nature of each defect (where, what, when, degree, etc). After you generate check sheet data, form a team of internal process experts to analyze defect commonalities and form hypothesis regarding causes. Then test these Ho’s and launch process improvement projects as warranted. If you still do not know where to begin, or lack the training or tools to do these things, then hiring a consultant might be your best option to get you started.It would also help to estimate what these defects are costing the organization, so you can justify economic investments to study and prevent them. The greater the failure costs, the more aggressive your approach can be. Good Luck.

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    #166535

    Om Sharma
    Participant

    Hi Roberto,
    Situation like yours is no different then others in the industry… dont worry, only a structural approcah would take care of the same.
    As per your requirement on choosing right tool to solve the problem through TQM tools. As you would be aware there are 4000 (four thousand) tools in TQM Philosophy).
    but to saolve a problem some basic 7 QC tools(Old and New) would solve maximum of problems.
    In your case particularly: you need look at C&E metrix with  Cause and Effect diagram (fish bone) to arrive at probable cause at macro level and then priortise the causes by frequency of occurance. chack for control and Uncontrol norms. through round robin brain storming arrive the possible solutions… and you are done.
    Do let me know if you need any clarification or further information
    Regards
    Om Sharma
    email: [email protected]
    web: http://www.qualityacademy.info
     

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    #166549

    Fake Harry Alert
    Participant

    That  is  difficult  for  just  as  beginner

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    #166552

    karl
    Participant

    PCB Soldering Issues – Suggestions
    First isolate the defects/types and where they originate
    1. Wave Soldering ( Fillets, Voids, Surface Defects, etc…)
    2. Surface Mount ( Reflow, Wetting, Mounting, etc)
    3. Hand Soldering ( Not a rework Process)
    4. Rework Processes for all the above.  This maybe the place to go to first to gather data and point back to the process where defect originated
    1. Tabulate totals from each category and create a Pareto Chart chart for the category.  If you can calculate costs of the defects within each category than create a pareto chart within each category for costs assosciated with each defect
    2.  Use a cause and effects matrix to establish where in each process (steps) the defects can occur to identify high risk processing steps. For instance wave solder step ( temperature of bath. flux, feed rate of board, etc)
    3. Identify high risk process steps on FMEA, and begin brainstorming prevention methds
    Regards

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    #166553

    Six Sigma Shooter
    Member

    Roberto,
    This looks a lot like a class assignment or a test question from a class that you might be taking.  As such, its scope is well defined, and has two elements: 1) create the list and 2) organize the list, show the relationships and priorities.
    For 1), you are looking at Cause and Effect (Ishakawa) Diagram and possibly the Five Why’s if no data exists, and Pareto Analysis if data does exist.  For 2) you are looking at the Affinity Process (to categorize the stuff from #1, above), the Interrelationship Diagraph (to show relationships among them) and Prioritization Matrices (to help management make their decisions).
    Shooter

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