This document summarizes an observation report on quality management systems and shop floor management. It discusses topics such as visual evaluation of manufacturing processes, quality targets and control plans, production control, quality development concepts, new shop floor management models, and mini-company management. Recommendations are provided on areas like process flow visibility, performance tracking, indirect staffing levels, and creating a positive working environment focused on continuous improvement.

1. Presented by YS Lin 2007-7-20 Observation Report

4. Visual evaluation of a good factory 5. Performance-information on the line per line per workplace Information on . Quality (short loop) . Efficiency (output) 6. Number of indirects on the floor? How many people “hanging-around” for . Supervision? (why?) . Q-problems . Material supply 7. Contact pattern? . Management presence on the floor? . Open offices?

5. Visual evaluation of a good factory 8. Is “production” the heart of the business? Are support departments really supporting? 9. Housekeeping Is the place clinically clean? 10. Working atmosphere? Do we smell the “winning spirit” ? 11. Would you like your son or daughter to work here in the “production” ?

6. Quality Target/Plan Control 1.Current state 2.Observation .Improvement plan by PDCA cycle with 5W2H approach .Variance analysis by CAR .Control chart/Flag chart system for management

8. Control Plan 1. Current state 2. Observation . Used for new product . Sampling plan design/correlation- Outside in IQC  EPI gate  FE gate  FQC  Customer IQC . Identical specification or engineering spec . Process verification between Product and Process characteristics . Responsibility between production and QA Production: operation, parameters check, self-inspection QA: Sampling, gate control, process audit .Visual inspection/control: QA  Production, Source management . Control method: application of MSA, SPC, Fool-proof, etc . Control document enhancement . Abnormal: Effectiveness of failure report

9. 3. Process check sheet design Ex: Prober by QA 4. ISO document review .Junior consultant? .Speak- Write – Doing  consistency? 5. Failure report review 異常報告單 .Design concept- open loop, sufficient analysis ability? .Top- 3 QMT teams organized- 側蝕 , 針痕 , 顏色異常 6. Reliability test- 恆溫恆濕 temperature, humidity? 7. Human resource: effective training, technical convention

10. Production Control M M+1 23 25 Sales forecast - Stock available =Net requirement Stagger table Production plan Production scheduling EPI FE BE PO Order Book Combined SO Shipping Instruction Bin table FQC Transaction Work order Closed SFM 驗證 Run Run card

11. 1.Coding: Raw material, parts, WIP, Finished product, Grade, Stock, Run card, Wafer no, Tape no, dept code, machine no, document, A/C, etc 2.Heavy loading to review the stock by bin and SO by range 3.MOQ, Lot size, extra costs for special grade? 4.Production to max capacity- high inventory 5.Capacity review model, bottle-neck management 6.No run card for EPI and BE  FIFO, real time tracking? 7.Mixed EPI lot input for FE – Between lot variation 8.Material requisition  Issue 9. 驗證 run- Process verification run

12. 10.Transaction stage: total 25 in FE  Main control stage 11.Manual tracking and expediting 12.Backlog issues: EPI, Quality, PM, single skill, 13.With 24 Hours full running: less flexibility to catch-up 14.Review mechanism: Sample run? Pilot run? New product? 15.Push  Pull, flow line, JIT, TPM? 16.Delivery performance indicators Throughput Yield Inventory Shipping quantity Loading OTD: on time delivery CLIP: cumulative line item performance CVP: cumulative volume performance Cycle time Inventory turns + σ ↓ Mean ↓

13. 品質的發展 品質的歷史面 品質的觀念面 品質的制度面 作業員的品質管制 領班的品質管制 檢驗員的品質管制 統計的品質管制 品質保證 全面品質管制 全面品質保證 品質是“檢查”出來的 品質是“製造”出來的 品質是“設計”出來的 品質是“管理”出來的 品質是“習慣”出來的 全面品管 (TQC) 品檢 (QI) 品管 (QC) 品保 (QA) 全面品保 (TQA)

14. CONTINUOUS IMPROVEMENT-CONCEPT 日常管理 實力維持 方針管理 實力提昇 . 減少變異 . 提昇水準 願景 A C P D A C P D A C S D A C S D

16. The New Shop Floor Management Model □ Glass wall management □ Scoreboard □ Floor meeting □ Organization of a work station □ Suggestion □ Storyboard □ Mini-company (Mission,Objectives,Business plan,PDCA) □ Improvement group □ Banker's meeting (Progress report,Monthly report ,Annual report) □ Study group □ Company awareness day □ Top management round table □ Sharing of progress (Display,Free lunch,Presentation ,Newsletter,Awards) □ Policy management □ Cross-functional management □ Management by exception □ Management by objectives □ Managing by wandering around □ Career planning □ 5S □ SOP □ JIT □ TPM □ Flow lines □ Poka-yoke Continuous Improvement □ Core values □ Vision □ Roles & responsibilities □ Management process □ Genba □ Exposing problems □ 5 Whys □ Empowerment □ Ownership □ Involvement of everybody □ Teamwork □ Collective wisdom □ Self-management □ Problem-solving tools □ Assessment □ Checklist □ Visual aids □ Benchmarking □ Upgrading skills □ Learning □ Recognition,Reward □ Communication □ Cross-training □ Job rotation Customer Need Customer-supplier relationship Thorough practice Adequate leadership Innovative culture Customer orientation Progressive organization People-oriented organization Increased capabilities Waste elimination Survival of the fittest Shop floor excellence CONCEPT/APPROACH ACTIVITIES GOALS

18. 品保部

20. QC 問題解決的步驟及 QC 手法 找出問題點 現狀的把握及目標的設定 表示原因及結果的關係 要因的解析 柏拉圖 散佈圖 直方圖 查檢圖 管制圖 特性要因圖 A B C 1 2 3 4 5

21. QC 問題解決的步驟及 QC 手法 要因的解析 層別 有相關 有時間的變化 對策的檢討及實施 效果的確認 標準化 ( 制 / 修定 ) 效果的維持 * * * * * * * * * * * A B C D E A B C D E

23. QC. STORY SHEET ASEK Dept .:_______ Leader :_______ Action Group :_______________________ 2. Why The Theme Selected 3. Analysis of Present Situation( Data Collection) 4. Cause & Effect Analysis Remark ： 8.Remaining Problems / Future Plan 1 ._________________________________ 2 ._________________________________ 3 .___________ ______________________ 4 ._________________________________ 5 ._________________________________ 6 ._________________________________ 7.Standardization 1 .________________________________ 2 .________________________________ 3 ._________________ _______________ 4 .________________________________ 5 .________________________________ 6 .________________________________ 7 .________________________________ 8 .________________________________ A P 6. Results Confirmation C Remark ： D 5. Action Plan / Implementation Remark ： 1. Theme Schedule Plan Actual Item Corrective Action Action by Fi ni sh Evidence

25. C A D P Team name ( 圈名 ) ： Dep’t ( 部門 ) ： 1.Theme ( 主題 ) ： 2.Why select this theme ( 選定理由 ) ： 3. Current status ( 現況分析 ) ： 4.Target Setting ( 目標設定 ) ： 5. Cause-Effect Analysis ( 要因分析 ) ： 6. Root Cause Verification ( 真因尋求 ) ： 7.Action implementation ( 對策實施 ) ： 8. Result Confirmation ( 效果確認 ) 9.Standardization ( 標準化 ) ： 10.Future chance ( 改善機會 ) ： ‧ 創意來源 ( 參考文獻 ) / Learning ‧ Solution ( 對策方法 ) ： ‧ Sharing ( 經驗分享 ) ： ‧ Learning ( 學習 ) ： ‧ Reference ( 參考文獻 ): One Page QC Story

31. 品質保證措施檢討

32. 異常報告之運用 異常處理 1. 管理 , 控制基準 2. 異常發現 3. 異常處置 4. 執行追蹤 異常報告 彙總 整理 經常發生 根本問題解決 檢討報告書 檢討‧ 分析 效果確認 標準化 日常管理 報告書要項 1. 問題點 2. 影響評估 3. CAUSE 4. 改進對策層別 5. 相關單位 / 擔當者 6. 完成日期 (EST,ACT) 應急措施 再發防止 點 線 面 ( 影響度 x 發生度 x 檢出度 = 重要度 ) 生產影響 , 重要度 ● 維持活動 ● HORIZONTAL DEPLOYMENT 推廣‧‧運用 擔當者 : 幹部 SUP. SR SUP. Y