Production Performance Results Internet Sample

Jan.06.2004 Monthly Business Review Contents 1. Key Initiatives 2. Issues Appendix : December, 2003 President Customer Director Prepared by A.Arenas

Dec. Productivity (Final Lines) ,[object Object],[object Object],[object Object],[object Object],[object Object],Ctrl Idle 12.3% 38.2% Purchasing Effi. Lose 3.9% 12.6% Plastics Issue Solution Purchasing : Continiuosly Late with Material Creating Schedule Changes and Idle Time Plastics : Delivery and Quality Problems . ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],71% Issue Solution Absenteeism: High (4.4%) Turn Over (22) 22% Production (OJT) Absenteeism 3 /4 Production : Skill Up of Operators is required . ,[object Object],[object Object],[object Object],[object Object],100% Ctrl Idle 12.3% 0.9 RW 1.6% Indirect 3.4% 81.8% Total Input Hrs Net Direct Effi. Lose 15.3% 66.6% RMH Total Losses

3. Issues Risk & Opportunity Major Activities ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Activities Good & Bad ,[object Object],[object Object],[object Object],[object Object],[object Object],Action Plan Issues Solutions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],4 / 4

MBR Review ,[object Object],[object Object],[object Object],[object Object],1 of 15 President Customer Director Prepared by A.Arenas

24.1% 15.8% 100% FINAL RMH Analysis for Dec.’03 Action Plan Status Total DT = 12.3% 7.1% ,[object Object],[object Object],[object Object],[object Object],[object Object],On Going 53.1% TE Purchasing Plastics Other 100% Sub-Assy Final RMH 3 of 15 IQC LCD Line Fill Diode Short in Chassis Box Other Delivery + Quality Purity / IC5100 Damage EDIT (L6) Equipment ,[object Object],[object Object],[object Object],[object Object],On Going ,[object Object],[object Object],[object Object],On Going

36.1% 28.8% 57.5% 67.4% Chassis RMH Analysis for Dec’03 Action Plan Status Total DT = 12.9 % 23.5% On Going ,[object Object],[object Object],[object Object],[object Object],[object Object],Transistor Purchasing IC Diode 13.5% Other TE Empty out Lines for Inventory Checksum Chassis RMH 4 of 15 Other Mech. Maint. Plastics 32.6% Move to Component Plt. 42.5% Functional + VT equipment ,[object Object],[object Object],[object Object],On Going Other ,[object Object],[object Object],[object Object],[object Object],Closed

36.1% 13.8% 39.8% Final Quality Analysis for Dec’03 Action Plan Status Total Defects = 1394 Other ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],7.4% 6.8 Plastics Chassis Part Elect. Module 9.2% 63.2% Distorted Video Defective Digital Bd. On Going Final Quality 5 of 15 LCD Related Defects : Programming / No Turn On / No Video / Solder Shorts 6.2% 5.8% No Audio 49.8% Other Scratches 13.8% Nicks Bubbling Other B&W Tracking (Video Output) No Audio (JkPAck) 46.0% Other Module ,[object Object],[object Object],[object Object],[object Object],On Going ,[object Object],[object Object],[object Object],On Going

85.2% 14.8% 68.8% 16.7% 58.7% Chassis Quality Analysis for Dec’03 Action Plan Axial Status Total Defects = 511 Soldering Radials 20.0% Others ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],8.0% Axial Soldering Radial W/Line Solder Short Missing Wrong Missing Wrong High Runners Prioritization =============> Chassis Quality 6 of 15 No Solder 14.5% Other Other ,[object Object],[object Object],[object Object],[object Object],Closed

90.6% Rework Analysis for Dec’03 Action Plan ,[object Object],[object Object],[object Object],Status Total Rework cost = $ 5,051.79 100% Design Test Equip. 47.7% Closed ,[object Object],[object Object],Closed Open Mgmt. Decision 26% ,[object Object],[object Object],[object Object],[object Object],Closed Rework 7 of 15 Due to Bad AGC Set-up In Chassis Area . 9.4% CSA Label Not Implemented Design Change Yoke Cable on Domex 20” CRT Video Mute Problem Add Capacitor for RGB PIP 23% Distorted Menu . Change Internal register Production Other

66.6% Scrap Analysis for Dec’03 Action Plan Total Scrap = $ 26,601.00 41.0% 88.6% Scrap 3141-Chassis by Mech. Devices 687-PCB Damage By Machine ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Chassis Final ACI Other Material 8 of 15 Module 14.0% 19.4% 3141-Chassis By Machine 60.4% Other 6401-Speaker (Obsolete) 11.4% Other (Obsolete) 687-Module Machine Damage

Over Time Analysis for Dec’03 Action Plan Total Over Time = $ 144,273.20 Over Time Scheduling Volume required ,[object Object],[object Object],9 of 15

Absenteeism Analysis for Dec’03 Action Plan Total Absenteeism = 4.4% Absenteeism Other Sickness Dead / Sick Relative No Reason Given Resign Wake Up Late ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],10 of 15

2003 LGERS PERFORMANCE INDEXES 11 of 15

2003 LGERS PERFORMANCE INDEXES cont... 12 of 15

New 2 nd Half Manufacturing 6 Sigma Teams 94% ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Dropped (Resigned) 15 of 15 Budget Status 6 SIGMA THEMES Define Measure Analize Improve Control Bud. Adv. Optimize Balance Delay Time (LOB) in Chassis July to Oct 100% 96% Improve In Process Quality in Final Lines July to Oct 100% 80% Optimize Balance Delay Time (LOB) in Final Lines July to Oct 100% 100% Optimize WIP in Chassis area July to Oct 0% 0% Nov Dec July Aug Sep Oct Leader Stage of Project Team Members Timing Remarks Define Measure Analize Improve Control Bud. Adv. Optimize model change ACI May to Oct 100% 100% May Jun July Aug Project Leader Sep Oct Theme Green Belt Black Belt Super " A" YR'2003 Actual YR'2003 Goal 6 10 3 1 9 9 1 1 6 Sigma Status Budget Status 400% 376%

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