對對對 No ITEM SITE F/F cost H/C DATE Writer 1 [WP special – 10] Removal classifying scrap screw with shape D2E 2.5” - 3 April CH.KIM To-Be To-Be As-Is As-Is effecti ve ■ Removal this duty base on GUMI’s process - It doesn’t need classifying the scrap screw because it will be destroyed 1. H/C optimization_SUB[T6] operator’s role of this duty - Classifying the scrap screw with shape . 3 operators are allocated (D2D 1F, 2F, D2E) Removal of classifying 3men/shift can be reduced - this duty is extra activity for WP’s profit. so shouldn’t include on H/C list
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對外秘
No ITEM SITE F/F cost H/C DATE Writer
1 [WP special – 10] Removal classifying scrap screw with shape D2E 2.5” - 3 April CH.KIM
To-BeTo-BeAs-IsAs-Is
effective
■ Removal this duty base on GUMI’s process - It doesn’t need classifying the scrap screw because it will be destroyed
1. H/C optimization_SUB[T6]
■ operator’s role of this duty - Classifying the scrap screw with shape . 3 operators are allocated (D2D 1F, 2F, D2E)
Removal of classifying
3men/shift can be reduced - this duty is extra activity for WP’s profit. so shouldn’t include on H/C list
對外秘
No ITEM SITE F/F cost H/C DATE Writer2 [SUB - 11] removal duty what is MBA visual D2E 2.5” - 2 April CH.KIM
To-BeTo-BeAs-IsAs-Is
effective
■ Combine VMI with label attaching - label attach/VMI/stacking MBA → Moving MBA to Assy Cell (Marshal)
1. H/C optimization_SUB[T6]
■ operator’s role of this duty - checking whether MBA are defected - now’s process . Label attach(①) → VMI(②) → Stacking MBA(②) → moving MBA to Assy cell(Marshal)
Two operator are allocated in D2E 2.5” → 2 men/shift can be reduced by combine the duty with label attaching
The different point of AUTO line between GUMI and WP - All of moving from Assembly to H/T is automatic by conveyor but WP is not all
■ allocation sate base on Re-Layout
ETC
2. H/C optimization_C/R [T6]
H/T relayout
D2ED2D 2F
- Total operator : 13 名 /shift . D2D 2F : 9 名 /shift .. STA Line : 3men/line (total 3 Line) . D2E : 4 名 /shift .. N-HIT : 2 名 /shift → Total 3 Line 中 2Line is auto, 1Line is manual . Block Cell : 2 名 / shift .. 1 名 / block (total 2 block)
對外秘
To-BeTo-Be
No ITEM Content SITE F/F cost H/C DATE Writer
3 H/TDIST
[C/R - 14] reallocation label attaching operator in TAB block D2D 3.5” - 16 (24 → 8) June BR.LEE
To-BeTo-Be
ETC
2. H/C optimization_C/R [T6]
Reference data for this Item - TAB Assy (TCT : 20sec) – 1 block is including three TAB cells → Attaching Label operator only need to finish a set within 6.3sec
Allocation state of CASTW & H/T
DISTLabel attaching (24 名 )
■ Re-allocation of attaching label operator to dist step - 2men/block can be reduced (total 8 block) → H/C reduction effective : 16men/shift
■ now’s operator allocation plan - 1 men/cell → Total 24 名 are needed
對外秘
Effect H/C Optimization by Efficiency of PCBA supply process upD2D 4 名 , D2E 2 名 → D2D 2 名 , D2E 1 名
■ WP Status : PCBA ~ PBA Assy supply once a hour . Adjust supply interval/quantity (1 回 ) after analyzing daily/hourly output
¼¼ºÎºÐ¼®
No ITEM Content SITE F/F cost H/C DATE Writer
1 PCBA [B/E – 21] PCBA logistics improvement ALL ALL - 3 JulySM.LEEYM.KWO
N
3. H/C optimization_B/E[T6]
對外秘
Effect
Cut down 2 operators that belonged to“Packing & pallet distribution”(12 名 → 10 名 ) : It may have workload gap according to allocation of each Site ※ Analyze it based on not using auto taping machine ( when reflect auto taping machine, Expected that additional workload decrease
▷ Run the GF,1F’s Output by “1 Operator ( D1E Pallet distribution)” : 1F Packing Operator perform “ moving to EV “ after stacking Box on the pallet”
■ Vacuum Packing & Distribution Operator Analysis Unit 3.5" 2.5"
□ too many operator is allocated : 4 (preparing 3, distribution 1)□ no rule to distribute box to line□ preparing without table : particle and low quality
□ right person is 3 (preparing 2, distribution 1)□ make rule with set up Call System □ set up working table (L 2000 * W400 * H600)
1ea attach each linepreparing
③ ① operator - Box folding - Pe-bag - Cushion
①
②
② operator - inject Guide - Box stacking
③ distribution
Box
Cushion Pe Bag
가이드
- H/C reduction 1 名 (preparing 1 名 )- make distribution rule with set up Call System
À̵¿½Ã°£ºÐ¼®
No ITEM Content SITE F/F cost H/C DATE Writer
2 Packing
[B/E - 19] Improvement of packing material distribution D2D ALL - 1 July BS.Jegal
3. H/C optimization_B/E[T6]
對外秘
To-BeTo-BeAs-IsAs-Is
개선효과
③②
Cushion
①
Box
Pe Bag
가이드
높이 : 200mm
No ITEM Content SITE F/F cost H/C DATE Writer
3 Packing
[B/E - 19] Improvement of packing material distribution D2E ALL - 1 July BS.Jegal
□ too many operator is allocated : 4 (preparing 3, distribution 1)□ no rule to distribute box to line□ preparing without table : particle and low quality
□ right person is 3 (preparing 2, distribution 1)□ make rule with set up Call System □ set up working table (L 2000 * W400 * H600)
- H/C reduction 1 名 (preparing 1 名 )- make distribution rule with set up Call System
3. H/C optimization_B/E[T6]
對外秘
To-BeTo-BeAs-IsAs-Is
개선효과
③②
Cushion
①
Box
Pe Bag
가이드
높이 : 200mm
④
No ITEM Content SITE F/F cost H/C DATE Writer
4 Packing
[B/E - 19] Improvement of packing material distribution D1E ALL - 3 July BS.Jegal
□ too many operator is allocated : 7 (preparing 5, distribution 2)□ no rule to distribute box to line□ preparing without table : particle and low quality
□ right person is 4 (preparing 2, distribution 2)□ make rule with set up Call System □ set up working table (L 2000 * W400 * H600)
□ WP C/R : Disk Eraser, Burnish - D2D 1F (3.5”) 1 名 Arranged - Burnish waiting time takes too long ( Burnish C/V buffer enough)
No ITEM Content SITE F/F cost H/C DATE Writer 1 RWK [RWK-8] Disk Burnish & Eraser Process D2D/D2E ALL - 1 ~4/10 DY.CHOI
4. H/C optimization_RWK [T6]
對外秘
□ DMR Disk Burnish, Eraser Process efficiencies
▶ H/C point● Burnish test waiting time is too long, so, could run with Disk Eraser. - Burnish buffer conveyor is enough, there waiting time take too long
● So, each C/R, 1 operator could manage each Burnish & Eraser.
▶ Capacity simulation Machine Capa. 1day 1shift
BurnishTape 3 7,500 22,500 11,250 Head 1 3,000 3,000 1,500 Total 4 25,500 12,750
□ WP C/R : Disk VMI Test - 100pcs / 1 Hr (Standard of Gumi site) - 15 名 , (6.3M product)
No ITEM Content SITE F/F cost H/C DATE Writer 2 RWK [RWK-4] Disk VMI Process D2D/D2E ALL - 3 ~4/15 DY.CHOI
4. H/C optimization_RWK [T6]
對外秘
□ DMR Disk VMI Process efficiencies
▶ Different point from SEC ● SEC : . SEC Disk VMI standard is 100pcs / 1hrs (1pcs VMI take 36 sec) . Actually, Disk VMI time is more shorten than standard criteria.
● W/P . WP Disk VMI is 70pcs/1hrs ( 1pcs VMI take 51 sec)
● Conclusion : . Based on Gumi site, W/P takes more time for Disk VMI. . About 15sec more takes per 1 Disk (pcs)
※ Ref) - DMR Disk Yield Comparison (Disk DMR & Prime HSA Based) . Gumi Site : 2.5” 85.65% . W/P Site : 3.5” 83.57% → There is no Yield Gap showed
▶ Capacity simulation5.2M 6.3M Remark
Disk VMI Capacity 70 / 1 Hr 100 / 1 Hr 100 / 1Hrs is Gumi standard45,150 / 1 month 64,500 / 1 month 1day, 21.5hrs Based
T/D HDA 520,000 630,000 TTL Yield 90%T/D Disk 780,000 945,000 1 Month Based
(1 HDA is 1.5 Disk)NG Disk 30,000 36,000
TTL Disk waiting 810,000 975,000 1 Month Based13,500 16,250 1shift Based
VMI Operator 18 名 15 名 - 3 名
4. H/C optimization_RWK [T6]
對外秘
To-BeTo-BeAs-IsAs-Is
Effect
□ WP C/R : - Separated Process - Head Screen operator : 5 名
□ No need screen operator - FA engineer manage the Head screen machine for their Judgment tooling.
Head screenMachine
FAEngineer
No ITEM Content SITE F/F cost H/C DATE Writer 3 RWK [RWK-7] Head screen Test (STW Machine) D2D/D2E ALL - 5 JUNE DY.CHOI
4. H/C optimization_RWK [T6]
對外秘
□ C/R Head screen machine process
▶ H/C point● W/P C/R failures, too many Head screen test. So, need to operators. - Need to FA engineer skill up. . FA engineer education plan ① Gumi site prepare to education curriculum. ② Need to help for WPPE.
- If change the C/R FA process (head screen process), could able to stably fix the prime STW capacity.
▶ Different point from SEC
※ SEC : FA engineer help from the Head screen for their exactly Judgment
Main C/R Failure
C/R FA engineer
T/D or Re test
Head Screen
Main C/R Failure
C/R FA engineer
T/D or Re test
FA Head Screen
DebugDebug ( FA engineer )
Head screenor not
There is already fixed Head screen inputting failures
Debug
1. SEC 2. W/PAll debug controlledfrom FA Engineer
4. H/C optimization_RWK [T6]
對外秘
No ITEM Content SITE F/F cost H/C DATE Writer 4 RWK [RWK-3] DMR HSA VMI process removal D2D/D2E ALL - 11 immediately DY.CHOI
To-BeTo-BeAs-IsAs-Is
Effect
□ Move to DMR vendor for VMI Process → Replacement BU3, H&T VMI Process□ WP just view the HSA Bent & recycle scrap
● Conclusion : Because DMR vendor has been tested incoming visual inspection. So, no need overlapped VMI test at the WP. → For working efficiency of the WP, 1st WP VMI process removing and making like as SEC VMI process
※ Ref) - In SEC, currently HSA packing and sorting operators has been inspected the HSA Bent and recycle over check - BU3 incoming VMI result : additional 5% ~8% VMI detect → enough to VMI screen skill
BU3 Ãß°¡ VMI ºÒ·®(2.5")
BU3 Ãß°¡ VMI ºÒ·® (3.5")▶ Line & operator allocation
4. H/C optimization_RWK [T6]
對外秘
To-BeTo-BeAs-IsAs-Is
Effect
□ WP C/R : - Separated Top screw T/D & HDA T/D
Op : 1 名 → 0 名 , 1 名 ↓ .. D2D 1F (1 名 ) → (0 名 )
HDA T/D(Include Top screw T/D)
HDA T/D operator
Top screw T/D
HDA T/D
Top screw T/D operator
1 名
HDA T/D operator
□ WP C/R : - Top screw T/D & HDA T/D is 1 step operating
No ITEM Content SITE F/F cost H/C DATE Writer 5 RWK [RWK-2] HDA T/D (Top screw T/D) D2D 3.5” - 1 4/15 DY.CHOI
4. H/C optimization_RWK [T6]
對外秘
□ HDA T/D Process efficiencies
▶ WP has separated Top screw T/D & HDA T/D → It takes too more time and it need to more human resource.
. Gumi site : 1 step HDA T/D. → Gumi site is just 1 Step T/D process (① + ②) . W/P site : 2 step HDA T/D. → After top screw T/D(①), moving to original T/D Cell and HDA T/D(② )
( W/P only applied process )
[ 3.5” T/D Process of W/P ]
( Gumi site has not separated Top screw & HDA T/D )
DMR Process
③ ~ ⑩
② The other Screw T/D① Top screw T/D
4. H/C optimization_RWK [T6]
對外秘
To-BeTo-BeAs-IsAs-Is
Effect
□ WP C/R : - Specially WP has F41H Disk Swap process. (operator 1 名 arranged)
Op : 1 名 → 0 名 , 1 名 ↓ .. D2D 1F (1 名 ) → (0 名 )
□ WP C/R : - When F41H EOL, it will cancel.
Re-STW Set
Cover Re-Assy
HT Test
Cover Open
Disk Swap
T/DProcess
HSA T/D
Disk T/D
DMR process
F4-1H T/D Process
□ F41H Disk Swap process removal
Re-STW Set
Cover Re-Assy
HT Test
Cover Open
Disk Swap
HSA T/D
Disk T/D
DMR process
□ F41H Disk Swap (Operator 1 名 Arranged)
No ITEM Content SITE F/F cost H/C DATE Writer 6 RWK [RWK-2] HDA T/D (F41H Disk Swap) D2D 3.5” - 1 4/30 DY.CHOI
4. H/C optimization_RWK [T6]
對外秘
□ HDA T/D Process efficiencies
▶ Specially, WP has F4-1H Disk Swap process. - F4_1H Disk Swap : For reducing the T/D qty. - It couldn’t run to the CASTW and F4-1H using the up-head, so could swap the Disk without damage of the disk. - Gumi site, has not applied above process because the its product very small. (Now, already Gumi F4_1H has been EOL.
- Also, WP site, if F41H has EOL, this process no more need.
ASSY
SC~FT
AT
DIST
PCBA
Pass
Fail
Disk Swap
HT※ Disk Swap 2times → Fail
RW transfer
Re STW
Debug<Pass / Fail >
[ Disk Swap Process ] Re-STW Set
Cover Re-Assy
HT Test
Cover Open
Disk Swap
Set Barcode Reading
T/D Preparation
<Disk Swap Check>
T/DProcess
4. H/C optimization_RWK [T6]
對外秘
To-BeTo-BeAs-IsAs-Is
Effect
□ Marshaling operating : → Separated each Sub-operating.□ HSA Sub operating → Separated from each station.
EffectRWK Process, Label removal 5 名 H/C (10 名 → 5 名 ) : Based to Gumi process, Human resource optimization need to operator skill up.
▷ SEC : 1 operator arranged (1.55M product based) → Change the 6.3M based, could able to run 5 名 (4.3 名 ) ▷ Detail analysis
■ RWK Process, Label removal.
Process Unit SEC1.55M
WP5.2M
WP6.3M
SEC 6.3M H/C efficient
Cover label removal 名 0.2 3.0 3.6 0.8 2.2
MBA label removal 名 0.8 4.5 5.5 3.0 1.5
HDA label removal 名 0.1 2.5 3.0 0.4 2.1
Total 名 1.1 10.0 12.0 4.3 5.7
▶ 現 , WP arranged 10 名 (5.2M), Label removal op. could able to 5 名 (4.3 名 ) from the Gumi based. Label removal operator was also arranged to Sub material VMI, so could effect to 5 名 reduction - Sub Material VMI need to more 0.7 operator.
4. H/C optimization_RWK [T6]
對外秘
Process Gumi1.55M
Gumi6.3M
WP5.2M
WP6.3M Effect H/C Charged
Sub-VMI
Sub material Visual 1.4 5.7 3.0 3.6 -2.7 5.7 Sub Material VMI operatorRamp & Latch Visual 0.3 1.2 2.0 2.4 0.8 1.2 Sub Material VMI operator
MBA Visual 1.3 5.3 6.5 7.9 1.2 5.3 MBA VMI operatorTotal 3.0 12.2 11.5 13.9 -0.7 12.2
Label
Cover label removal 0.2 0.8 3.0 3.6 2.2 0.8 Sub Material VMI operatorMBA label removal 0.8 3.0 4.5 5.5 1.5 3.0 MarshalHDA label removal 0.1 0.4 2.5 3.0 2.1 0.4 Sub Material VMI operator
Stick label 0.0 0.0 2.0 2.4 Main processWindow label stick of
MBA 0.0 0.0 1.0 1.2 Main processTotal 1.1 4.3 10.0 12.1 5.7 4.3
Total 4.1 16.5 21.5 26.0 5.0 16.5
■ RWK Label removal operator.
- Based Gumi arranged operator, same rate applied. → VMI operator and Label removal operator is same process.
※ Sub-material H/C 5.7 名 reduction. ① Sub material VMI H/C (-0.7 名 ) - Sub material VMI (except, MBA, Ramp & Latch) : 2.7 名 increase - Ramp & Latch : 0.8 名 reduction (microscope VMI) - MBA VMI : 1.2 名 reduction (Except MBA Air-blowing operator) ② Label removal H/C ( 5.7 名 ) - Cover, HDA Label : Sub material VMI operator : 4.3 名 reduction
- MBA Label removal : MBA VMI operator : 1.5 名 reduction - Label (include, Window Label ) Stick : Main process. (except)
[ Unit : 名 ]
4. H/C optimization_RWK [T6]
對外秘
No ITEM Content SITE F/F cost H/C DATE Writer
9 RWK [WP special - 11] Unify RWK with Re-STW/HT D2D 3.5” - 2 名 (3.5 →
1.5) June
effective
Re-STW H/C optimization in RWK Process (3.5 名 → 1.5 名 ) : H/C optimization from modify WP process to GUMI’s one
To-BeTo-BeAs-IsAs-Is
□ separate MAIN process from RWK process - port gap of each cell in Main process - RWK Status : 5.5Cell / 3.5 名
□ MIAN □ RWK
□ Unify MAIN with RWK - Unify Main Prime & RWK - correlation the number of facility in each cell
□ MIAN □ RWK
4. H/C optimization_RWK [T6]
對外秘
To-BeTo-BeAs-IsAs-Is
Effect
□ WP, C/R inputting HDA process. . Human resource was separated for two station. . Gumi based, It is just one station and could optimize H/C.
▷ SEC : 1 FA Engineer controlled OOB set is 15.9K per shift.▷ WP : 1 FA Engineer controlled OOB set is 12.1K(5.2M) and 14.6K(6.3M) per shift. (current engineer based)
■ RWK Process, B/E FA Engineer.
1 shift 1 shift based
B/E 月 Capacity 月 OOB(Qty)
1 FA engineercontrol count
(Qty)WP need engineer
現 engineerarranged Effect
Gumi (1.55M) 1.55M 95K 15.9K 3 3 0
WP (5.2M) 5.2M 193K 15.9K 6 10 4
WP (6.3M) 6.3M 234K 15.9K 7.3 10 2.7
▷ It based each product Qty, so if changed product Qty, could able to change the FA engineer count.
□ WP, PCBA Rework Process improving. . From the Gumi site based, PCBA VMI operator control the PCBA dispose process. ( effect : 2 名 → 1 名 ) . cf.) Gumi has not issued PCBA discolor, so VMI process combined PCBA code D/L process
No ITEM Content SITE F/F cost H/C DATE Writer
12 RWK [RWK – 10 ] RTV PCBA & MRB material dispose D2E, D2D 2.5”
3.5” - 1 名 (2 → 1) 5 月
4. H/C optimization_RWK [T6]
對外秘
□ B/E PCBA Process optimization 1. W/P site : Each PBCA Rework process separated. - PCBA T/D - PCBA code D/L - PCBA discolor repair and VMI - RTV PCBA & MRB material dispose
2. Gumi site : For efficiently operating, some process has combined and simplified. - PCBA T/D - PCBA code D/L and VMI - RTV PCBA & MRB material dispose
※ Gumi has not issued PCBA discolor, so VMI process has combined with PCBA D/L station.
3. From the Gumi’s resource standard, RTV PCBA & MRB material dispose operator has arranged 1 operator. 4. PCBA D/L machine : Need to study for its efficiency (D/L Port increase & Code D/L speed up, etc)
5. Discolor issue : Need to study of root cause for its process removal.