SMTA International Conference Proceedings


APPLYING SIX SIGMA TECHNIQUES TO CONTROL SCRAP COSTS AND IMPROVE QUALITY IN SMT MANUFACTURING

Authors: Hersh Kohli and *SooBeng Khoh, Ph.D.
Company: Motorola, Inc.
Date Published: 9/21/2003   Conference: SMTA International


Abstract: Controlling scrap in SMT manufacturing is of utmost importance to realize low conversion costs and to stay competitive in the market. This paper discussed some Six Sigma methodologies and tools used to achieve business results and improve process quality.

Manufacturing Pulse. software, i.e. a Motorola Six Sigma software tool, which is capable of reducing scrap costs by as much as 50% within weeks of field deployment is presented. The integration with Enterprise Resource Planning (ERP) software, coupled with its extensive suite of statistical tools, has enabled the software to control scrap costs in real-time. This simple but novelty approach in real-time scrap cost management is discussed.

This paper also discusses some of the common process control strategies and explains the need for SPC on input process parameters. With the advent of Automated Optical Inspection (AOI) in SMT manufacturing industry, this paper also examines on how Agilent’s (MVT) AOI machines can work in tandem with Motorola’s Manufacturing Pulse software in controlling SMT machine’s placement quality.

Key words: SMT, Six Sigma, process control, e-manufacturing, conversion cost, scrap, input, output, process parameters, DOE, design of experiments.



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