CODE ORGANISATION TEAM - MPC

CODE ORGANISATION TEAM

E01 STMICROELECTRONICS SDN. BHD. UNITE WARRIORS TEAM

E02 SHAMAWAR ELEKTRIKA (M) SDN. BHD. FANTA'LECTUAL TEAM

E03 PANASONIC INDUSTRIAL DEVICES MALAYSIA SDN. BHD. MAX-Q

E04 STMICROELECTRONICS SDN. BHD. MCD WING

E05 PANASONIC INDUSTRIAL DEVICES MALAYSIA SDN. BHD. MUSE

E06INSTITUT PENYELIDIKAN DAN KEMAJUAN PERTANIAN

MALAYSIA (MARDI)AS INNOVATION

E07INSTITUT PENYELIDIKAN MARIN BORNEO UNIVERSITI

MALAYSIA SABAHKRUSTASI

E08JABATAN BOMBA DAN PENYELAMAT MALAYSIA NEGERI

SEMBILANTHE INVENTOR

E09 KEMENTERIAN PERTAHANAN MALAYSIA (MINDEF) SMART UAV

E10UNIVERSITI TUN HUSSEIN ONN MALAYSIA, PUSAT

KESIHATAN UNIVERSITISYNERGY

E11 FUJITSU COMPONENTS MALAYSIA SDN. BHD BANZAI

E12 AMKOR TECHNOLOGY MALAYSIA SDN. BHD. TORNADO

E13 STMICROELECTRONICS SDN. BHD. ONE QFP TEAM

E14 FUJITSU COMPONENTS MALAYSIA SDN. BHD MEGA FORCE

E15 PANASONIC MANUFACTURING MALAYSIA SDN. BHD. SUPERB GUARD

E16 PANASONIC INDUSTRIAL DEVICES MALAYSIA SDN. BHD. PLD FIRST VISION

E17 FUJITSU COMPONENTS MALAYSIA SDN. BHD MOMENTO

E18 INFINEON TECHNOLOGIES MALAYSIA SDN. BHD. EXCELLENCE

E19 STMICROELECTRONICS SDN. BHD. COMPAQ GOLD TEAM

E20 INFINEON TECHNOLOGIES MALAYSIA SDN. BHD. SEN GEN II

CODE ORGANISATION TEAM

E21 AMKOR TECHNOLOGY MALAYSIA SDN. BHD. MY TEAM

E22 SALUTICA ALLIED SOLUTIONS SDN. BHD. SPHERE 1.0

E23 PANASONIC MANUFACTURING MALAYSIA SDN. BHD. SUPREME PHENOLS

E24 SANMINA-SCI SYSTEMS (M) SDN. BHD. DRC GLADIATORS

E25 PANASONIC MANUFACTURING MALAYSIA SDN. BHD. Q-CSI

E26PANASONIC APPLIANCE AIR-CONDITIONING MALAYSIA

SDN. BHD.CHALLENGER

E27 PANASONIC INDUSTRIAL DEVICES MALAYSIA SDN. BHD. IDEOLOGY

E28 TAIPING MEDICAL CENTRE AMARYLLIS

E29 BI TECHNOLOGIES CORPORATION SDN BHD REPAIR BUSTER

E30 DENSO (M) SDN. BHD. ONE LOGISTIC

E31 BI TECHNOLOGIES CORPORATION SDN BHD MAT GAVER REBORN

E32 FINISAR MALAYSIA SDN BHD ALPHA

E33 FINISAR MALAYSIA SDN BHD TRANS - 7

E34 INFINEON TECHNOLOGIES MALAYSIA SDN. BHD. DESIRE

E35 PANASONIC SYSTEM NETWORKS MALAYSIA SDN. BHD. SUPERSONIC

E36 SANMINA-SCI SYSTEMS (M) SDN BHD THE B.BOT

E37 PANASONIC SYSTEM NETWORKS MALAYSIA SDN. BHD. CHALLENGER

E38 SANMINA-SCI SYSTEMS (M) SDN BHD APX RANGERS

E39 PANASONIC SYSTEM NETWORKS MALAYSIA SDN. BHD. FINESSE

E40PANASONIC AVC NETWORKS JOHOR MALAYSIA SDN.

BHD.H.A.I TEAM

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BORANG ABSTRAK

ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018 KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018

KATEGORI : ICC QE/5S √ LEAN TRIZ LAIN-LAIN

NAMA KUMPULAN TEAM NAME

: FANTA’LECTUAL TEAM

ORGANISASI ORGANISATION

: SHAMAWAR ELEKTRIKA SDN BHD

TAJUK PROJEK

PROJECT TITLE :

HIGH TIME FOR MACHINE SETTING, STOPPAGES AND BREAKDOWN AT IRONWORKER

PENJIMATAN PROJEK (RM /SETAHUN) PROJECT SAVINGS (RM /PER YEAR) *catatan: Penjimatan kos sebenar, masa & ruang yang terlibat)

:

RM 155,714.00

(Sila huraikan dalam Bahagian 2 – Borang D)

i. LATAR BELAKANG PROJEK : (MAKSIMUM 10 BARIS AYAT) PROJECT BACKGROUND: (MAXIMUM 10 LINE SENTENCES)

- Staff and operator did not familiar with machine parts and how to maintain machine. - High change over time for mould, it takes 2 to 4 hours to change one mould to another at

Ironworker. - Difficult installation process for machine mould. - High machine stoppages while running machine because of lack maintenance work. - High machine breakdown and it takes more than 1 hour to repair machine

ii. PUNCA UTAMA MASALAH : MOST POSSIBLE CAUSE(s) :

- High maintenance time for machine Ironworker - High machine breakdown and minor stoppages

- High change over time for Ironworker

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF : PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

- Total Productive Maintenance - Autonomous Maintenance

- Single Minute Exchange Die

iv. TANDA ARAS :

BENCHMARK :

To reduce 50% for below activity:

- Total Time for cleaning activity from 9,000sec to 4,500sec - Total Time for inspection activity from 1,885sec to 942.5sec - Total Time for lubrication activity from 2,214sec to 1,107sec

To reduce 50% for below activity :

- Machine breakdown 4 times/month to 2 times/month - Machine stoppages 5 times/month to 2.5 times/month

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BORANG ABSTRAK

To reduce 50% :

- Total Time for changing mould from 2,250sec to 1125sec

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI : PROJECT ACHIEVEMENT & VALUE CREATION :

- Total Time for Cleaning Activity = 66.4% - Total Time for Inspection Activity = 70.4% - Total Time for Lubrication Activity = 94.9% - No. of stoppages = 100.0% - No. of breakdown = 80.0% - Total time for stoppages and breakdown = 38.7%

vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN : AWARD, REWARD & RECOGNITION :

- 10 Terbaik PTL-PKS Creanova 2017 - Anugerah Emas Team Excellence Team Wilayah Tengah 2017

- 3 Bintang Pertandingan APIC 2017 di Genting Highland - Anugerah Emas Team Excellence Team Wilayah Tengah 2018

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA) PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

Muka 1/2

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BORANG ABSTRAK

Maklumat Penting:

1. Borang abstrak perlu dihantar selewat-lewatnya 15 Oktober 2018 (Isnin).

2. Sila kembalikan borang (dalam bentuk Microsoft Word) kepada Sekretariat APIC 2018 seperti di bawah melalui email atau faks (03-7955 1824) :

i. Mohd Khairul Nazir Nawi [email protected]

ii. Nik Haneez Amizan Nik Rosdi [email protected]

iii. Afiqah Liyana Abd Razak [email protected]

iv. Norliza Rosli [email protected]

mailto:[email protected]




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BORANG ABSTRAK

ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018

KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018

KATEGORI : / ICC QE/5S LEAN TRIZ LAIN-LAIN


: MCD WING


: STMICROELECTRONICS SDN BHD

TAJUK PROJEK PROJECT TITLE

: MENGHAPUSKAN SALAH LETAK KEDUDUKAN TRAY DI HANDLER DELTA MATRIX


:

RM 63,543.20



Projek ini adalah berkenaan dengan operator meletakkan tray yang salah kedudukan ke input loader. Masalah yang akan timbul ialah unit-unit yang hantar ke test akan mengakibatkan unit open short. Mengikut peraturan Antimixing Procedure open short tidak boleh ditest semula. Mesin perlu diberhentikan untuk mengeluarkan unit-unit yang barada di dalam mesin. Lepas itu lot tersebut perlu ON HOLD bagi jurutera dan melambatkan process seterusnya. Masalah ini berlaku di mesin Delta Matrix2, ia boleh menyebabkan yield, mesin OEE dan produktiviti menurun. Kumpulan kami telah menggunakan “T-Matrix” untuk membantu kita memilih masalah mata yang tertinggi untuk membuat projek. Untuk menganalisa punca masalah, kumpulan kami menggunakan Analisis Tool Ishikawa Diagram, 5W dan Why-Why Analysis. Kesimpulan projek penjimatan kos sebanyak RM 63,543.20 ditanggung oleh syarikat Delta Matrix disebabkan mesin masih bawah jaminan 2 tahun dan masalah dapat dihapuskan dengan kaedah poka yoke.

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BORANG ABSTRAK

ii.

PUNCA UTAMA MASALAH : MOST POSSIBLE CAUSE(s) :

Setelah menggunakan Analisis tool Ishikawa diagram punca utama datang dari mesin, bahan dan manusia.

Mesin – Bentuk guide tidak sesuai Manusia – Operator baru masih kurang kemahiran “Handling Lot Procedure” Bahan – Tiada tanda arah pada tray

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BORANG ABSTRAK

iii.

CADANGAN PENYELESAIAN INOVATIF & KREATIF : PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

Cadangan penyelesaian: 1. Mencadangkan guide tray diubahsuai agar selain menjadi guide terhadap tray, ia

turut juga menjadi Poka Yoke terhadap posisi tray.

2. Memberi rujukan ‘Handling Lot Procedure’ kepada operator baru semasa praktikal di production.

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BORANG ABSTRAK

iv. TANDA ARAS :

BENCHMARK :

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BORANG ABSTRAK

v.

PENCAPAIAN PROJEK & PENCIPTAAN NILAI : PROJECT ACHIEVEMENT & VALUE CREATION :

Pencapain projek dan penciptaan nilai ialah:

1. Mesin OEE telah meningkat kepada 59.8%

2. Pengeluaran MCD telah meningkat kepada 1413k pada Q4’17.

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BORANG ABSTRAK

3. Tiada aduan dari pelanggan

4. Bilangan lot meletakkan tray yang salah posisi telah menurun 100% iaitu sifar.

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BORANG ABSTRAK

vi.

ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN : AWARD, REWARD & RECOGNITION :

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BORANG ABSTRAK

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BORANG ABSTRAK

Maklumat Penting:







ABORANG ABSTRAK C

ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018


NAMA KUMPULANTEAM NAME : A.S. INNOVATION

ORGANISASIORGANISATION : INSTITUT PENYELIDIKAN DAN KEMAJUAN PERTANIAN (MARDI)

TAJUK PROJEKPROJECT TITLE : KOS UPAH KERJA PEMBERIAN MAKANAN DI KOLAM IKAN

TINGGI

PENJIMATAN PROJEK(RM /SETAHUN)PROJECT SAVINGS(RM /PER YEAR)*catatan: Penjimatan kos sebenar,masa & ruang yang terlibat)

:

RM / SETAHUN RM PER YEAR :

Penjimatan kos (outcome) :Kos sebelum projek dilaksana – Kos setelah projek dilaksana =Penjimatan (per tahun)= RM 43,200 – RM 36,900 = RM 6,300/tahun

*Penjimatan (impak) :RM 6,300 x 1587 = RM 9, 998, 100/tahun*Andaian 10% penternak di seluruh Malaysia menggunakan AquASoFF


i. LATAR BELAKANG PROJEK : (MAKSIMUM 10 BARIS AYAT)PROJECT BACKGROUND: (MAXIMUM 10 LINE SENTENCES)

Pemberian makanan ikan memberi kesan kepada pengurusan kolam penternakan ikan dan ikan itusendiri. Sekiranya ikan diberi makan pada waktu yang tidak tetap atau tidak menentu ia akanmempengaruhi tumbesaran ikan. Kebiasaannya, ikan diberi makan secara konvensional iaitu menaburterus makanan itu ke dalam kolam. Namun, kaedah ini memerlukan masa yang lama dan pekerja perlumenunggu sehingga ikan menghabiskan makanan. Makanan yang tidak dimakan akan mempengaruhimutu air kolam dan memberi kesan kepada tumbesaran serta penyakit kepada ikan.

Dengan menggunakan alat pemberi makanan ikan secara automatik, ianya memudahkan pekerjamemberi makanan kepada ikan dengan lebih sistematik dan dapat mengurangkan pembaziran.Penggunaan alat ini juga dapat menjimatkan kos upah kerja sekaligus mengurangkan penggunaan tenagakerja dan menjimatkan masa pengurusan kolam .

PUNCA UTAMA MASALAH :MOST POSSIBLE CAUSE(s) :

a) Kos upah kerja yang tinggib) Pembaziran makanan ketika pemberian makan ikanc) Memerlukan masa yang lama ketika memberi makan ikand) Pekerja menerima bebanan tugas melebihi kapasitie) Sistem pengurusan di kolam tidak cekap

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF :PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

Membangunkan satu mesin pemberian makanan ikan automatik yang dilengkapi dengan alat tetapan masadan boleh di set mengikut sela waktu tertentu. Mesin ini menggunakan bateri 12v dengan kapasiti 7.2AHdan di caj semula menggunakan panel solar 10W untuk memudahkan penternak sekiranya kolam beradajauh dari punca elektrik. Mesin ini juga mempunyai kapasiti isian makanan sehingga 20 kg dengantambahan 20 kg dalam ruang penyimpanan dan jarak sebaran 2.68 m x 1.2 m serta mampu menyemburmakanan keluar pada kadar 200 hingga 500 g dalam tempoh 1 minit.

iv.TANDA ARAS :BENCHMARK :

ABORANG ABSTRAK C

Teknologi ini mampu menjimatkan sebanyak 66.67% kos upah kerja dan dapat mengurangkan jumlahpenggunaan pekerja dari 3 orang kepada seorang (peratus penjimatan 66.67%). Teknologi ini jugadapat menjimatkan masa kerja pemberian makanan ikan di kolam sebanyak 88.33% iaitu dari 60 minitkepada 10 minit untuk kerja-kerja tersebut. Penggunaan makanan ikan dapat dikurangkan sehingga36.00% berbanding kaedah konvensional.

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI :PROJECT ACHIEVEMENT & VALUE CREATION :

*Jumlah Kolam = 9 kolam3 kolam = 1 pekerjaJangka hayat AquASoFF = 2 tahunJumlah penternak ikan air tawar di seluruh Malaysia = 15869 orang*Anggaran purata jumlah kolam yang dimiliki oleh setiap penternak di seluruh Malaysia

Penjimatan Kos Upah Kerja dan Pengurangan Tenaga Kerja

*Mesin AquASoFF hanya dibeli pada bulan pertama sahaja. Penjimatan adalah lebih pada tahun ke-2 danseterusnya.

Penjimatan Kos MakananSEBELUM SELEPAS PENJIMATAN

1 kolam = 25 beg makanan/bulan1 beg = 20kg (25 beg x 20kg =500kg)9 kolam x 25 beg/bulan = 225 beg(4500kg)Harga untuk 1 beg makanankomersial ialah RM80.00RM80 x 225 beg =RM18,000/bulan*Anggaran purata jumlah kolam yangdimiliki oleh setiap penternak di seluruhMalaysia

1 kolam =16 beg makanan/bulan(320kg)RM80 x 16beg = RM12809 kolam x 16beg/bulan = 144beg/bulanRM80 x 144 beg/bulan =RM11,520/bulan

Penjimatan kos makanan:RM18000 – RM11520 =RM6480/bulanPengurangan pembaziranmakanan: 25 beg – 16 beg =9 beg/bulanPenjimatan untuk setahun= RM 6480 x 12 bulan =RM77760/tahun

Penjimatan MasaSEBELUM SELEPAS

Penternak memerlukan 1 jam (20 minit x 3 kali)setiap kolam/hari untuk memberi makan ikan

Penternak hanya memerlukan 10 minit sehariuntuk memastikan mesin dalam keadaan sediadigunakan (isi semula makanan jika habis)

20 minit x 3 kali/hari = 60 minit 10 minit x 1 kali/hari = 10 minitTempoh penjimatan : 60 minit – 10 minit = 50 minit

% penjimatan : 50 minit x 100 = 83.33%60 minit

KONVENSIONAL AquASoFF

Tahun pertamaMemerlukan 3 orang pekerjaUpah kerja untuk 1 orang ialah RM 1,200/bulan

Upah kerja3 orang x RM 1,200 = RM 3,600/bulan

Upah kerja untuk 1 tahunRM 3,600 x 12 bulan = RM 43,200/tahun

Kos keseluruhan setahun ialah RM 43,200

Tahun pertamaHarga seunit mesin adalah RM 2,500

Untuk 9 kolamRM 2500 x 9 unit = RM 22,500

Upah kerja untuk 1 orang pekerja= RM 1,200/bulan

Upah kerja untuk 1 tahunRM 1,200 x 12 = RM 14,400/tahun

Kos keseluruhan setahunRM 22, 500 + RM 14,400 = RM 36,900

ABORANG ABSTRAK C

Kadar Pulangan PelaburanKadar diskaun Nilai

Nilai Kini Bersih (NPV) 10% $163,764Kadar Pulangan Dalaman (IRR) 98%Nisbah Faedah Kos (BCR) 10% $1.31Tempoh Pulang Modal Tahun 1Daya Maju Projek Berdaya Maju

Perkara/Tahun 1 2 3 4Keuntungan Bersih/Kg (RM) MYR 1.85 MYR 1.85 MYR 1.85 MYR 1.85Kos Pengeluaran/Kg (RM) MYR 3.15 MYR 3.15 MYR 3.15 MYR 3.15Pendapatan Bulanan (RM) MYR 7,484.17 MYR 7,484.17 MYR 7,484.17 MYR 7,484.17Titik Pulang Modal (Kg/Tahun) 11250 11250 11250 11250Titik Pulang Modal (Kg/Hari) 39.06 39.06 39.06 39.06

Purata Keuntungan Bersih (RM) MYR 89,810.00Purata Keuntungan Bersih/Kg (RM) MYR 1.85Purata Kos Pengeluaran/Kg (RM) MYR 3.15Purata Titik Pulang Modal (Kg/Tahun) 11250Purata Titik Pulang Modal (Kg/Hari) 39.06

Peningkatan tahap kepuasan pelanggana) Memudahkan aktiviti pengurusan kolamb) Dapat menjimatkan kos operasic) Boleh meningkatkan kerjasama antara penternak dengan MARDId) Dapat meningkatkan pendapatan penternak

Pencapaian objektif projekPerkara Sebelum

ProjekSelepasProjek

Peningkatan/penurunan (%)

Kos upah kerja (bulan) RM3600.00 RM1200.00 Menurun66.67%

Pengurangan tenaga kerja 3 1 Menurun66.67%

Penjimatan Kos Makanan RM2000 RM1280 Menurun36.00%

Penjimatan Masa (minit/hari) 60 10 Menurun83.33%

vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :AWARD, REWARD & RECOGNITION :

i. Pingat Perak Anugerah Akar Umbi MARDI 2016ii. Tempat Ketiga Konvensyen Kumpulan Inovatif Dan Kreatif (KIK) Peringkat MARDI 2017iii. Pingat Emas Konvensyen Team Excellence Peringkat Wilayah (RTEx) 2018iv. Pengkomersialan teknologi AquASoFF oleh pihak MARDI

Muka 1/2

ABORANG ABSTRAK C

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA)PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

ABORANG ABSTRAK C

Maklumat Penting:


2. Sila kembalikan borang (dalam bentuk Microsoft Word) kepada Sekretariat APIC 2018 seperti dibawah melalui email atau faks (03-7955 1824) :

i. Mohd Khairul Nazir Nawi [email protected]. Nik Haneez Amizan Nik Rosdi [email protected]. Afiqah Liyana Abd Razak [email protected]. Norliza Rosli [email protected]

Muka 2/2

ABORANG ABSTRAK


KATEGORI : x ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : KRUSTASI

ORGANISASIORGANISATION : INSTITUT PENYELIDIKAN MARIN BORNEO, UNIVERSITI MALAYSIA SABAH

TAJUK PROJEKPROJECT TITLE : PENGGUNAAN AIR LAUT DAN KOS GUNATENAGA YANG TINGGI DALAM

PENTERNAKAN INDUK KETAM BAKAU DI DALAM TANGKI


:

RM35,144.00


i. LATAR BELAKANG PROJEK : PROJECTBACKGROUND:

Sebagai usaha untuk mengatasi kebergantungan kepada bekalan induk ketam bakau dari kawasansemulajadi, IPMB melalui Hatceri Udang telah mengambil inisiatif untuk menternak induk ketam bakau didalam tangki. Secara umumnya, sistem pengurusan induk ketam di dalam tangki memerlukan air laut yangbanyak, pertukaran air laut yang kerap dan guna tenaga yang tinggi. Di samping itu, proses penggantiandan pembersihan lapisan pasir di dasar tangki yang berfungsi sebagai penapis dan habitat kepada ketambakau turut mengambil masa yang lama serta guna tenaga yang tinggi. Bagi mengatasi masalah tersebut,Kumpulan KIK KRUSTASI daripada IPMB telah merekacipta satu sistem baharu iaitu ‘Autonomous Tidal TankSystem' bagi tujuan pengurusan induk ketam bakau di dalam tangki. Sistem ini berupaya mengurangkanguna tenaga pengurusan tangki induk ketam bakau sehingga 90%, mengurangkan penggunaan air lautsehingga 86%, menjimatkan masa pengurusan tangki sehingga 81% dan menjimatkan kos pengurusantangki induk sehingga 81%. Habitat dalam tangki Autonomous Tidal Tank System yang menyerupai keadaansemulajadi telah berjaya meningkatkan jumlah penghasilan serta kualiti telur ketam bakau.

ii. PUNCA UTAMA MASALAH :MOST POSSIBLE CAUSE(s) :

Punca utama masalah penggunaan air laut dan kos guna tenaga yang tinggi dalam penternakan indukketam bakau di tangki ialah ;

1. Penggantian air laut dan bahan penapis (pasir) tangki induk perlu dilakukan lebih kerap2. Penggantian air laut tangki induk mengikut air pasang surut dilakukan secara manual3. Masa yang diperlukan untuk kerja-kerja penggantian air laut dan bahan penapis tangki induk lebih

lama


Membangunkan sistem tangki induk ketam bakau ‘Autonomous Tidal Tank System' dimana penggunaansistem ini membolehkan penukaran air laut dapat dilakukan secara automatik mengikut air pasang surut.


1. Berdasarkan penyelidikan oleh penyelidik di Institut Penyelidikan Marin Borneo (IPMB, UMS2. Berdasarkan beberapa siri percubaan pembangunan sistem tangki induk ketam bakau oleh

kakitangan Hatceri Udang, IPMB

ABORANG ABSTRAK


Bejaya mencapai sasaran projek;1. Mengurangkan guna tenaga pengurusan tangki sehingga 90% (42 Jam/Minggu ke 4 Jam/Minggu)2. Menjimatkan penggunaan air laut sehingga 86% (14000 ltr/Minggu ke 2000 ltr/Minggu), Seterusnya

dapat mengurangkan kos utiliti dan kos penyelenggaraan pam.3. Menjimatkan masa pengurusan tangki sehingga 81% (21 Jam/Minggu ke 4 Jam/Minggu)4. Menjimatkan kos pengurusan tangki induk sehingga 81% (RM168.00/Minggu ke RM32.00/Minggu)

Impak Projek1. Meningkatkan jumlah penghasilan dan kualiti telur ketam bakau2. Mengurangkan kebergantungan kepada populasi ketam di kawasan semulajadi seterusnya

menyokong Industri Akuakultur Lestari3. Membangunkan industri akuakultur ketam bakau melalui latihan kepada pengusaha akuakultur.4. Menyokong Amalan Penjimatan5. Meningkatkan kualiti air dalam tangki induk ketam bakau6. Membudayakan Amalan ’Do It Yourself (DIY)7. Membudayakan Amalan Kitar Semula8. Menyokong Dasar Keselamatan dan Kesihatan Pekerjaan

Jumlah Penciptaan Nilai = RM43,144.00 (Perincian seperti Borang D)


1. Johan, Konvensyen Kumpulan Penggerak Inovasi, Sempena Sambutan Bulan Kreanova UMSTahun 2017, Universiti Malaysia Sabah.

2. Anugerah Emas, Konvensyen Mini Team Excellence (MTEx) 2018, Wilayah Sabah, 17 April 2018,Kota Kinabalu.

3. Anugerah Emas, Konvensyen KIK Wilayah Sabah-Sarawak, 1 – 2 Ogos 2018, Kota Kinabalu4. Anugerah Perak, Konvensyen Peringkat Universiti Awam 2018, 13-15 Ogos 2018, Universiti Malaya

vi. GAMBAR PROJEK:PROJECT PICTURE(s) : Muka 1/2

Autonomous Tidal Tank System yang dilengkapidengan dengan sistem kawalan masa timer sertalapisan pasir yang berfungsi sebagai penapis danhabitat kepada induk ketam bakau. Tangki ini jugadilengkapi dengan sistem pengudaraan dan stoktangki air laut.

Sistem kawalan air pasang surut AutonomousTidal Tank System menggunakan timer. Sistem iniberjaya mengujudkan keadaan yang menyerupaikawasan semulajadi

ABORANG ABSTRAK C


KATEGORI : √ ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : SYNERGY

ORGANISASIORGANISATION : UNIVERSITI TUN HUSSEIN ONN MALAYSIA (UTHM)

TAJUK PROJEKPROJECT TITLE : PROSEDUR ”EAR SYRINGING” MENGAMBIL MASA YANG LAMA


: RM 44,107.54



1. KAEDAH RAWATAN UNTUK MEMBERSIHKAN “ AUDITORY CANAL” (SALUR TELINGALUAR) DI DALAM KEADAAN SEPERTI SUMBATAN OLEH “CERUMEN” (TAHI TELINGAMAMPAT), KEHADIRAN BENDA ASING DAN “OTITIS EXTERNA” (JANGKITAN SALURTELINGA LUAR). PESAKIT BIASANYA AKAN MENGADU TELINGA PEKAK DAN SAKIT.

2. TEKANAN DARIPADA ALAT YANG DIGUNAKAN SEMASA PROSEDUR MENYEBABKANPESAKIT MERASA SAKIT.

3. AIR TADAHAN KOTORAN MUDAH TERTUMPAH KETIKA PROSEDUR DIJALANKAN.4. AIR LELEHAN MENYEBABKAN BAJU PESAKIT BASAH5. PESAKIT TIDAK SELESA KERANA BERKONGSI TEMPAT PROSEDUR DENGAN PESAKIT

LAIN.


PROSEDUR ”EAR SYRINGING” MENGAMBIL MASA YANG LAMA

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF :PROPOSED INNOVATION & CREATIVE SOLUTION (S) :

MENCIPTA ALAT UNTUK RAWATAN MEMBERSIHKAN KOTORAN TELINGA YANG TERSUMBATDENGAN CARA MUDAH, MENJIMATKAN MASA, TENAGA KERJA, MENGURANGKAN MASAMENUNGGGU, ”ANTI-LEAKING”, SELESA DAN TIDAK MENYAKITKAN.


1. KLINIK KESIHATAN PARIT RAJA, BATU PAHAT, JOHOR.2. KLINIK SEJAHTERA, PARIT RAJA, BATU PAHAT, JOHOR.3. PUSAT KESIHATAN UNIVERSITI UNIVERSITI SAINS ISLAM MALAYSIA (USIM)


1. PENJIMATAN MASA2. PENJIMATAN BAHAN PAKAI BUANG3. PENJANAAN PENJIMATAN MASA4. PENJIMATAN TENAGA5. SELAMAT DAN SELESA

ABORANG ABSTRAK C


1. KONVENSYEN KIK UTHM 2018 - 15 MEI 2018 - BILIK BANQUET DSI UTHM- PENARAFAN EMAS

2. KONVENSYEN TEAM EXCELLENCE WILAYAH PANTAI TIMUR 2018 – 4-5 JULAI 2018 -BUKIT GAMBANG CITY RESORT, PAHANG-PENARAFAN EMAS


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KATEGORI : ICC QE/5S LEAN TRIZ LAIN-LAIN


: BANZAI


: FUJITSU COMPONENT (M) SDN. BHD.

TAJUK PROJEK

PROJECT TITLE : MENGURANGKAN REJECT COIL ASSY DROP


:

RM 9436.88



Kami dapati rejek di Mesin Auto Core Yoke Riverting adalah diantara tertinggi berbanding mesin yang lain dan rejek coil assy drop adalah rejek yang tertinggi diantara rejek di Mesin Auto Core Yoke Riverting . Oleh itu, setelah membuat pelbagai analisa kami telah memilih tajuk untuk mengurangkan reject coil assy drop disebabkan semasa pemasangan core dan yoke.Kami juga telah membuat analisa bahawa punca masalah yang kami jumpa jika diselesaikan boleh mengurangkan rejek keseluruhan Mesin Auto Core Yoke Riverting ini. Ahli kumpulan kami telah mengemukakan pelbagai punya masalah yang mungkin berlaku bagi mendapatkan keputusan yang sebenar.


1. Pemasangan Core

2. Pemasangan Yoke


1. Merekabentuk sensor baru pemegang sensor PS1 2. Menukar jenis bahan unit CY 16

3. Menukar jenis sensor PS1

iv. TANDA ARAS :

BENCHMARK :

Penggunaan analisa masalah digunakan bagi penyelesaian masalah dan menghasilkan idea seperti

1. Struktur perlu diubah suai 2. Ketepatan penggunaan sensor


Pengurangan Rejek Di Mesin Auto Core Yoke Riverting dapat diatasi .


2018 – Keempat Peringkat QCD Internal Convention 2018 – Emas di Konvensyen Team Excellence Peringkat Wilayah Selatan

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NAMA KUMPULANTEAM NAME : TORNADO

ORGANISASIORGANISATION : AMKOR TECHNOLOGY MALAYSIA SDN BHD

TAJUK PROJEKPROJECT TITLE : TSOP MOLD SCRATCH REDUCTION


: RM50.5 RIBU /SETAHUN



For the past 4 month ( May. 17 - Aug. 17 ), Mold Scratch is the one of the main assembly defect for TSOPpackage. This defect impact our profitability with cost of poor quality (COPQ) of 94.8KRM/year. This projectwill targeting to reduce Mold scratch defect by 50% from defect rate of (0.28% to 0.14%) on Jan 2018 withtotal saving of 45.9KRM/year.


2 main cause :-1. Guiding block dented/scratch2. Drum Blade dented/scratch


X1 Guiding block dented/scratch- Change new design to guiding block

X2 Drum Blade dented/scratch- Change new design to full covered window clamer


BENCHMARK – Package TO-220FP – Defect Mold Scratch 0.15%


Defect Mold Scratch rate of 0.28% to 0.14%

ABORANG ABSTRAK


Internel 2nd Runner Up SIT ProjectGold Medal MPC Konvesyen Wilayah Team Excellence (RTex) Peringkat Wilayah Tengah 2018


Maklumat Penting:




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Drum blade

Guiding block

Old New

Old New

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KATEGORI : X ICC QE/5S LEAN TRIZ LAIN-LAIN


: OneQFP


: ST MICROELECTRONICS SDN BHD


: TO REDUCE INDEXING PROBLEM AT WIRE BOND AND PLASMA


:

Jumlah Nilai Tambah Hasil : RM 1,715,314

Jumlah Penjimatan Kos Dihasilkan : RM 1,191,204

Jumlan Penciptaan Nilai : RM 2,906,518

Penjimtan Masa : 492hrs


In ST Microelectronics, we manufacture sophisticated electronic part that is assemble in Top Range Model Cars used for ABS, Air Bag and Fuel injection etc. The Automotive manufacturing market demand for Zero Defect in each unit that shipped out from our plant. To meet this market expectation and demand a robust process is inevitable and inadvertent human error cannot be compromise. ST Muar has “Lean Manufacturing Concept” whereby it focuses on Muda: Waste Reduction, Poka-Yoke: Error Proofing, Jidoka: Auto Detection of Defects, Heijunka: Level Loading, Gemba, Total Employee Involvement, ICC and Supply Chain Management. Damaged Frame is a defect that causes the product to fail which lead to scarp and quality defect. Our Team OneQFP formed in the month Jun 17 to eliminate or reduce Damaged Frame at Plasma & Wire Bond Process. The OneQFP team spend endless effort in achieving the target and expectation of the project through Systematic Problem Solving (Data Collection, Interrelationship diagraph, Ishikawa, Pareto, PM analysis, Why-Why Analysis, PDCA, Kaizen). It was a very challenging moment where simple idea where made into realistic solution. We delivered an estimated cost saving of about RM 2.9 million and time saving of 492 hrs through systematic removal potential root causes.

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ii.

PUNCA UTAMA MASALAH : MOST POSSIBLE CAUSE(s) :

Using the famous Ishikawa Diagram the team was able look at all the possible causes that were mainly contributed by “Machine factors”, after then applying “Causal Factor verification” to screen down between significant and non-significant causal factors, there were 5 potential causal factors which then analyzed by Why-Why Analysis for associated root cause.


A brainstorming session to generate innovative ideas, a systematic screening was done to sort out the best ideas for implementation and we were able to produce 8 innovative solution that will help suppress Damaged frame. We tested all the 8 Ideas and only selected 5 idea that was valid to overcome the root cause.

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iv. TANDA ARAS :

BENCHMARK :

Benchmark past performance data for 2 years on damaged frame and identified the lowest possible rate that could be achieved .Used the 2550 (Nov’15) firgure as reference to set target for the team project.


With Installation all 5 innovative ideas on the Plasma & Wire Bond machines, an estimated Saving of = RM 2,906,518 821,813per year due to scrap reduction and cost avoidance. Downtime Saving of 492 hrs. Impact to environment on recycle reduced by 87% due to scrap reduction.

• Eliminated unwanted stoppages at WB for KNS Output, ASM Output & ESEC by 50% and Plasma Input to zero.

• Prevent unwanted NVD Task on Gripper paw replacement • 45 min per Machine Downtime reduction 372 hrs. • MTBI improved from 37 min to 47 min gain 35%. • Reduction on Defect Rate from 4267 to 563 with 87% gain. • Prevented damaged frame at the mold input from 6603 to Zero defect • Productivity improved for from 26.5 k to 28 k, gain 4.8% /month. • Eliminate ECC on AL FM coming from Back Rail. From three cases to Zero. • Project Cost Saving : RM 2.9 Million

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vi.


• ST ICC Convention won Champion team

• Mini convention MPC 2018 – Gold Award

• Mini convention MPC 2018– Most promising Innovative and Creative Team Award

• Regional Convention 2018– Gold Award

• Best Suggestion Award -2018

• Best Lean Workshop Team Award -2018

• ST New Breakthrough Invention Award – 2018

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Creative and Innovative 4 cost saving RM 972K

Creative and Innovative1 cost saving New Breathrough Innovation to prevent damaged Frame at plasma input

When load exceed 140gram due to jamming the the additional not transmitted on the frame and damaged frame averted .

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KATEGORI : × ICC QE/5S LEAN TRIZ LAIN-LAIN


: MEGA FORCE

ORGANISASI

ORGANISATION : FUJITSU COMPONENT (MALAYSIA) SDN BHD


: TO REDUCE P4 RELAY REJECT CAUSED BY DUST

PENJIMATAN PROJEK (RM /SETAHUN)

PROJECT SAVINGS (RM /PER YEAR) *catatan: Penjimatan kos sebenar, masa & ruang yang terlibat)

:

RM5093.09 / MONTH.

SAVE RM61,117.08 / YEAR



1. Project are carry out due to high relay spoilage reject at Relay Production. 2. P4 relay series is among the highest relay reject compare others relay series. 3. P4 process Middle scope and Final electrical is highest reject. 4. Dust matter is the main factor contribute to high reject. 5. Improvement of the dust matter also improve the quality supply to the customer.


1. MAN - Reject Wrong judgement by operator (defect bypass). 2. MACHINE - Machine not enough cleaning to remove dust. 3. MATERIAL - Cover stick and Make Terminal insertion produce dust. 4. METHOD - No standardization of wearing cleanroom uniform.


1. MAN - Provide SOP for details checking items. 2. MACHINE - Additional air blow at important process (base assy, checker and ADC). 3. MATERIAL - Cover modify and Make Terminal modify. 4. METHOD - Provide SOP for standardization of wearing cleanroom uniform.

iv. TANDA ARAS :

BENCHMARK :

Project is bench mark from company KPI which to reduction of 30% spoilage items. 30% reduction also within members ability target.


1. For members - Enhance team work and members responsibility. 2. For company - Cost saving, increase productivity and quality. 3. For Environment - Save the nature by reduce spoilage. The most important is good quality product and customer trust.


2nd PRIZE - Fujitsu Internal QCD In-house convention in April 2018. EMAS - SOUTHERN CONVENTION 2018

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FACTOR PROBLEM SOLUTION

Modification Area

MACHINE

MATERIAL 1

PROCEDURE OF ROUGH SKETCH

OPERATION AND REMARK

The scope check process must carry out to overall relay position.

The relay position to check is follow as step1 to step6.

THE STEP FOR MIDDLE INSPECTION SCOPE CHECK

Step Photo Description

Base surface area 1: Base surface.

a: Resin minus.

b: Resin Plus.

c: No sealing.

d: Base-up.

Step 1 e: Base dirty

f: NG assembly.

Yoke, bobbin & base area. 2: Yoke, base mould & Bobbin area.

a: Terminal Bend.

b: Bobbin crack.

c: Base damage.

Step 2 d: Base-up.

e: Contact floating / shifting.

f: NG assembly.

g: Contact rivet NG.

h: Core rivet NG.

Top coil surface 3: Coil surface

a: Surface damage

b: Stray wire

Step 3 c: Wire loose.d: Lead terminal bend.

e: Wire welding NG.

f: Lead wire damage

g: Lead wire bend.

h: wire broken.

Spring and core area. 4: Spring and core area.

a: Movable bending.

b: Welding NG.

c: Armature touch bobbin.d:

Step 4 d: base/bobbin/spring scratch or

damage.

e: NG assembly.

Side Make terminal insert area. 5: Side Make terminal insert area.a: Armature rivet damage.

b: Make terminal Bend / damage.c: Terminal bending.

d: Bobbin damage

Step 5 e: Base damage

f: NG assembly.

Side movable spring area. 6: Side movable spring area.a: Armature rivet damage.

b: Movable Spring Bend./ damage.

c: Terminal bending.

Step 6 d: Bobbin damage

e: Base damage

f: NG assembly.

TITLE SPEC NO : SHEET

OPERATIONAL INSTRUCTION FOR OPIN-RLEN-5002-0023 11 FUJITSU COMPONENT ( M ) SDN. BHD.

MIDDLE INSPECTION DRAW NO : 20

MAIN POINT OF OPERATION

12

MAN

Wrong judgement

by operator. Review SOP to detail inspection items.

Machine not enough cleaning to remove dust.

Additional air blow

unit.

Cover stuck. Cover modify.

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METHOD

Cleanroom uniform wearing no follow

standard rules.

SOP provide detail about correct method of wearing cleanroom

uniform.

Terminal Insert bari. Terminal modify.

MATERIAL 2

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: SUPERB GUARD


: PANASONIC MANUFACTURING MALAYSIA BERHAD


: REDUCE FRONT AND REAR GUARD REJECTION


:

RM / SETAHUN : RM 40, 787.66



Our main project is to reduce rejection rate that affected serious quality issue and high lost cost. Our theme selected is to reduce guard rejection in electric fan department. Our project was based on PDCA where the PDCA means Plan, Do, Check, and Action cycle. We plan to complete our project by 298 days. Based on data collected on May 2017 to Apr 2018, Defective rate at 0.65% We would like to reduce 50 % by SEPT 2018.

ii. PUNCA UTAMA MASALAH :

MOST POSSIBLE CAUSE(s) :

There are five possible causes in this project.: 1) Conveyor dirty and dusty 2) Oven dirt. 3) Angle hanger 4) Guard scratches Guard poor arrangement

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF :

PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

There are five countermeasures in our project. : 1) Service conveyor every 6 month. 2) Production engineering change the new oven tube. 3) New design, change angle hook from 60°to 45°degree to avoid the parts easy to drop inside

oven. 4) Reduce maximum quantity front guard on working table.

5) Put bubble sheet to prevent guard touch each other.

iv. TANDA ARAS :

BENCHMARK :

The project achievement result is benchmarked using the bar chart method by monitoring the perfomance of the process monthly versus the targetted plan. The project is launched with the mission of reducing at least 50% of its initial defective ratio.


In terms of tangible benefits, we managed to achive a gross saving of Rm 40,787.66 per year from the rejection of defective and the accomplishment of the project plan and target. For tangible benefits, we managed to improve the awareness of the members towards the workplace and their surrounding, exposed to varios kinds of technology enhancement, generated the theoretical thinking of members and to cultivate the courtesy of the members towards the quality improvement.

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vi.


Award : 1) 2018 PES Internal Qcc – Best Effort. 2) 2018 ES MY QCC – Best Effort. 3) 2018 Konvensyen Team Excellence Peringkat Wilayah (Rtex) – Gold Award

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA)

PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

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Introduction Company Background Arrow Diagram

PMMA Organisation Group Profile Circle Profile

Gantt Chart Affinity Diagram Data Check Sheet

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Maklumat Penting:


2. Sila kembalikan borang (dalam bentuk Microsoft Word) kepada Sekretariat APIC 2018 seperti di

bawah melalui email atau faks (03-7955 1824) :




iv. Norliza Rosli [email protected] Muka 2/2

Tree Diagram 1st Analysis 2

nd Analysis

3rd

Analysis 4th

analysis 5th Analysis

Tangible Benefits Radar Chart Table Future Challenge





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: PLD FIRST VISION


: PANASONIC INDUSTRIAL DEVICES SDN BHD


: INCREASE PRODUCTIVITY FOR SHIPMENT PROCESS


:

*Activity 1 - Use Scanner instead of PC for Return Product, cost saving is RM 5475/mth

*Activity 2 – Re-layout Carton Box Storage, cost saving is RM 4572/mth

*Activity 3 - Change Carton Box Size, cost saving for operation time reduction is RM 7744/mth

*Activity 4 - Implement new Logistics System or NLS system RM 15118/mth. For the total

Saving from all activities is KRM 395/Year



HAVE OPPORTUNITY TO IMPROVE LOGISTICS PROCESS THRU IMPROVEMENT ACTIVITY. SUCH AS FLOW PROCESS, EQUIPMENTS AND SYSTEM.



METHOD APPLICATION USED AT WORKPLACE



1.USE SCANNER INSTEAD OF PC FOR RETURN PRODUCT. 2.RE LAYOUT CARTON BOX STORAGE 3.CHANGE CARTON BOX SIZE 4.IMPLEMENT NEW LOGISTICS SYSTEM

iv. TANDA ARAS :

BENCHMARK :

1. INCREASE PRODUCTIVITY. 2. COST SAVING. 3. PROCESS EFFCIENCY.

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI :

PROJECT ACHIEVEMENT & VALUE CREATION :

1.Cost saving KRM 395 2.Manual activity to systemization process.

vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :

AWARD, REWARD & RECOGNITION :

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1.GOLD AWARDED IN PANASONIC QCC CONVENTION 2.GOLD AWARDED IN REGION TEAM EXCELLENCE IN SABAH


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: MOMENTO


: FUJITSU COMPONENT (M) SDN. BHD.

TAJUK PROJEK

PROJECT TITLE : REDUCTION MISFILL FOR F3 CARD


:

RM 33,171.28 / YEAR

RM 14,250.08


For injection moulding of F3 Card relay’s part, we facing high reject of part due to

short mould with the total cost more than RM10k / month or we scrap more than 20% of

our parts for each die. At the same time, our customer (relay assembly) are strongly

claimed regarding bypass of the defective part due to misfill. This defect occurance was

intermittence and sometimes failed to detect by our inspection system.Therefore, it’s a

challenge to our group to find the root cause and preventing bypass to our customer.


Misfill occurance are sometimes and intermittent at several cavity. This problem

caused sampling inspection operator couldn’t detected and bypass to customer. F3 card

is small parts and many factor that lead to this problem such as injection moulding

machine parameter setting, moulding die wear & tare, moulding material contamination.

Therefore further investigation are required to identify the root cause.


The new design of injection moulding die with design change at the sharp area and

increasing the thickness to easy material flow for all cavity. Therefore each cavity will

receive the same quatity of material when material injection pressure is applied.

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iv.

TANDA ARAS :

BENCHMARK :

Water flow from slide are smoothly and easy to skate. For moulding injection, inside

the die, the end cavity facing high misfill occurance due to insufficient material as less

pressure received.


1. Reduce defect on misfill and others defect on appearance

2. Die running with full cavitation (16/16). Improve productivity and output

3. Reduce machine downtime


1. Potential team for FCM internal convention 2017 for the 1st project.

2. Gold Award Southern Region ICC 2017

3. 3 Star National region APIC 2017

4. No.1 team for FCM internal convention 2018 for 2nd project

5. Gold Award Southern Region ICC 2018

6. Most successful team on spoilage reduction activites (RM33,171k/ year)


Thickness

0.35mm Thickness

0.45mm

BEFORE AFTER

Sharp Radius 0.2º

1

2

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NAMA KUMPULANTEAM NAME : EXCELLENCE

ORGANISASIORGANISATION : INFINEON TECHNOLOGIES (MALAYSIA) SDN BHD. BATU BERENDAM

FTZ, 75150 MELAKA

TAJUK PROJEKPROJECT TITLE : TO IMPROVE PRODUCTIVITY BY ELIMINATE COVER TAPE DEFECT AT ISMECA

MACHINE


:

RM 1‘449.474.40 PER YEAR



The project triggered and Inline with company Road of Success program that is Next Level Initiative.In respond to the Self Managing Team KPI of QCDMS which represent Quality, Cost, Delivery, Morale andCost , indicates that Quality, Cost & Delivery not meet set target. Team Excellence used theprimer/advance QC Tools to solve the problem systematically.Conducting brainstorming session,detail analysis,trial run which came up with innovative solutions toovercome the root cause.The idea implemented by provides special guide and new method of cover tape flow direction.With the commitment from all team members, we managed to meet the challenging target of:This project has contributed to our internal stakeholder satisfaction. All procedures were endorsed,adopted and also shared with other production line.


The most possible causes identified are:Cover Tape (production material) tends to slip in the spool during rolling,which resulted to stuck.Since the machine running in high speed and there is a pulling force to complete the process, the covertape will break off.From the verification and validation,team conclude:

Range for cover tape guide is too widen and make the cover tape slip at the gap Cover tape twisting


After identify various potential solutions,team do the evaluate various most Potential Solutions byconsidering advantages and disadvantages.Final solution from the team:

Install a ”Ring Guide” infront of Cover Tape Spool Change direction for Cover Tape Spool rolling –from clockwise to anti clockwise.

Positive results presented to Managemant team and approved for full implemention.


ABORANG ABSTRAK

Self Managing Team Target (SMT) measurable for: Quality:Number of Internal Customer Complaints Cost:Quantity of Scrapping Good Products Delivery:Machine downtime


Reduce number of internal complaints from 372 case to 199 case by eliminate cover tape shrink(46.5% reduction)

Avoidance on scrapping production units; 4’528.836 pcs per year Exceeded production output from set target by 5’200,000 pcs per year Avoidance on scrapping F1 Material(production material) Reduced machine downtime by 1.26%, from 5.51% to 4.25%. Increase OEE(Overall Equipment Effectiveness) by 0.74%,from 84.49% to 85.74%.


Awarded as Gold in Infineon Mal Team Excellence Convention 2018. Awarded Gold in RTex 2018,in Johor Bahru,Johor. Selected to participate in National Team Excellence Convention,2018 Monetory award from Management Team: RM1300. Rewarded RM1500 from YiP(Your Idea Pays)-idea scheme program. Appreciation lunch with Management Recognition from Top Management during All Hand Meeting


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NAMA KUMPULANTEAM NAME : SENS Gen II

ORGANISASIORGANISATION : Infineon Technologies ( M ) Sdn Bhd

TAJUK PROJEKPROJECT TITLE :

New Benchmarked Standard in Yield And OEE Improvement- SENS PSSO STS Gen2 Taper Performance Improvement WithBreakthrough Innovative Solutions


:

RM / SETAHUN : RM 1’169 million savingRM PER YEAR



Gen2 Taper is built by Infineon THA which is used for taping the component into ammopackpacking. Gen2 taper is running 100% volume of PG-SSO-2-53 in PSSO STS line.The improvement project was self-initiated by team looking at the poor performance of Gen2Taper with OEE 52.5% (Target 75%) and Yield 96.43% (Target 97.60%). The poor yieldperformance is the main detractor that caused overall PSSO STS unable to achieve the TCR(Target Cost Roadmap) target. It had been a bottleneck process deciding the delivery quality tothe customers.The initiative above has got very positive management buy-in as this would avoid poor deliverywhich upset the customers. Harvesting the project will directly contributed to NLoP(Next Level ofProductivity) because of better delivery and better yield.Synergy between Infineon and OEM (Original Equipment Manufacturer) in this project harvesteda total cost saving of RM1’169 due to yield improvement of 1.67% and OEE improvement of9.1%. This excellent achievement has proven sustainable over time and contributed to greatachievement of Green Line and Stability Index.


High machine stoppages which impact machine OEE (below target 75%) due to below 3 mainroot

Causes:1. High reject rate of sealing tape offset and machine stoppages due to press head design

not optimized2. High machine stoppages to replace singulation tools spring due to spring broken/fatigue3. High machine stoppages at draw roll area due to parts broken

ABORANG ABSTRAK


Team performed DOE and various analysis to improve Gen II machine OEE by improving 3potential solutions as below

1. Improvement in press head design from full rubber type to hybrid presshead(metal+rubber) to solve sealing tape offset

2. Improvement for singulation tool mechanism from 1 tier compression spring to 2 tiercompression spring to improve on spring broken which lead to high machine stoppages.

Improvement for draw roll movement from using cylinder to motor which can improve highmachine stoppages and improve machine cycle time by 3 %.


SMART concept was used to benchmark the projectS: Specific

Improved OEE at machine Gen II machine at STS PSSO PackageM: Measurable

Improved OEE from 52.5% to 76.2% Improved process yield from 96.4% to 98.1%

A: Achievable Involved technical experts from local and external to consult the project

R: Realistic Applied DOE and FMEA to access risk and confirm feasibility

T: TimelyCompleted the project by Q2’18


Measurable Current Target ActualOEE 52.5% 75.0% 76.2%Process Yield 96.4% 97.6% 98.1%


1)Team of the Quarter”, ToQ – Achievement: Gold Award for Infineon.ToQ is an award that honors teams and small groups who have set priorities and have achievedoutstanding results in projects with focus on:

•Continuous improvement•Innovation improvement by new approaches•Customer focus and profitable growth

2) Your Idea Pays, YIP – Reward: RM23,000YIP is a tool to collect ideas, proposals and thoughts, to document them and to foster theirevaluation. Everyone can contribute to the company through this tool and help InfineonTechnologies to get better every day with small improvements up to most sufficient ideas.

3) Project selected to participate in Interactive Poster Competition in 38th International ElectronicManufacturing Technology(IEMT) Conference 2018.

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4) Gold Award & Top 3 in Infineon Melaka Team Excellence Convention 2018-Reward: RM1000+ Trophy

5) Gold Award in Southern Region Team Excellence 2018

6) Project sharing with MMU University Student (Mechanical & Electrical Engineering) In MMUIndustrial Talk 2018


Improvement PicturesPress Head Design

Singulation Tools Design

Draw Roll Design

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ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : MY TEAM

ORGANISASIORGANISATION : AMKOR TECHNOLOGY MALAYSIA SDN BHD

TAJUK PROJEKPROJECT TITLE : REDUCE SCHEDULE CLEANING LOSS TIME


:

Reduce Schedule Cleaning Loss Time >1800Min

RM 769, 253 / YEAR


Based on 6 months of data, we find that our Department's productivity quantities (M2LM) are decreasing.Schedule Cleaning Loss Time contributes to lower productivity in M2LM. Therefore, our group has madediscussions to reduce the 70% Schedule Cleaning Loss Time from 6,000 minutes to 1,800 minutes permonth. This causes our company loss RM769, 253 per year.


1) Heater Roller Cleaning Time Loss.2) Taping drum Cleaning Time Loss.3) Syntron Bowl Cleaning Time Loss.


1) Heater Roller Cleaning Time Loss: Change manual heater roller cleaning to automatic heater roller cleaning

2) Taping Drum Cleaning Time Loss: Change the width dimensions of the brush which use for Taping Drum cleaning

3) Syntron Bowl Cleaning Time Loss: Change the dust exit hole size by follow the largest of ”solder ball” dust size.


Our 'Benchmark' is at M3XF department at 2,000 minute per month.


The reduction of 83% Schedule Cleaning Loss Time from 6,000 minutes to 1,026 minutes,exceeding our target of 70%.

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Top 5 Sigma Team (SiT) for In House Exhibition Amkor Technology Malaysia. Gold Medal MPC Konvesyen Wilayah Team Excellence (RTex) Peringkat Wilayah Tengah 2018


1) Change manual heater roller cleaning to automatic heater roller cleaning

2) Change the width dimensions of the brush which use for Taping Drum cleaning

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3) Change the dust exit hole size by follow the largest of ’solder ball’ dust size.

Maklumat Penting:




ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : SPHERE 1.0

ORGANISASIORGANISATION : SALUTICA ALLIED SOLUTIONS SDN. BHD.

TAJUK PROJEKPROJECT TITLE : TRUE CC BASE OUTSIDE; FLOW MARK IMPROVEMENT


:

RM221,941.26



Tremendous high scrap for True CC Base Outside due to flow mark during PB 3.0 build(Mid Jun’ 17). About 34.1% PB 3.0 lots were sorted & scraped for flow mark based ontemporary internal limits. If these issue unable to resolved, low production yield issue willdefinitely lead to severe delivery failure to customer. Furthermore, all issues have to beresolved within 4 weeks before MP, which start from Wk. 30’ 2017. To overcome thisissue, our main objectives were to achieve the target production yield above 93.0%.


Improper process optimization & not fully utilize the machinery.


1. Application of Lean Manufacturing, 6 Sigma & 7 QC Tools to identify & filter out thenoises & wastes.2. Upgrade of machinery.


Benchmarked on historical data with similar products’ requirements / design & latestinternational expectation.


Reduction of operation costs.


Won 1stprize at PIT2018–Six Sigma Inter-department competition.Won Gold Award at Konvensyen Team Excellence Wilayah Tengah.Won Honorable Prize at Logitech’s FY18 CIP competition.

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ABORANG ABSTRAK


Maklumat Penting:




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Flow Mark

A

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ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018

KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018



: Q-CSI


: PANASONIC MANUFACTURING MALAYSIA

TAJUK PROJEK

PROJECT TITLE : TO IMPROVE MONTHLY QUALITY REPORT EFFICIENCY


:

RM 91,636



- To improve quality management - Data submission take too long to submit - Report complitation take long time due to pending submission for monthly quality report


- Lead time for report submission to long - Poor quality management system

- Data collection not tally with actual planning


- Train new member on how to fill up quality report - Improved information sharing by using sharing folder - Standardize check sheet / format - Improve quality awareness among all section

iv. TANDA ARAS :

BENCHMARK :

- Monthly Quality Assurance meeting - Monthly Quality report - Monthly lost cost data


- Improved 70% compare with target ( 50%) - Monthly quality report data collection more efficient ( Before : 10 working days, After : 3 working

days ) - Total cost saving RM 91,636 / year - Circle member improved on problem solving, know how, 7 QC tools analysis & leadership

- Circle member improved on QMS knowledge & Process innovation improvement

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BORANG ABSTRAK

vi.


- 2nd ES Malaysia QCC Convention ( 12 April 2018 )– Best effort for WIT category - 2nd Internal PES QCC Convention ( 12 Feb 2018 )– 1st place for WIT category

- 46th PMMA In-house QCC convention 2016 – 1st place in PESES Production category


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Maklumat Penting:











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: IDEOLOGY


: PANASONIC INDUSTRIAL DEVICES MALAYSIA SDN. BHD. (PIDMY)


: TO REDUCE 60% PROCESS DEFECTIVE OF LTSW 6MM LONG STROKE


:

RM 931,164 PER YEAR



➢ Based on 1st Quarter 2017 result shows that in-process defective loss for Light Touch Switch 6MM Long Stroke was the highest contributor for the quality lost cost in PIDMY.

➢ In order to improve this problem, our team set 7 months and a half time frame to solve this problem and our group able to be achieved the improvement activity within time line set.

➢ By this improvement activity, our team manage to save about MYR 77,597 monthly and MYR 931,164 yearly.

➢ Improvement activity has been approved and standardized globally with Japan. ➢ Group succeed to get the first place for AIS industrial devices company represent Panasonic

Malaysia in competition AIS ASEAN in Mac’18 as a result Silver achievement and PIDMY convention in May’18 as a result 2nd runner up.

➢ Manage to achieve gold award in MPC 2018 (South Region) recently.



➢ Failure mechanism of die parting performance impact to click ratio low due to contact step moulded case is low specification

➢ and aging unit process. ➢ Inconsistence variation for process stability and control. ➢ Current maximum aging force is 15N but click ratio variance histogram show toward minimum

specification.



➢ Change die stroke setting change from 10 Millions to 8 Millions for Total Preventive Maintenance and regrinding top surface of Die insert Maru Dabo to increase the height.

➢ Standardize die stroke to various punch and improve click ratio with more stable trend. ➢ Result Testing Aging Force by difference Spring Type (Spec control of aging unit : 10N ~ 30N) ➢ To increase click ratio by improved aging force change spring type from WT4-25 to WM4-25 to

improve spring force.

iv. TANDA ARAS :

BENCHMARK :

➢ Benchmark global improvement activity with Panasonic Japan. ➢ Benchmark improvement activity with other Light Touch Switch products. ➢ Benchmark and feasibility study by making comparison for the spring type. ➢ Performing lab test to acquire accurate result. ➢ Improvement activity by customer feedback\customer voice.

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v.

PENCAPAIAN PROJEK & PENCIPTAAN NILAI :

PROJECT ACHIEVEMENT & VALUE CREATION :

➢ Process defective achieved more than 63% from target setting activity. ➢ Huge monthly saving amount MYR 77,597 monthly and MYR 931,164 yearly. ➢ Contribute to resin material usage reduction by reducing waste. ➢ Recognized for global Panasonic Kaizen activity for part life control.

vi.

ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :

AWARD, REWARD & RECOGNITION :

1) AIS QCC Convention 2014 (1st Place) 2) 41st PIDMY QCC CONVENTION (1st Place) 2014, 2015,2016 and (2nd place) 2017, 2018. 3) Represent ASEAN for Automotive Industrial System (AIS) QCC competition in Osaka, Japan in

June’14. 4) Represent ASEAN for Automotive Industrial System (AIS) QCC competition in ASEAN, Japan in

Apr’16. 5) Represent ASEAN for Automotive Industrial System (AIS) QCC competition in ASEAN, Japan in

Apr’18 6) Gold Award in Malaysia Productivity Cooperation (MPC) 2018 – South Region

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA)

PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

ACTIVITY 1

BEFORE

Click ratio low due to contact step molded case is low specification

Terminal bending cannot reach to maximum reading due to punch and insert worn out condition.

AFTER

Regrinding top surface of Die insert Maru Dabo to increase the height To improve terminal bending height (maru dabo) to be increased the click ratio percentage. Regrind die insert height of Maru dabo punch bending. Change from 10 millions to 8 millions stroke to control Part life.

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ACTIVITY 2

BEFORE

Current maximum aging force is 15N but click ratio variance histogram show toward minimum specification

AFTER

Change spring type from spring constant, K 1.5N/mm to 2.0N/mm

A

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Maklumat Penting:







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ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : Alpha

ORGANISASIORGANISATION : Finisar (M) Sdn Bhd

TAJUK PROJEKPROJECT TITLE : Scrap & yield improvement for product Chip on Flex (COF) in a single process

die attach


:RM / SETAHUN : RM 114 000

RM PER YEAR



a. Epoxy short was the top reject for the expensive product COFR 28G in Q4’17.b. Continuous feedback and increasing failure detection at electrical test area.c. Failure analysis reveal the test failure happened due to epoxy overflow whichcausing short circuit.d. The management feels that this issue need to be contained and solved in housee. The failure caused scrap cost higher while yield faltersf. Alpha Team formed to tackle this issue.

ABORANG ABSTRAK


ABORANG ABSTRAK




1. Finalist in 2016 APIC in PICC2. Battle of Lean Teams – Internal company level competition, 20173. Alpha took GOLD in Regional Convention in Batu Ferringhi 2017

ABORANG ABSTRAK

vii. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA)PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

ABORANG ABSTRAK

ABORANG ABSTRAK


KATEGORI : X ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : Trans 7

ORGANISASIORGANISATION : Finisar (M) Sdn Bhd

TAJUK PROJEKPROJECT TITLE : Productivity improvement in cable TV product line

by reducing setup and test time


:

RM / SETAHUN : RM 250 000

RM PER YEAR



a. Request from program Manager of Finisar USA to have a solution for FTTH testing.b. Product Engineer and planner’s concern of high loading but testing is purely manual.c. Technician feedback on the difficulty of manual testing plus handling of equipmentd. Customer demand continuously going up but productivity do not match the output.e. Held back of the customer orders and long delivery time cut into the satisfaction and Customer report

card.


ABORANG ABSTRAK

ABORANG ABSTRAK


a. Weekly demand fulfillmentb. Quarterly revenuec. Cutomer Satisfaction Report Card



Battle of Lean Teams – Internal company level competition, 2018GOLD – Regional MPC 2018


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Maklumat Penting:




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ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : DESIRE

ORGANISASIORGANISATION : IINFINEON TECHNOLOGIES (M) SDN BHD

TAJUK PROJEKPROJECT TITLE : TO REDUCE DEFECT LIFTED STITCH ON LEAD FOR PACKAGE TO263-7 HD LPL

BY 80% AT WIRE BOND PROCESS


:

RM 1,433,960/YEAR



Power Logic Assembly (PLA) is the biggest segment in Malacca which compromise of 5 modules. Our projectis focusing at LPL (Linked Power Line) module, which produce various semiconductor automotiveapplications products. Our weekly demand is 19 million and it is without fail our customer come first and wemust fulfilled all expectation in terms of Productivity and Quality.From our historical performance data, LPL TO263-7 HD wire bond process were not meeting the expecteddelivery target at CW15 (April’17) and analysis confirmed that the caused was due to defect Lifted Stitch onLead failure. Hence, the quality failure also contributed to low yield to TO263-7 HD & to the overall Wire bondyield. Team Excellence Desire initiated the brainstorming and identified several improvement actions toimprove the Delivery & Quality KPI by reducing 80% of Lifted Stitch on Lead defect at TO263-7 HD. Theinnovative idea improvement was to redesign the wire bond lead clamper with special features.


Based on analysis applying 7QC tools & Von-Mises Stress Formula , Lifted Stitch On Lead happens:1) When floating lead frame occurs.2) Worn out Lead clamper.


Team Excellence Desire was motivated to drive this project towards continuous improvement and exploreto new innovative idea solutions. From a series of brainstorming within the members, the team derived 2ideas; 1) Redesign the wire bond clamper: Longer tip with extended depth center lead clamp & slotextension + thru hole design. 2) Improved strength of material: Stainless steel grade 420 to grade 440C.The innovative ideas presented & approved by our Management. Evaluation was carried out at pilotmachine DEL 144 (worst machine performance based on historical data) to monitor the effectiveness of thesolution. After 3 weeks of monitoring at DEL144, we validated the outcome results and it was confirmedthat Lifted Stitch on Lead defect was eliminated. We then cascaded across 45 Wire Bonders in LPL andfurther monitoring was done and results after 8 weeks proven we have eliminate the problem at TO263-7HD.


The idea was documented in Infineon TeamCentre and shared to other modules in PLA : todate we haveroll out at SON & DPAK module.Besides that, idea was also shared & adopted to other wire bond plaform in Infineon Melaka such asDelvotec & Ortodyne.


ABORANG ABSTRAK

1. Successfully reduced Lifted Stitch on Lead from average 5 cases per week to Zero - managed tosustain Zero up to-date (September 2018).

2. Successfully improved yield performance from 95.21%/week to >99.75%/week for PackageTO263-7 HD.

3. Successfully improved overall yield from 99.63%/week to >99.75%/week at Wire Bond Process.4. Successfully improved Delivery performance from 2.2 million/week to >2.5 million/week for

Package TO263-7 HD5. Successfully improved overall Delivery from 18.7 mil/week to >19mil/week at Wire Bond Process.


1. Awarded Gold & Overall Champion during Team Excellent Convention 2018 inInfineon Malacca.

2. Segment recognition as best SGA team on innovative idea & Best PracticeSharing by PLA Management and awarded with Certificate of Excellence.

3. Awarded Gold during Southern Regional Team Excellent Convention 2018.


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ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : H.A.I TEAM

ORGANISASIORGANISATION : PANASONIC AVC NETWORKS JOHOR (M) SDN BHD

TAJUK PROJEKPROJECT TITLE : TO ENHANCE WORKPLACE SAFETY AWARENESS AMONG PAVCJM

EMPLOYEES


:

PERBANDINGAN KES BAGI TAHUN 2017, PENURUNAN CUTI SAKIT SEBANYAK5 HARI DARIPADA SUKU TAHUN PERTAMA KE SUKU TAHUN KEDUA, DENGANNILAI KOS PENJIMATAN SEBANYAK RM 412.50 (Huraian dalam Bahagian 2 –Borang D)


Terdapat kekerapan kes kemalangan ditempat kerja yang tidak dilaporkan di premis yang menyebabkanseksyen keselamatan perlu membuat satu tindakan bagi menyedarkan pihak pengurusan dan pekerjatentang kepentingan aspek keselamatan. Justeru, satu bentuk program kesedaran dan kempendilaksanakan bagi melihat perubahan tahap kesedaran tentang keselamatan di tempat kerja dalamkalangan pekerja dan kesannya terhadap kadar laporan kemalangan yang dibuat. Terdapat 4 projek utamayang digerakkan bagi menjayakan kempen berkenaan, iaitu Safety Video Show, Safety Bulletin, SafetyPublic Announcement, dan Health Talks and Health Screening. Pencapaian keberkesanan setiap programturut dinilai.


Kebanyakkan pekerja merasa takut dan bimbang untuk melaporkan kepada Seksyen Keselamatansekiranya mereka terlibat dengan kemalangan di tempat kerja. Ini berpunca daripada kurangnya kesedarandan pengetahuan dalam kalangan pekerja dan pihak pengurusan tentang peri pentingnya keselamatan ditempat kerja. Masalah ini perlu di atasi pada peringkat awal melalui pendidikan kesedaran


Melaksanakan kempen kesedaran secara berperingkat. Bermula dengan pelaksanaan tayanganvideo/filem pendek kesedaran keselamatan di tempat kerja (mini cinema). Program seterusnya ialahmengadakan satu bulan kempen keselamatan (Februari) di mana pada bulan berkenaan telah diadakanPengumuman Awam setiap pagi berkaitan slogan-slogan kempen keselamatan. Dalam bulan yg samaturut diadakan Buletin Keselamatan di mana setiap kali berlakunya kemalangan di tempat kerja, kestersebut akan dikongsi bersama jabatan-jabatan lain agar mereka mengetahui langkah pencegahan yangsesuai. Selain aspek keselamatan, turut ditekankan semasa kempen ialah kesedaran kesihatan. Bagitujuan tersebut telah diadakan program kesihatan iaitu Ujian Saringan Kesihatan dan Health Talks dalamkalangan pekerja.


(1) Mencapai tahap kesedaran pekerja tentang aspek keselamatan di tempat kerja daripada 39% kepada50% ke atas.

(2) Peningkatan lapor kemalangan/pemakluman dalam kalangan pekerja dan pihak pengurusansekiranya ada pekerja yang terlibat dengan kemalangan di tempat kerja.

(3) Mengurangkan Loss Amount disebabkan Cuti Sakit yang disebabkan oleh kemalangan industri(4) Penambahbaikan dari segi standardisasi mewujudkan borang baru bagi memastikan tiada isu

kemalangan industri yang lewat dilaporkan.(5) Penarapan budaya dan persekitaran tempat kerja yang selamat dan sihat

ABORANG ABSTRAK


Tahap kesedaran pekerja tentang keselamatan di tempat kerja meningkat daripada 39% kepada 54%(sasaran peningkatan, >50%) berdasarkan penilaian yang telah dibuat pada sebelum dan selepaspelaksanaan projek. Peningkatan kadar laporan berkaitan isu-isu keselamatan di tempat kerja, meningkatdaripada 3 laporan kepada 10 laporan. Walaupun terdapat peningkatan dari segi laporan kemalangan,namun begitu, kategori kemalangan tersebut adalah minor atau kosong hari cuti sakit (0 MC Days).Peratusan loss amount yang ditanggung oleh pihak majikan disebabkan cuti sakit (kemalangan industri)juga mampu dikurangkan sebanyak 13.51%.


Memenangi tempat Ketiga dalam In-House QCC Convention 2018 di Panasonic AVC Networks JohorMalaysia, Pasir Gudang bagi kategori non-manufacturing.Memenangi Anugerah Emas dalam Regional Team Excellent Convention 2018 Wilayan Selatan bertempatdi Holiday Villa Johor Bahru City Centre


Tayangan Video

Saringan Kesihatan danHealth Talks

Pengumuman SloganKeselamatan

ABORANG ABSTRAK

Maklumat Penting:




CODE ORGANISATION TEAM - MPC

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