Download - Manpower optimization_2nd_0407_Eng

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


effective

■ Combine VMI with label attaching - label attach/VMI/stacking MBA → Moving MBA to Assy Cell (Marshal)


■ 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

12

對外秘


Effective Operator : 5 名 → 1 名 , 4 名 reduction - D2D[1F] : 5 名 → 1 名 ( 4 名↓ )

□ Machine state of each Area - D2E : 1EA / 1 名 , D2D : 2EA / 4 名

- LCA is not including particle suction function so separate machine is needed to suction particle

□ minimize machine from reallocation of Assy machine - LCA 14EA → 1EA ※ reference : D2E LCA 14EA will be operated

1. H/C optimization_SUB[T6]No ITEM SITE F/F cost H/C DATE Writer

3 [SUB – 11] removal Vacuum Suction Particle machine by improving Assembly machine D2D 3.5” - 4 April CH.KIM

對外秘


effective Operator reduction : 8 名 → 4 名 , 4 名 efficiency - D2D[1F] : 8 名 → 4 名 ( 4 名↓ )

□ Allocation Status - D2D : 4EA / 8men (1machine /2men allocated) - stand-by time is too many due to moving speed of ABA Filter Cylinder

□ allocating just 1 operator on a cell - correlate balance with movement of cylinder . 1operator/machine

No ITEM SITE F/F cost H/C DATE Writer

4[WP special - 11] re-allocation of 3.5 Stick ABA operator (1op/machine)

D2D 3.5” - 4 April CH.KIM


對外秘

No ITEM Content SITE F/F cost H/C DATE Writer

- Assy [WP Special] combine CASTW with HDA collector D2D 3.5” - 1 (4 → 3) May BR.LEE


The different point of AUTO line between GUMI and WP - the moving from H/T to CASTW is automatic by conveyor but WP is manual

■ each operator’s role ① operator : CASTW & H/T ② operator : collect HDA & move to CASTW Cell

■ combine CASTW & HDA collect - by changing layout of H/T Cell to enable one operator manage two H/T cell

ETC

2. H/C optimization_C/R[T6]

21 2

※ Operator allocation of 3.5” Auto Line - GUMI : 3 名 /line, WP : 4 名 /line

Remove HDA collect operator

對外秘


1 H/T [CR – 12] Manual H/T&CASTW operator reduction by re-layout D2D 3.5” - 21 (70 → 49) June BR.LEE

To-BeTo-Be

■ allocation sate base on Re-Layout

ETC

2. H/C optimization_C/R [T6]

D2D 1F

- Total operator : 49 名 /shift . STW : 25 名 /shift .. Operator allocation : 1 名 / Line .. Number of operating facility : 25EA . H/T : 24 名 /shift .. Operator allocation : 0.5 名 / Cell .. Number of operating facility : 48EA

H/TCASTW

The different point of AUTO line between GUMI and WP - the set moving from H/T to CASTW is automatic by conveyor but WP is manual

對外秘


2 H/T [CR - 13 Manual H/T operator reduction by re-layout

D2ED2D 2.5” - 15 (28 → 13) June BR.LEE

To-BeTo-Be

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


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


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


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®


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"

D1E 1F D1E GF D2D 1F D2E D2D 2FOutput(bade on 630 萬 ) 台 440,000

1,460,000 550,000 1,850,000

1,750,000

Hourly Qty. 台 771.93 2561.40 964.91 3245.61 3070.18 Hourly Box Qty. ea 38.60 128.07 48.25 64.91 61.40 Packing Box Cycle sec 93.27 28.11 74.62 55.46 58.63 Actual work time for Vacuum sec 50 Allocated Operator(current) 名 1 2 2 2 -pallet distribution operator(current) 名 1 1 2 1 -Allocated Operator(expect) 名 1 2 1 1 1 pallet distribution operator(expect) 名 - 1 1 1 1


5 PCBA [B/E – 21] PCBA logistics improvement D2E, D2DD1E

2.5”3.5” - 2 名 (12 → 10) July

SM.LEEYM.KWO

N


對外秘


개선효과

□ 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

ÀÌµ¿½Ã°£ºÐ¼®


2 Packing

[B/E - 19] Improvement of packing material distribution D2D ALL - 1 July BS.Jegal


對外秘


개선효과

③②

Cushion

①

Box

Pe Bag

가이드

높이 : 200mm


3 Packing

[B/E - 19] Improvement of packing material distribution D2E ALL - 1 July BS.Jegal



① operator - Box folding - Pe-bag - Cushion② operator - inject Guide - Box stacking

③ distribution




對外秘


개선효과

③②

Cushion

①

Box

Pe Bag

가이드

높이 : 200mm

④


4 Packing

[B/E - 19] Improvement of packing material distribution D1E ALL - 3 July BS.Jegal



① operator - Box folding - Pe-bag - Cushion② operator - inject Guide - Box stacking

③ distribution




對外秘


Effect

□ WP C/R : Disk Eraser, Burnish - D2D 1F (3.5”) 2 名 Arranged

Op : 4 名 → 3 名 , 1 名 ↓ .. D2D 1F (2 名 ) → (1 名 ) .. D2D 2F (1 名 ) → (1 名 ) .. D2E (1 名 ) → (1 名 )

Location Inch /Op. Description

D2D 1F 3.5”(2 名 )

D2D 2F 2.5”(1 名 )

D2E 2.5”(1 名 )

Burnish

Eraser

Burnish

Eraser

Burnish

Eraser

Eraser

Location Inch /Op. Description

D2D 1F 3.5”(1 名 )

D2D 2F 2.5”(1 名 )

D2E 2.5”(1 名 )

Burnish

Eraser

Burnish

Eraser

Burnish

Eraser

Eraser

□ 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

Eraser2.5" 2 7,500 15,000 7,500 3.5" 2 7,500 15,000 7,500

Total 4 　 30,000 15,000

RWK Disk Qty. 5.2M 6.3M

1month(30days)

Product 5,200,000 6,300,000 HDA T/D 520,000 630,000 Disk T/D 810,000 981,346

1day Disk T/D 27,000 32,712 1shift Disk T/D 13,500 16,356

Disk BurnishMachine

Disk EraserMachine

Disk BurnishConveyor


對外秘


Effect

□ WP C/R : Disk VMI Test - 70pcs / 1 Hr - 18 名 , (5.2M product)

Op : 18 名 → 15 名 , 3 名 ↓ . Current Op. status : D2D 1F (8 名 ) / D2D 2F (5 名 ) / D2E (5 名 ) Arranged

□ 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


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


對外秘


Effect

□ WP C/R : - Separated Process - Head Screen operator : 5 名

(Arranged 5.5 名 / 1 Shift)

Op : 5 名 → 0 名 , 5 名 ↓ .. D2D 1F (2 名 ) → (0 名 ) .. D2D 2F (2 名 ) → (0 名 ) .. D2E (1 名 ) → (0 名 )

Head screenMachine

Operator

□ 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


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


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


Effect

□ Move to DMR vendor for VMI Process → Replacement BU3, H&T VMI Process□ WP just view the HSA Bent & recycle scrap

□ WP C/R : HSA VMI Test - By using microscope

Op : 11 名 → 0 名 , 11 名 ↓ - D2D 1F : 4 名 → 0 名 (4 名 ↓ ) - D2D 2F : 4 名 → 0 名 (4 名 ↓ ) - D2E : 3 名 → 0 名 (3 名 ↓ )

WP (Remove 1st VMI) - HSA Bent (naked eye VMI) & Recycle over check

BU3 (2nd VMI) - Using the microscope VMI

WP (1st VMI) - Using the microscope VMI

BU3 (2nd VMI) - Using the microscope VMI


對外秘

B/L (430 萬 ) WP Target (630 萬 ) Remark

Location Operator Location Operator

D2D 1F 8 名 D2D 1F 0 名 8 名 ↓

D2D 2F 8 名 D2D 2F 0 名 8 名 ↓

D2E 6 名 D2E 0 名 6 名 ↓

Total 22 名 Total 0 名 22 名↓

□ DMR HSA VMI Process efficiencies

▶ Different point from SEC ● SEC : . SEC 1st VMI : Naked-eye VMI → HSA Bent(viewed naked eye) & Recycle over HSA check . DMR vendor 2nd VMI : Microscope VMI (More detailed VMI)

● W/P . WP 1st VMI : Microscope VMI . DMR vendor 2nd VMI : Microscope VMI (More detailed VMI)

● 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


對外秘


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


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


對外秘


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


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


對外秘


Effect

□ Marshaling operating : → Separated each Sub-operating.□ HSA Sub operating → Separated from each station.

Op : 18 名 → 8 名 , 10 名 ↓ .. All C/R (18 名 ) → (8 名 )

□ Marshaling operating : → Combine the Sub-operating and controlled by the Marshal.□ HSA sub operating combined from the HSA sorting operator

Marshal

Return MRB

Dispense Empty Tray

Dispense Material (HDA)HDA input to C/R from

B/EHSA sorting by Model

HSA Packing

3 名

3 名

2.5 名

2 名

2.5 名

3 名

2 名

Total18 名

Marshal ( 마샬 )

Return MRB

Dispense Empty Tray

Dispense Material (HDA)

HDA input to C/R from B/E

HSA sorting by Model

HSA Packing

5 名

3 名

Total8 名

※ WP, Current 5.2M Product Based ※ WP, After H/C 6.3M Product Based

No ITEM Content SITE F/F cost H/C DATE Writer 7 RWK [RWK-5] Sub Operating All All - 10 4/15 DY.CHOI


對外秘

□ C/R Sub operating Process efficiencies Station

Current

(5.2M)H/C

Simulate

(6.3M)Change Description Picture

Marshal 3 名 - 3 名 0 名

Marshaling operating

Gumi arranged 2 person of Marshaling operating (Gumi 1.55M Based) - Return MRB (0.2 名 ) - Dispense Empty Tray (0.4 名 ) - Dispense Material (HDA) (0.4 名 ) - HDA input to C/R from B/E (0.2 名 ) - MBA label removal (0.8 名 )

So, WP (6.3M) arranged about 8 名 - Return MRB (0.8 名 ) - Dispense Empty Tray (1.6 名 ) - Dispense Material (HDA) (1.6 名 ) - HDA input to C/R from B/E (0.9 名 ) - MBA label removal (3 名 )

cf.) MBA label removal H/C will cover at Sub Material VMI H/C

Return MRB 3 名 -2.2 名 0.8 名

Dispense Empty Tray 2.5 名 -0.9 名 1.6 名

Dispense Material (HDA) 2 名 -0.4 名 1.6 名

HDA input to C/R from B/E 2.5 名 -1.6 名 0.9 名

HSA sorting by Model 3 名 -0 名 3 名 Combine

the operating

※ HSA VMI operating (3 名 / 1shift) - Naked eye VMI - HSA sorting by Model - RTV HSA Packing ※ Process - Naked eye VMI → HSA sorting → Packing. - This is 1 process charged from HSA VMI op.HSA Packing 2 名 -2 名 0 名

Total 18 名 10 名 8 名


對外秘


8 Label remove [RWK – ] Label removal D2E, D2D 2.5”

3.5” - 5 名 (10 → 5) 5 月

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.


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 ]


對外秘


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


□ 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


對外秘


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.

Op : 5 名 → 3 名 , 2 名 ↓ .. B/E, C/R inputting process optimize (5 名 ) → (3 名 )

※ WP, Current 5.2M product based → 5 名 (4.5 名 ) Arranged

※ 6.3M Product Based (After H/C) → 3 名 (2.4 名 ) Arranged

C/R inputting HDA Cleaning

HDA input to C/R

5 名

□ Gumi based, it could able to one operator for each C/R (D2D 1F, D2D 2F, D2E).

C/R inputting HDA Cleaning

+HDA input to C/R

3 名


10 RWK [RWK – 12] C/R inputting process D2E, D2D 2.5”3.5” - 2 名 (5 → 3) MAY DY.CHOI


對外秘

□ C/R inputting process optimization ※ C/R inputting HDA Cleaning + HDA input to C/R

Each C/R 1 operator arrange (6.3M Based) . SEC (1.55M) : 0.3 名 + 0.3 名 = 0.6 名 arranged . SEC (6.3M) : 1.2 名 + 1.2 名 = 2.4 名 arranged . W/P (5.2M) : 3.5 名 + 1.0 名 = 4.5 名 arranged

→ About 3 operator could optimize. And more reduction of inputting HDA cleaning is need to more discussion.


對外秘


11 RWK [RWK – 9] B/E FA engineer D2E, D2D 2.5”3.5” - 2 名 (10 → 8) 5 月

EffectRWK, B/E FA engineer required, 10 名 → 8 名 (6.3M product)

▷ 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.


對外秘

■ RWK B/E FA engineer H/C

OOB rate & simulation

※ C/R Yield 95.71%※ W/P (B/E OOB rate) : 2.5" - 40.47%, 3.5" - 36.51%, TTL - 38.36%※ SEC (B/E OOB rate) : 2.5" - 70.19%, 3.5" - 46.64%, TTL - 64.34%


對外秘


Effect

□ WP, PCBA Rework Process. . Separated PCB Code D/L process, PCBA VMI (PCBA Discolor repair) and PCBA dispose process. . So, each process arranged operator.

Op : 2 名 → 1 名 , 1 名 ↓ .. B/E PBA VMI & Dispose process improving (2 名 ) → (1 名 )

※ WP, Current 5.2M product based → 2 名 (1.5 名 ) Arranged

※ 6.3M Product Based (After H/C) → 1 名 (0.8 名 ) Arranged

RTV PCBA Dispose

MRB Material Dispose2 名

PCB discolor repair & VMI 3 名

RTV PCBA Dispose

MRB Material Dispose1 名

PCB discolor repair & VMI 0.5名

□ 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


12 RWK [RWK – 10 ] RTV PCBA & MRB material dispose D2E, D2D 2.5”

3.5” - 1 名 (2 → 1) 5 月


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.


Download - Manpower optimization_2nd_0407_Eng

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