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Six Sigma for Electronics Design and Manufacturing This page intentionally left blank. Six Sigma for Electronics Design and Manufacturing Sammy G. Shina University of Massachusetts, Lowell McGraw-Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto Copyright © 2002 by The McGraw--Hill Companies,Inc. All rights reserved. Manufactured in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be repro- duced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior writ- ten permission of the publisher. The material in this eBook also appears in the print version of this title:0-07-139511-3. All trademarks are trademarks of their respective owners. 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We hope you enjoy this McGraw-Hill eBook! If you’d like more information about this book, its author, or related books and websites, please click her e . To my wife, love, friend, and companion Jackie, and our children and grandchildren Contents Illustrations and Tables xvii Abbreviations xxiii Preface xxvi Chapter 1. The Nature of Six Sigma and Its Connectivity 1 to Other Quality Tools 1.1 Historical Perspective 1 1.2 Why Six Sigma? 4 1.3 Defending Six Sigma 7 1.4 The Definitions of Six Sigma 8 1.5 Increasing the Cp Level to Reach Six Sigma 9 1.6 Definitions of Major Quality Tools and How 10 They Effect Six Sigma 1.7 Mandatory Quality Tools 10 1.8 Quality Function Deployment (QFD) 11 1.8.1 Engineering 11 1.8.2 Management 11 1.8.3 Marketing 12 1.9 Design for Manufacture (DFM) 00 1.10 Design of Experiments (DoE) 00 1.11 Other Quality Tools 20 1.11.1 Process mapping 21 1.11.2 Failure modes and effects analysis (FMEA) 26 1.12 Gauge Repeatability and Reproducibility (GR&R) 29 1.13 Conclusions 30 1.14 References and Bibliography 31 Chapter 2. The Elements of Six Sigma and 33 Their Determination 2.1 The Quality Measurement Techniques: SQC, Six Sigma, Cp and Cpk 34 2.1.1 The Statistical quality control (SQC) methods 34 2.1.2 The relationship of control charts and 35 six sigma 2.1.3 The process capability index (Cp) 36 2.1.4 Six sigma approach 39 vii Copyright 2002 The McGraw-Hill Companies, Inc. Click Here for Terms of Use. For more information about this book, click here. 2.1.5 Six sigma and the 1.5 shift 41 2.2 The Cpk Approach Versus Six Sigma 42 2.2.1 Cpk and process average shift 43 2.2.2 Negative Cpk 44 2.2.3 Choosing six sigma or Cpk 45 2.2.4 Setting the process capability index 46 2.3 Calculating Defects Using Normal Distribution 47 2.3.1 Relationship between z and Cpk 54 2.3.2 Example defect calculations and Cpk 54 2.3.3 Attribute processes and reject analysis for 57 six sigma 2.4 Are Manufacturing Processes and Supply Parts 59 Always Normally Distributed? 2.4.1 Quick visual check for normality 59 2.4.2 Checking for normality using chi-square tests 60 2.4.3 Example of 2 goodness of fit to normal 62 distribution test 2.4.4 Transformation data into normal distributions 63 2.4.5 The use of statistical software for 65 normality analysis 2.5 Conclusions 65 2.6 References and Bibliography 66 Chapter 3. Six Sigma and the Manufacturing Control Systems 69 3.1 Manufacturing Variability Measurement and Control 70 3.2 The Control of Variable Processes and Its 72 Relationship with Six Sigma 3.2.1. Variable control chart limits 74 3.2.2 Control chart limits calculations 74 3.2.3 Control and specifications limits 75 3.2.4 X ෆ , R variable control chart calculations 76 example 3.2.5 Alternate methods for calculating control 78 limits 3.2.6 Control chart guidelines, out-of-control 78 conditions, and corrective action procedures and examples 3.2.7 Examples of variable control chart 82 calculations and their relationship to six sigma 3.3 Attribute charts and their Relationship with 84 Six Sigma viii Contents 3.3.1 The binomial distribution 85 3.3.2 Examples of using the binomial distribution 86 3.3.3 The Poisson distribution 86 3.3.4 Examples of using the Poisson distribution 87 3.3.5 Attribute control charts limit calculations 88 3.3.6 Examples of attribute control charts 89 calculations and their relationship to six sigma 3.3.7 Use of control charts in factories that are 91 approaching six sigma 3.4 Using TQM Techniques to Maintain Six Sigma 91 Quality in Manufacturing 3.4.1 TQM tools definitions and examples 92 3.5 Conclusions 99 3.6 References and Bibliography 99 Chapter 4. The Use of Six Sigma in Determining the 101 Manufacturing Yield and Test Strategy 4.1 Determining Units of Defects 102 4.2 Determining Manufacturing Yield on a Single 104 Operation or a Part with Multiple Similar Operations 4.2.1 Example of calculating yield in a part with 105 multiple operations 4.2.2 Determining assembly yield and PCB and 106 product test levels in electronic products 4.2.3 PCB yield example 107 4.3 Determining Design or Manufacturing Yield on 108 Multiple Parts with Multiple Manufacturing Operations or Design Specifications 4.3.1 Determining first-time yield at the electronic 110 product turn-on level 4.3.2 Example of yield calculations at the PCB 110 assembly level 4.3.3 DPMO methods for standardizing defect 112 measurements 4.3.4 DPMO charts 113 4.3.5 Critique of DMPO methods 115 4.3.6 The use of implied Cpk in product and 116 assembly line manufacturing and planning activities 4.3.7 Example and discussion of implied Cpk in 118 IC assembly line defect projections 4.4 Determining Overall Product Testing Strategy 120 Contents ix [...]... Variability Reduction Using DoE Using DoE Methods in Six Sigma Design and Manufacturing Projects Conclusions References and Bibliography 211 215 217 220 221 225 227 227 228 231 232 234 236 238 240 241 241 Six Sigma and Its Use in the Analysis of Design and Manufacturing for Current and New Products and Processes 243 8.1 244 246 250 8.2 8.3 Current Product Six Sigma Strategy 8.1.1 Process improvement in current... Implementing Six Sigma in Electronics Design and Manufacturing 11.1 Six Sigma Design Project Management Models 318 319 320 323 327 328 329 329 330 332 334 335 338 339 340 Contents 11.1.1 Axioms for creating six sigma within the organization 11.2 Cultural Issues with the Six Sigma Based System Design Process 11.3 Key Processes to Enhance the Concurrent Product Creation Process 11.3.1 Six sigma phased... second in 31 years! Therefore, Motorola expanded the six sigma program in 1992 and beyond to achieve the following: 1 Continue their efforts to achieve six sigma results, and beyond, in everything they do 2 Change metrics from parts per million to parts per billion (PPB) 3 Go forward with a goal of 10 times reduction in defects every 2 years 4 Six Sigma for Electronics Design and Manufacturing Many other... Design Information Flow and Six Sigma System Design 10.2.1 Opportunities in six sigma for system or product design improvements 10.2.2 The system design process 10.2.3 The system design steps 10.2.4 Composite Cpk 10.2.5 Selecting key characteristics for systems design analysis 10.2.6 Standardized procedures in design to determine the composite Cpk 10.2.7 Standardized procedures in manufacturing to determine... Mechanical design and tolerance analysis Types of tolerance analysis Statistical tolerance analysis for mechanical design 8.3.5 Tolerance analysis example 8.3.6 Statistical analysis of the mechanical design example 8.3.7 Tolerance analysis and CAD 8.3.8 Tolerance analysis and manufacturing processes 8.3.9 Mechanical design case study 8.3.10 Thermal design six sigma assessment example 8.3.11 Six sigma for. .. Product Development to Six Sigma 8.2.1 Design analysis for six sigma 8.2.2 Measuring the capability of current manufacturing processes 8.2.3 Investigating more capable processes for new products 8.2.4 Case studies of process capability investigations for manufacturing: Stencil technology for DoE Determining Six Sigma Quality in Different Design Disciplines 8.3.1 Mechanical product design process 251 253... especially QS9000 These standards contain many of the principles of six sigma and associated quality tools, such as Cpk requirements These manuals were published in the mid-1990s and are available from the Automotive Industry Action Group (AIAG) in Southfield Michigan Six sigma can be used as a standard for design and manufacturing, as well as a communication method between design and manufacturing groups,... belts” and “master black belts.” They work on six sigma full time and assist in training and leading six sigma projects Regular employees who receive abridged training are called “green belts.” 1.2 Why Six Sigma? During the last few decades, advances in the high-technology and electronics industries have accelerated The price/performance ratios continue to follow the industry idioms of more performance for. .. many companies and organizations whose engineers and managers were using original and ingenious applications of six sigma in traditional design and manufacturing Out of these experiences came many of the examples and case studies in this book I observed and helped train many engineers in companies using tools and methodologies of six sigma The companies vary in size, scope, product type, and strategy,... groups, especially when part of the design or manufacturing is outsourced This is important for companies in meeting shorter product lifecycles and speeding up product development through faster access to design and manufacturing information and the use of global supply chains 1.3 Defending Six Sigma Six sigma, like many new trends or initiatives, is not without its critics and detractors The author has . Six Sigma for Electronics Design and Manufacturing This page intentionally left blank. Six Sigma for Electronics Design and Manufacturing. process 10.2 Technical Design Information Flow and Six Sigma 327 System Design 10.2.1 Opportunities in six sigma for system or 328 product design improvements