Request for 4M change self management strengthening

Transcription

1 Request for 4M change self management strengthening 1.Aug.2016 Device engineering Dep. Partner management Dep. Sony Global M&O Corp. 1

2 Request for 4M change self management strengthening Past cases of Sony TV market announcement of October 12, 2013 Of the rear cabinet material is assumed Degraded above, when external force is applied, is that it may lead to rarely damaged was found. Deterioration of the resin butadiene (rubber component) The added components influence as a coloring agent Often until the abnormal component content (Silent change)

3 2015 4M change the results and problems Change the number of applications (Japan) Parts D-Cost analysis Apr May Jun Jul Aug Sep Oct Nov Dec FY14 FY FY14 vs FY15

4 Re thorough partner self-management item 14% 17% 7% D-COST Content 30% 36% Equipment management Jigs and tools management Die management US$38,000 Working instruction management US$ 460,000 Worker management US$ 24,000 D-Cost Defect cost 5 item of the autonomous management strengthening

5 Case 1 Working instruction management Paint peeling problem of repair D-Cost US$30,000 occurred Undercoat Filled putty Putty shine Air blow Undercoat painting When turned on again after the repair, Work instruction is poor Step jump Step jump Peeling in the tape test Topcoat painting Character print Topcoat painting Character print Inspection Pass Fail Shipping Repair Inspection Pass Shipping 5

6 Case 2 Die management Die abrasion problem D-Cost US$7,400 occurred Die OK NG Die management Maintenance and verification methods are poor abrasion occurs Die Matches the criteria dimension Larger than the criteria dimension 6

7 Sony's change management rules 1. Production site Plant 2. Manufacturing method and conditions Method/procedure Conditions Process equipment Change or addition of production plants and sites (including subcontractor and parts partner of first tier partner ) Mechanical Electric Semiconductor PWB Approval Approval Approval Approval Change in the work environment (temperature, humidity, cleanness, lighting, etc.) * * * * *6) Content of change Change in the production method (e.g. from batch from cell or vice versa) Application Application Application Change of lines (e.g. from line A to line B) or deletion Application Application Application/* Change in the work procedure (work sequence/work addition or deletion) Application Application Application Maintenance of work standards * * * Shift change * * * Approval/ Change in the work conditions (e.g. SPM, painting conditions, soldering conditions, etc.) Application * Comply with Application STM-0028 Change in the program (NC/drill) Application * Application Switch between manual and automatic, between manual and tool-based, and between singleaxis and multi-axis Change to different equipment (press machine, molding machine, etc.) Application * Category Change category *2) Approval Application Application Addition of equipment of the same type Application * * Occurrence of and recovery from equipment failure * * * Change in the maintenance interval or method and implementation of maintenance * * * *4) *1) Approval/ Application *3) Approval Re-approval sample submission Application 4M change application submission partner autonomous management 7

8 Purpose Partners in a portion other than the "approval", "application" of change management category of 4M change application guidance for the "autonomous management" item, will promote the strengthening of the quality management system. change management category of 4M change application guidance 大項目 中項目 小項目 機構 電気 半導体 PWB 生産場所 工場 生産工場の変更検定検定検定検定作業環境の変更 * * * * 生産方法の変更 申請 申請 申請 ラインの変更 申請 申請 申請 /* 方法 手順 作業手順の変更 申請 申請 申請 作業標準書の変更 申請 申請 申請 シフトの変更 申請 申請 申請 製造方法 手順 条件 工程設備 作業条件の変更申請 * STM- 0028に従う 検定 / 申請 プログラムの変更 申請 * 申請 工程設備の変更 検定 申請 申請 異なる設備への変更 申請 * 申請 /* 同型設備の追加 申請 * * 設備の故障発生 復帰時 * * * メンテナンス頻度 方法の変更 メンテナンス実施時 * * * 設備の追加 廃止 修理 改造 変更 * * * * 周辺設備例 : 取り出し機 レベラー加工補助剤加工補助剤例 : 申請 * * * FY16 focus item: strengthening 金属加工油 離型剤 of autonomous 治具の追加 廃止 修理 改造 変更申請 * * * 治工具工具の変更 * * * * management item of partners タップの変更 ( 転造 切削 ) 検定 * * * autonomous management item 8

9 all 22 items Items medium items No. small items The configuration of the guideline 1.Operation Change 1.1 Operation Standard Book Making Operation Instructions 2.Change of People Temporary Operation Change Management 1.2 Confirm Operation Confirm Operation Content 1.3 Change Operation Conditions Change Operation Conditions 1.4 Traceability Traceability 2.1 Change of Operators Advanced Education(Basic Education) Operator Instruction Confirm Final Results 2.2 Change of Quality Controller Manager Training 2.3 Charge Instead Act Operation Instead Description of Failure case and root cause To analyze the past of failure cases, it describes the portion that is not possible for the ideal scheme. 3.Change of Mold and Die 4.Equipment Change 5.Fixture Change 2.4 Traceability Traceability 3.1 Mold and Die Management Regular Maintenance Daily Spot Check Abnormality Dealing 3.2 Traceability Traceability 4.1 Equipment management Regular Maintenance Daily Spot Check Abnormality Dealing 4.2 Traceability Traceability 5.1 Fixture management Regular Maintenance Daily Spot Check Abnormality Dealing 5.2 Traceability Traceability Description of self-management content as an ideal scheme Including "the operation of the actual Sony site" Explain the correct operation at the moment Ideal scheme = ultimately aim scheme We will consider a scheme that can be managed with close scheme. 9

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