The Failure Analysis And Countermeasure Study For Machines In Ball Attach Station In Chipset Assembly Line In A Foreign Enterprise

Production Planning is the important constituent of the enterprise operation plan. The production planning stipulates explicitly each department's production task and the production target during this plan period, which enables each department work designedly and regularly. The production planning mainly includes confirming productivity level and production target, as well as arranging rationally production task of whole year. Enterprise's productivity level is one of key restraint conditions in formulating production planning.The capacity of the permanent asset is one of most important productivity in industrial enterprise. Therefore, the factory's goal should be the maximized the income of the fixed asset, in other words is to make the equipment to be as efficient as possible.Generally, each kind of equipment has its own biggest capacity theoretically, which will be realized without any disturbances or quality loss. But, in the actual production, it is impossible to achieve this requirement. As a result of many factors, the equipments in workshop have massive failure, for example, equipment breakdown, setup in product replacement, replacement with spare parts as well as complete renewal of equipment, and so on. When the production equipment works failure, there will be taking many negative influences, the most serious in which is that it will not be able to complete the production task according to the plan, meanwhile will have to arrange the man power, the physical resource and the financial resource carries on the maintenance of the equipment.In present, majority of enterprises adopt Breakdown Maintenance and Plan Maintenance in the maintenance management of equipment. Breakdown Maintenance belongs to passive form, which can not effectively reduce the equipment failure rate. But due to the influence of the veracity of plan, Plan Maintenance stands a good chance to cause work too much or insufficient. Therefore, Forecasted Maintenance, which can effectively enhance Overall Equipment Effectiveness (OEE), based on the equipment running status, will be one of future development directions of equipment maintenance.This article is to do Failure Analysis and Countermeasure Study for eight equipments in Ball Attach station, one of key stations in chipset assembly line in a famous foreign enterprise. These eight equipments frequently appear various failures, for example, Assist, Setup, Engineering Time, Idle_lack of MS, Idle_lack work, and so on. Regarding services for these breakdowns, formerly they formulate the equipment maintenance plan all depending on experience, auxiliary to Breakdown Maintenance. This has brought more indefinite factors to make and take the Production Planning. The author utilizes SPSS software to carry on Cluster Analysis and Correlate Analysis to the down time data of these eight machines in longer period, to discover several primary factors in down time. After that, separately analyze each machine with these primary factors, discover the general breakdown cycle on each machine, forecast the time which failure is going to occur. Based on these analyses, carry on the Forecast Maintenance management to the production equipment, and adjust Production planning.This research is to provide one kind of comprehensive method combining mathematics with experience for the production manager in semiconductor factory like chipset operation, to adjust Production Planning and establish Forecasted Maintenance plan through analyzing the monitoring information of productive equipment.