Application Of Lean Manufacturing To Flash Assembly And Test Production Line Optimization

In order to enlarge its market and sales in Asia area continuously, AAA China Corp. introduces and implements Lean Production, requires its Production Dept. to eliminate waste and reduce production cost.According to the production status quo of flash department, the paper uses VSM (Value Stream Mapping) technology to identify waste in current process activities. Meanwhile, use the six sigma tool DMAIC (Define, Measure, Analyze, Improvement and Control) to optimize the production line. Additional quality control tool was used to assess quality impact after line optimization, such as FMEA and SPC chart.The paper utilize IE theory and lean manufacturing tool to plan and implement a set of lean project, mainly focus on 3 stations in Assembly line. Firstly, use work measurement method to re-organization the die batch process, it save the operator headcount, reduce the lead time and eliminate the waster of substrate at utmost; Secondly, use process map, measure/analyze critical thought map and FEMA to optimize DA PM (Production Maintenance) process, reduce 1hr non-value added, equivalent to 0.05% ; Lastly, use Cause and Effective Matrix and six sigma basic tools to optimize Wire Bond station, make the output linearization, and improve machine utilization by 6% through the project. Finally, we summarize the result, draw"To Be"value stream mapping.By means of lean manufacturing implementation, Flash department improve the Lead Time by 7.58%, Production Cycle Efficiency by 7.65%, the same time save $2605K cost in 5 years. Lean manufacturing application in Flash manufacturing department is a good beginning of continuous improvement, and set a solid fundamental to boost lean thinking to whole company.