Based On Six-sigma Research On Process Analysis And Improvement Of Automatic Insertion

Foxconn Group A department aims at the production of electronic productsconnectors for Apple corporation. Since2012, in order to meet market demand, mobilephone I/O structure has undergone great changes, the length is reduced to one-third ofthe original, in the assembly process, the automatic insertion pin station has a high defectrate, too much malfunctions make the production efficiency extremely low. This paper ismade in this background, automatic insertion process analysis and process improvementare base on6sigma, and apply6sigma core processes to quality management of connector.This paper researches the implementation of core processes of6sigma of five stepsDMAIC (define, measure, analyze, improve, control) as well as those used for each step ofthe quality tools and methods. This paper defines the failure mode is that the contactsbellow gap is not in specification, by assess the measurement system and finally find thatthe design of contact is poor, after analysis the structure of contact and its status in housingfind that it is not a stable design, base on how to fix contact in housing well, redesign thecontact barb structure and improve process, finally control the key factors that effects thequality and achieves the improvement target. This paper use the project of "Qualityimprovement for automatic insertion" as an example, described in detail how to apply6sigma core processes for quality improvement. Minitab is used in the analysis for the keyfactors in setting standards of the pre-insertion height and pre-insertion depth for theregression analysis and predictive modeling.Through the improvement, automatic insertion quality promoted significantly,production efficiency is also greatly improved, and A department wins the customer’sapproval.