Study On Product Quality Improvement At S Company Based On Six Sigma Management

Electronics Manufacturing Services(Hereinafter referred to as EMS)is a highly competitive and cruel industry.Production cost and quality level played a decisive role in the process of competition,the quality level is also one of the important factors that affect the cost of production.Six sigma management is a systematic quality improvement method,the company can greatly improve the level of product quality and significantly reduce the poor quality cost by using six sigma management method.At first,this paper introduces the background,significance of the subject,research objectives and content,then introduces the basic theory DMAIC of six Sigma management,some tools of six sigma management and domestic and foreign research status.then applies six sigma tools in each stage of the DMAIC process to deeply research on K1 product quality problems solving at S CompanyIn Definition phase of the six sigma DMAIC process,we take advantage of product shipment data analysis and principle of pareto chart to find out main model K1 and major defective items that affected the product yield of K1 product.Then use the SIPOC diagram to analyze and find the related process about each main defective item.on the basis of above work,S company establishes the project team and has been clear about the project goals.In the measurement and analysis phase of Six Sigma DMAIC,the measurement system analysis and process capability analysis were carried out by using Minitab software to confirm the reliability of data and the product quality level before improvement.Through the analysis of the related process matrix and key input and output variables of process and process failure mode effect analysis(PFMEA),the significant factors of each improvement defective item were preliminarily determined,and then the factors of each improvement.Significant factors were verified by using the hypothesis test(P test and T test)and experimental design(DOE)of Minitab software.In the improvement and control phase of six Sigma DMAIC,after analyzing the improvement difficulty of significant factors,the simple significant factors were improved through the conventional working method.and the experimental design was continued to determine the optimization parameters of the complex significant factors,thus the work in the improvement stage was completed.In view of the standardized control of the improvement actions,the process failure mode effect Analysis(PFMEA),control plan and work instruction were updated.and the improved defect rate was real-time monitoring through statistical process control,so as to steadily control the defect rate of K1 products(from 1.78% to 0.3%).Eventually brought more than 1 million direct economic benefits to the company.Based on the results of this project,the management of S Company decided to introduce the six Sigma management comprehensively and formulated relevant safeguard measures for how to guarantee the effective implementation of the six Sigma management.Through the successful implementation of this study,the improved model of Six Sigma DMAIC has been improved from the general theoretical practice to the specific product quality improvement of S Company.This study not only brings good benefits to S company,but also strengthens its management’s determination to carry out six Sigma management comprehensively.By summarizing the problems encountered during implementation and the improvement plan,S company has formulated relevant safeguard measures for the comprehensive implementation of the six Sigma management in the future.