Overview

There’s a part called VCM on the hard disk. It is like a frame to hold another functional part in a hard disk. Before assembly, VCM needs to be cleaned and put in a jig for automation assembly. Process VCM to be loaded in jig needs human work. 

Key Problem

1. During interview operator feel fatigue after works in station load VCM

2. Due to fatigue, focus operator being low and drive to increase VCM rejected

Why reject? During the load process the operator has to move VCM from cleaning machine to jig. Due to fatigue, the hand operator often makes the VCM fall to the floor and causes contamination. This is called rejection.

Key Solution

1. Observation the fatigue by : 

   1. Video load process 

   2. Assessment the movement operator by RULA method 

2. Create design tools that help RULA score to be lower (acceptable score) 

3. Create mock up and trial to one station 

4. Conduct testing and review with Operators whether tools acceptable to help them

5. Approval for changes the tools 

6. Production

Key Result

1. Improve cycle time process loading VCM average ~16% faster 

2. Improve score RULA from 7 to 3 

3. Getting good feedback from Operators for the changing tools and feel not fatigue anymore

Tools 

1. Excel  

2. Video Recorder

3. RULA assessment sheet

4. Ansys

Overview

1. based on observation IE team during Gemba: a lot of waiting process happened in assembly HDD process

2. optimize number operators in manufacturing process before ramp up production on next year (2016) for new line production

Key Problem

How much waiting time happened during assembly process ?

Key Solution

1. Record video for each process in line assembly for all shift working

2. Conduct time study for all process 

3. Discussion with Supervisor assembly and IE team which waiting process able to substitute into value added activity

Key Result

1. Reduce operator assembly for ~50% by optimize their workload instead waiting activity 

2. Reduce headcount expense for HDD assembly process

Tools 

1. Excel   

2. Video Recorder