1.
Lean Six Sigma Project
Scrap Reduction in Electronic Circuit Board Production
Lassi Uusitalo
Lean Six Sigma Green Belt Trainee

2.
Public
Continental Company Presentation
Continental Corporation
Overview 2017
05.09.2018
2Continental AG
Since 1871
with headquarters
in Hanover,
Germany
235,473
employees
worldwide
554 locations in
61 countries
Status: December 31, 2016

3.
Public
Continental Company Presentation
Continental Corporation
Overview 2017
05.09.2018
3
Sales of appr.
€44 billion
ContiTech
14%
Chassis & Safety
22%
Powertrain
18%
Interior
20%
Tires
26%
Sales
by division
in %
Status: December 31, 2016
© Continental AG

4.
For ESTIEMers
Corporate Function Quality&Environment
› Project was conducted on during summer 2017
› In one of the plants in Germany
› Highly standardized serial production
› Data is created based on real world observations for this project presentation
Project Introduction
Scrap Reduction in Electronic Circuit Board Production
5 September 2018
4CFQ&E, © Continental AG

5.
For ESTIEMers
Corporate Function Quality&Environment
Project Leader: Lassi Uusitalo
Team: Maintenance Specialist
Failure Analysis Specialist
Team Leader in Prodction
IT / Data Specialist
Sponsor: Plant Manager
Project Charter
Scrap Reduction in Electronic Circuit Board Production
5 September 2018
5
Project Goal: Find & eliminate the rootcause of a long standing problem of a
repeated defect which has lead to customer returns.
DMAIC - Time plan:
Define: 06 / 2017
Measure: 06 / 2017
Analyze: 06-07 / 2017
Improve: 07 / 2017
Control: 07-08 / 2017
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
There have been problems with different parts of the
external housing and connectors being
mechanically damaged during the production.
Problem Description:
CFQ&E, © Continental AG

6.
For ESTIEMers
Corporate Function Quality&Environment
› Since March several customer returns
of defected products from repeated
mechanical damage in circuit boards
› A very specific and systematic
problem with a specific cause
› A range of other unexplained
mechanical damages
Problem Description
Scrap Reduction in Electronic Circuit Board Production
5 September 2018
6
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
CFQ&E, © Continental AG

7.
For ESTIEMers
Corporate Function Quality&Environment
Amount of Scrap Varies Over Time
Scrap reduction in Electronic Circuit Board production
5 September 2018
7
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
1110987654321
4.0%
3.0%
2.0%
1.0%
0.0%
Observation
IndividualValue
_
X=1.9%
UCL=3.5%
LCL=0.3%
1
I Chart of Scrap rate per week
CFQ&E, © Continental AG

8.
For ESTIEMers
Corporate Function Quality&Environment
Deployment Diagram
Scrap reduction in Electronic Circuit Board production
5 September 2018
8
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
CFQ&E, © Continental AG

9.
For ESTIEMers
Corporate Function Quality&Environment
Fishbone Diagram
Scrap reduction in Electronic Circuit Board production
5 September 2018
9
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Machinery Methods Manpower
MeasurementsMother NatureMaterials
Transport Scrap
CFQ&E, © Continental AG

10.
For ESTIEMers
Corporate Function Quality&Environment
Potential Problem Analysis
Scrap reduction in Electronic Circuit Board production
5 September 2018
10
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Process Step Potential Problems Possible Effects Likely/Possible Causes
Shaking during manual handling
Circuit boards bump into each
other
Loose shelves without up/down
movement prevention mechanism
Circuit boards are not aligned in
the logistics box
The vertical plastic part
touches various areas of the
circuit board above it
Slippery non-fixed shelves
ICT Misplacing the reader
Misread in testing (non-failure
read as failure)
Mechanical and/or calibration
problem
Too hasty handling
Carelesness
The jig is too tight?
Change in equipment pieces
Forgetting reprogramming
Gets stuck midway Too snug fit of the jig
Unwelcome stress on the
hinge between the microchip
and the connector
Handler lifts the
microchip+connectors from one
corner, creating an angle which
causes the microchip+connectors
to slide against the walls of the jig
Parts which should be
pressed end up in scrap
Laser scanning is not suitable for
checking the alignment of pieces?
Parts which scrapped go
through the press
Lhe scanner is dirty?
-> parts get further damaged
down the line
Wrong calibration?
Awkward position of the
operator
The connectors could be set
with a bit of an incorrect angle
The jig is positioned in around 40
degree angle when outside of the
machine
The microchip is taken out
forcefully
Unnecessary stress on
components
Tight schedule, haste
Loading
Pressfit
(connectors)
Misplaced connector in the jig
Pieces are not completely
aligned -> pressfit will merge
them with error/defect
Calibration problem Several types of errors
The assembled
microchip+connectors are taken
out at the wrong angle (not
straight up)
There is a reading error in the
scanner before pressing
› Done for all process steps
› 32 Possible causes identified
› How to get data?
› Where to focus?
CFQ&E, © Continental AG

11.
For ESTIEMers
Corporate Function Quality&Environment
Pareto from Scrap Analysis Results
Scrap reduction in Electronic Circuit Board production
5 September 2018
11
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Measurement points
ICT test
Check the
alignment and
connectors
Check the
result
Check the seal
EOL testing
ICT Testing Machine
Press Fit Machine 1
Paste Machine
Hand press
EOL Test Machine
Count 928 207 48 60
Percent 74.7 16.7 3.9 4.8
Cum % 74.7 91.3 95.2 100.0
Subscripts OtherICT Testing MachineHand pressEOL Test Machine
1400
1200
1000
800
600
400
200
0
100
80
60
40
20
0
Count
Percent
Pareto Chart of defects per location
CFQ&E, © Continental AG

12.
For ESTIEMers
Corporate Function Quality&Environment
Process Steps for Paste Machine and Press fit
Scrap reduction in Electronic Circuit Board production
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Place
housing
pieces in
the paste
machine
Place
pasted
housing
pieces on
the pre-
assembly
table
Place
circuit
board in
the
assembly
jig
Place
pasted
upper
housing in
the
assembly
jig
Place the
battery in
its slot
Place &
press the
battery
protector
w/
handpress
Place the
upper+
lower
housing in
the final
(small)
pressfit
Apply
paste
Seal the upper and the
lower housing together
Flash the
tracking
barcode of
the battery
Check
the
seal
Check
the
result
Place the
tracking
label on the
product
Operator 2
Paste
Machine
Hand
Press
Scrap Analysis
CFQ&E, © Continental AG
5 September 2018
12

13.
For ESTIEMers
Corporate Function Quality&Environment
Weeks 14 to 16 Have the Highest Scrap Rate
Scrap reduction in Electronic Circuit Board production
5 September 2018
13
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Counts EOL 270 152 138 108 93 80 49 38
Percent 29.1 16.4 14.9 11.6 10.0 8.6 5.3 4.1
Cum % 29.1 45.5 60.3 72.0 82.0 90.6 95.9 100.0
Defects in EOL
O
ther
problem
in
Antenna
23
Protocol 1
problem
in
connectors 12-14
Protocol 2
Protocol 3
Protocol 4
problem
in
connectors 1-3
900
800
700
600
500
400
300
200
100
0
100
80
60
40
20
0
CountsEOL
Percent
Pareto Chart of Defects in EOL
Most problems are occurring with connectors
CFQ&E, © Continental AG

14.
For ESTIEMers
Corporate Function Quality&Environment
Weeks 14 to 16 Have the Highest Scrap Rate
Scrap reduction in Electronic Circuit Board production
5 September 2018
14
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Counts 155 52
Percent 74.9 25.1
Cum % 74.9 100.0
Defects in Hand Press Connector 12Connector 23
200
150
100
50
0
100
80
60
40
20
0
Counts
Percent
Pareto Chart of Defects in Hand Press
Most problems are occurring with connectors
CFQ&E, © Continental AG

15.
For ESTIEMers
Corporate Function Quality&Environment
Closer Look at the Fishbone Diagram
Component Breakages Detected After Hand Press
5 September 2018
15
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Machinery
Error In Hand Press
Wrong
setting
Mounting
component
incorrectly
CFQ&E, © Continental AG

16.
For ESTIEMers
Corporate Function Quality&Environment
Problem Potentially Caused by Wrong Setting
Problems started occurring after latest maintenance
5 September 2018
16
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
› Handpress has been set to
go lower than the top of
the assembled part
› There is excess force
inflicted on the parts in the
hand press station
› All force that is not used for
clipping the battery cap is
directly transferred to the
circuit board, causing it to
bend
CFQ&E, © Continental AG

17.
For ESTIEMers
Corporate Function Quality&Environment
Improvements
Contact of Antenna and Housing in Hand Press
5 September 2018
17
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
Recalibration of the hand press
Strain gauge measurements
Immediate improvements
Making a new reference block
Additional supports on hand press jig
Long-term improvements
CFQ&E, © Continental AG

18.
For ESTIEMers
Corporate Function Quality&Environment
Any Questions?
Thank you!
5 September 2018
18CFQ&E, © Continental AG

19.
For ESTIEMers
Corporate Function Quality&Environment
› Common for all is the structured approach for solving problems
› Always need for data to support the process and validate improvements
› Six Sigma is the most data focus approach
› Tools are used flexibly, no matter how the approach is called!
Lean Six Sigma in Automotive Industry
Need for Structured Problem Solving
5 September 2018
19
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
A3 8D Six Sigma
CFQ&E, © Continental AG