Practical actions done to reduce electronic manufacturers\' operating cost.

1. Productivity Improvement Plan
Year 2007, Q3
Prepared: Jansen Cheng (Manufacturing
Engineering Manager)
Review: P.C. Yeung ( Sr. Operation Manager )

2. Content–manpower reduction
● 1. Production line change to Stand up operation
● 2. Step up stencil
● 3. Recycle solder bar
● 4. FFC cable hand soldering
● 5. Component Preform automation
● 6. Outsource reduction
● 7. Electricity expense

3. Content
● 8. Standard time improvement
● 9. Inspection headcount
● 10. Floor space allocated
● Attached files : Details of this
presentation please ref to the attached
file:
manpower reduction 20070413.xls

4. Production line change to Stand up
Operators are stand up to work,
efficiency is increased by 5.7 % and up
to 20% in some case.
Floor space is increased by reclamation.
Preform lines

5. Production line change to Stand up
Already implemented in Manual insertion,
WS and packaging lines, and most of the
Preform lines.
Manual insertion WS to packaging

6. Production line change to Stand up
● Nine of fourteen lines will change to
Stand up operation before Jun.2007.
● Totally reduce 40 operators
● Responsible : M.E. Dept.

7. Step up stencil
Use "Step up stencil" to add extra
glue to the IC location. The “hand-
add-glue” operator is saved.
通过开设向
上孔洞，
可以增加选
定元件
的 red glue
用量。
Before change New Step up stencil

8. Step up stencil
● Affected 14 lines by reduce one
operator per SMT line.
● Totally reduce 28 operators.
Complete before May.31.
● Responsible : M.E. Dept.

9. Recycle solder bar
● Using Recycle machine to
regenerate solder bar
● Saving is 7 % of monthly solder
consumption
● Countermeasure to rising price of
SAC305 solder

10. Recycle solder bar - RoHS
Compliance Test
● The sample will also be subjected to
RoHS compliance testing using XRF
analyzer in our QRS Lab.
● Responsible : QA

11. FFC cable hand soldering
● Replace hand soldering process by
Heat seal machine to solder FFC.
● Total reduce 22 operators.
● Complete date: Jul.2007
● Responsible: M.E. dept.
Heat seal machine

12. Component Preform automation
● Hand cutting lead change to
machine cutting.
● Two operators is saved. Affected 6
lines.
● Responsible: PIE dept.

13. Outsource reduction
● Add new Auto-insertion line in
Production and reduce outsource
equivalent line equals to 2 lines.
● Complete by: Apr.07
● Responsible: M.E. dept.

14. Electricity expense
● Use city electricity to replace power
generator in-house. The electricity
cost is reduced.
● Responsible: PTE dept

15. Standard time improvement
● Work with CEE to improve std time.
● Continuous improvement by regular
review of std time.
● Responsile: CEE, M.E.dept. and
Production

16. Attached file
● manpower reduction 20070413
(rev1).xls, this file is delibrately
deleted to protect intellectual
privacy.
● The content of this presentation file
is not allowed to reproduce without
permission of the author.