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HARIPERTAMA

NAMA KUMPULAN : ALZA

ORGANISASI : INFINEON TECHNOLOGIES (MALAYSIA) SDN BHD. MELAKA

TAJUK PROJEK : ELIMINATING TILTED UNIT DEFECT THUS INCREASING

PRODUCTIVITY AND CUSTOMER SATISFACTION

PENJIMATAN PROJEK : RM22,507/WEEK

A. LATAR BELAKANG PROJEK

i. THE STANDARD KPI OF QCDMS INDICATES THAT Q,C & D NOT MEET SET TARGET.

ii. IN RESPOND TO THE Q,C & D NOT MEET THE TARGET, TEAM ALZA CHOOSE THE OPTIMAL

STRATEGIES OF PROBLEM SOLVING METHODOLOGIES TO IDENTIFY THE UNDERLYING CAUSES AND

DEVELOP COUNTER MEASURE TO EDUCATE THE PROBLEM.

iii. A SYSTEMATIC EXAMINATION AND EVALUATION OF DATA TO UNDERSTAND THE RELATIONSHIP

BETWEEN CAUSES AND EFFECT. THUS PROVIDING BASIS FOR PROBLEM SOLVING HAS TO LEAD TO

INNOVATIVE IDEA.

B. PUNCA UTAMA MASALAH

VARIOUS ANALYSIS AND VERIFICATION WAS PERFORMED TO DISTINGUISH THE POSSIBLE CAUSES

RESULTS TO THE FACTOR OF MACHINE THAT IS INCONSISTENT VACUUM VALUE AT PIPETTE MODULE.

C. CADANGAN PENYELESAIAN INOVATIF & KREATIF

AFTER IDENTIFY VARIOUS POTENTIAL SOLUTIONS, TEAM DO THE EVALUATE VARIOUS MOST POTENTIAL

SOLUTIONS BY CONSIDERING ADVANTAGES AND DISADVANTAGES. FINAL SOLUTION WAS CHOOSE

THAT IS TO SPLIT AIR VACUUM CONVERTER ONLY FOR PIPETTE MODULE. FOR THE PAST 2 WEEKS WE’VE

TRIAL RUN AND SHOWS POSITIVE RESULT. THE RESULT WERE PRESENTED TO MANAGEMENT FOR BUDGET

APPROVAL TO IMPLEMENT AT BALANCE 13 MACHINES.

D. TANDA ARAS

WE BENCHMARK FROM OTHERS MACHINE MODEL AT OUR PRODUCTION FLOOR THAT IS IS MECA

MACHINE AND SRM MACHINE WHICH WAS USING INDIVIDUAL VACUUM CONTROLLER FOR EACH

PICKUP HOLDER. THIS GAVE US AN IDEA TO APPLY THE CONCEPT TO OUR THA MACHINE WITH

CREATIVELY DESIGN.

E. PENCAPAIAN PROJEK & PENCIPTAAN NILAI

AFTER 6 MONTH OF HARD WORK AND GREAT TEAM SPIRIT, ALZA TEAM HAS COMPLETED THE TASK AND

CRAVES THE SUCCESS TOGETHER TO ACHIEVE THE COMMON ONE GOAL WHICH IS TO ELIMINATE

TILTED ISSUES. THE TEAM HAD ACHIEVED QUALITY, COST AND DELIVERY TARGET FOR TSXP PACKAGE

CONTINUOUSLY TILL TO-DATE. THE QUANTIFIABLE BENEFITS GAINED FROM THIS PROJECT:-

REDUCE ABORT REEL ISSUES BY 61.9%.

PIPETTE MODULE DOWNTIME REDUCED BY 67.24%.

REDUCE SCRAPPED UNITS BY 54.79% DUE TO ELIMINATE TILTED UNIT.

COST SAVING PER YEAR OF RM1,150,225.00

F. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN

i. ALZA WAS AWARDED AS GOLD TEAM FOLLOWED BY 1ST RUNNER UP IN INFINEON, INTERNAL SGA

COMPETITION WITH REWARDS OF RM750.

ii. THE TEAM ALSO REWARDED RM400 AFTER SUBMITTED TO YIP PROGRAM.

iii. ~YIP (YOUR IDEA PAYS) IS THE IDEA MANAGEMENT USED IN OUR COMPANY TO PROMOTE

SUGGESTIONS.

NAMA KUMPULAN : 13 4U

ORGANISASI : MAJLIS DAERAH BERA

TAJUK PROJEK : KEKERAPAN KAD INDEN MINYAK TIDAK DIPULANGKAN

PENJIMATAN PROJEK : PENJIMATAN MASA MENCARI KAD INDEN MINYAK YANG

TIDAK DIPULANGAN


i. PENGGUNAAN RAK LUT SINAR MEMUDAHKAN PEMANTAUAN OLEH PEGAWAI KENDERAAN BAGI

MENGENALPASTI PEMANDU YANG TIDAK MEMULANGKAN KAD INDEN MINYAK SELEPAS

DIGUNAKAN DALAM MASA YANG SINGKAT.

ii. KAEDAH SEDIA ADA ADALAH PENGGUNAAN BUKU ‘CARD HOLER’ BAGI MENYIMPAN KAD DAN

REKOD PEMULANGAN YANG TIDAK SISTEMATIK MENYEBABKAN PEGAWAI KENDERAAN

MENGAMBIL MASA LEBIH KURANG 30 MINIT UNTUK MENCARI DAN MENGENALPASTI KAD INDEN

MINYAK YANG TIADA DIDALAM ‘CARD HOLDER’ TERSEBUT.

iii. RAK LUT SINAR DILETAKKAN BERSEBELAHAN MEJA PEGAWAI KENDERAAN SEKALIGUS

MEMUDAHKAN PEMANTAUAN SECARA VISUAL DAN PEMANDU SENDIRI AKAN MENYIMPAN KAD

DENGAN PENGAWASAN SERTA PENGESAHAN PEGAWAI KENDERAAN.

iv. BAHAN YANG DIGUNAKAN BAGI MEMBUAT RAK JUGA LEBIH MURAH DAN MEMPUNYAI KUNCI

KESELAMATAN SERTA MEMPUNYAI KELEBIHAN 3 DALAM 1 IAITU PENYIMPANAN KAD INDEN

MINYAK, TOUCH N GO DAN KUNCI KENDERAAN.


i. TIADA KAWALAN PEMANTAUAN YANG SISTEMATIK TERHADAP KAD INDEN MINYAK YANG TIDAK

DIPULANGKAN.

ii. PENYELIA MENGHADAPI BEBAN KERJA YANG BANYAK.

iii. CARD HOLDER YANG DIGUNAKAN DISIMPAN DALAM LACI DAN MUDAH ROSAK.

iv. MASA PENYEMAKAN REKOD KAD INDEN MINYAK YANG LAMA.


i. MENCIPTA RAK YANG BOLEH MENEMPATKAN KAD INDEN MINYAK, TOUCH N GO DAN KUNCI

KENDERAAN PADA SATU TEMPAT SUPAYA IANYA MUDAH DIPANTAU DAN DIKAWAL PERGERAKAN

KAD INDEN MINYAK, TOUCH N GO DAN KUNCI KENDERAAN DENGAN LEBIH SISTEMATIK DENGAN

KAEDAH 5S

ii. MEMPERKENALKAN 2C PERFECT KEY

D. TANDA ARAS

i. MENGURANGKAN KEKERAPAN KAD INDEN MINYAK YANG TIDAK DIPULANGKAN

ii. MENJIMATKAN MASA MENCARI KAD INDEN MINYAK DARI 30 MINIT KEPADA 2 SAAT


i. BERJAYA MENGURANGKAN KEKERAPAN TIDAK PEMULANGAN KAD INDEN MINYAK

ii. BERJAYA MENJIMATKAN MASA PENCARIAN KAD INDEN MINYAK YANG TIDAK DIPULANGKAN


i. JOHAN MINI KONVENSYEN KIK MAJLIS DAERAH BERA 2017

ii. PINGAT EMAS ICC WILAYAH UTARA 2017

NAMA KUMPULAN : FI SILICON POWER


TAJUK PROJEK : TO REDUCE SCHEDULE DOWN AND UNSCHEDULE DOWN TIME

AT WAFER SAWING PROCESS.

PENJIMATAN PROJEK : COST SAVING RM3,487.962.00


HIGH SCHEDULE DOWN TIME AND UNSCHEDULE DOWN TIME DUE TO HIGH TRANSFER ARM FAILURE

DURING SETUP AND PRODUCTION MODE. GREENLINE STABILITY REQUIRES ZERO (0) TRANSFER ARM

ERROR DURING PRODUCTION MODE. AS TODATE, AVERAGE 3 CASES RECORDED EVERY SETUP. TEAM

DECIDE TO REDUCE TRANSFER ARM ERROR FROM 3 CASES TO ZERO (0).


OUR FOCUS AREA IS AT WAFER SAWING, WE FOUND THAT TRANSFER ARM ERROR IS CAUSED BY CHUCK

TABLE CLOGGED DUE TO SAW DUST TRAPPED INSIDE THE CHUCK TABLE DURING THE WAFER CUTTING

PROCESS.


TEAM PROPOSE 2 ALTERNATIVE SOLUTION WHICH IS GRINDING & ULTRASONIC CLEANING. FROM

VERIFICATION AND VALIDATION FURTHER ANALYSIS, OUR TEAM DECIDE TO IMPLEMENT ULTRASONIC

CLEANING WITH DIAMAKLEEN AS CLEANING AGENT WHICH IDENTIFIED USING PROCESS DECISION

PROGRAM CHART (PDPC).

D. TANDA ARAS

BY IMPLEMENTING ULTRASONIC CLEANING WITH DIAMAKLEEN AS CLEANING AGENT. FINALLY TEAM

MANAGE TO REDUCE OUR SCHEDULE DOWN TIME FROM 8.20% TO 5.30% (TARGET 6.00%) AND

UNSCHEDULE DOWN TIME FROM 2.20% TO 1.50% (TARGET 1.50%). TEAM ALSO MANAGE TO IMPROVE

QUALITY (UNDERSIDE CHIPPING, CRACK DIE AND BROKEN WAFER) BY INCREASING THE YIELD FROM

98.74% TO 99.09% (TARGET 99.00%).


ABLE TO IMPROVE OEE FROM 85% TO 88.6%. MANAGE TO REDUCE CHUCK TABLE MAINTENANCE COST

BY INCREASE THE LIFESPAN OF CHUCK TABLE WITH NEW CLEANING METHOD FROM 6 MONTH TO 5

YEARS WITH TOTAL SAVING RM 3,487,962.00.


i. GOLD AWARD IN INFINEON MELAKA SGA COMPETITION 2017.

ii. TEAM RECEIVE AWARD UNDER INFINEON YOURS IDEAS PAY (YIP) RM 6000

iii. GOLD AWARD IN SOUTHERN REGIONAL ICC CONVENTION

NAMA KUMPULAN : MANIFESTO

ORGANISASI : KPJ SELANGOR SPECIALIST HOSPITAL

TAJUK PROJEK : MENANGANI MASALAH KEHADIRAN BENDASING DALAM

MAKANAN YANG DISEDIAKAN UNTUK PESAKIT

DI KPJ SELANGOR SPECIALIST HOSPITAL

PENJIMATAN PROJEK : RM / MASA SETAHUN : RM 68,720.20

A. LATAR BELAKANG PROJEKV

KEHADIRAN BENDASING YANG TIDAK SEPATUTNYA BERADA DI DALAM MAKANAN SERTA MAMPU

MEMBERI ANCAMAN FIZIKAL TERHADAP MAKANAN SEPERTI PAKU, SKRU, LIPAS, ULAT, RAMBUT DAN

SEBAGAINYA. KES SEPERTI INI MEMBERI KESAN YANG BURUK KEPADA PESAKIT, HOSPITAL SERTA

PERSEKITARAN PEKERJAAN. TERDAPAT 10 KES BERLAKU DI DALAM PERKHIDMATAN MAKANAN KPJ

SELANGOR SPECIALIST HOSPITAL DALAM MASA 1 TAHUN. TERDAPAT SATU KES DIMANA PESAKIT

MENANG SAMAN RM67,000 TERHADAP KPJ SELANGOR AKIBAT INSIDEN INI PADA TAHUN

2015.KUMPULAN MANIFESTO CUBA MENCARI PENYELESAIAN AGAR KES SEPERTI INI TIDAK BERULANG

DAN HASILNYA SIFAR KES BERLAKU SEJAK IMPLEMENTASI.


i. TIADA PENGAGIHAN TUGAS YANG SPESIFIK KETIKA PROSES PLATING

ii. PENYUSUNAN BARANG YANG TIDAK EFISYEN DI DALAM STOR

iii. PANDANGAN MANUSIA YANG TERHAD UNTUK MENEMUI BENDASING YANG TERSOROK DI DALAM

MAKANAN

iv. SAYUR BERONGGA DALAM KUANTITI YANG BANYAK SUKAR UNTUK DICUCI

v. TIADA PENYUSUNAN BERSTRUKTUR KAIN PENGELAP

vi. TERDAPAT KOTAK DALAM STOR KERING YANG MENGUNDANG LIPAS

vii. KEHILANGAN PERALATAN YANG KERAP DAN DIGANTIKAN DENGAN PERALATAN SENDIRI YANG

TIDAK DISELENGGARA DENGAN BAIK


i. FORMASI RIVEPRO – FORMASI YANG SPESIFIK KETIKA PROSES PLATING

ii. SUSUN BARANG DI DALAM STOR IKUT PRINSIP 5S

iii. KOD WARNA HARIAN UNTUK KAIN PENGELAP

iv. METASCAN – MESIN YANG BOLEH MENGENALPASTI BENDASING LOGAM DALAM MAKANAN

v. SISIH KOTAK, KELUARKAN DAN SUSUN BARANG SETIAP KALI TERIMA BARANG

vi. SATU STESEN KHAS UNTUK LETAK SEMUA PERALATAN AGAR MUDAH DIPERIKSA

vii. GANTIKAN SAYUR BERONGGA DENGAN SAYUR LAIN

D. TANDA ARAS

i. KPJ KLANG

ii. KPJ TAWAKKAL

iii. KPJ AMPANG


i. TIADA INSIDEN BERLAKU DARI MEI 2016 HINGGA SEKARANG.

ii. INDEKS KEPUASAN PELANGGAN MENINGKAT DARI 75% KEPADA 90.5%

iii. TIADA LAGI KOS DISKAUN DAN SAMAN PERLU DIKELUARKAN AKIBAT INSIDEN BENDASING DALAM

MAKANAN

iv. MORAL STAFF MENINGKAT

v. PERSEKITARAN HOSPITAL YANG LEBIH SELAMAT

F. ANUGERAH, PENGHARGAAN & PENGIKTIRAFANi. 1. GOLD AWARD MPC REGIONAL (SOUTH) TEAM EXCELLENCE 2017

NAMA KUMPULAN : PERINTIS

ORGANISASI : JABATAN KEHAKIMAN SYARIAH SELANGOR

TAJUK PROJEK : MEREKABENTUK KELENGKAPAN BAGI PERBICARAAN DI LUAR

DEWAN BICARA BERBENTUK KOMPAKPENJIMATAN PROJEK : RM 861,048.00 (ONE OFF) / RM / MASA SETAHUN : RM861,048.00A. LATAR BELAKANG PROJEKV

MOBILE COURT KIT (MCK) IAITU SATU SET KELENGKAPAN YANG DIREKABENTUK KHAS DAN

MENGANDUNGI SET PERALATAN YANG LENGKAP UNTUK KEGUNAAN PERBICARAAN DI LUAR DEWAN

BICARA. PROJEK INI DIPILIH KERANA MENGAMBIL KIRA PENGGUNAAN KOS YANG SEDERHANA,

MENEPATI FUNGSI, VISI DAN MISI JABATAN, MAMPU DISELESAIKAN DAN BOLEH DISELESAIKAN DENGAN

SEGERA SERTA TIDAK MENGUBAH DASAR JABATAN. IA BERTUJUAN MEMBERI PENYELESAIAN DAN

KEMUDAHAN KEPADA PELANGGAN YANG TIDAK UPAYA UNTUK HADIR KE MAHKAMAH ATAS SEBAB

PELBAGAI MASALAH SEPERTI MASALAH KESIHATAN YANG KRITIKAL, PELANGGAN YANG TINGGAL DI

KAWASAN PEDALAMAN SERTA TIDAK MEMPUNYAI AKSES PERHUBUNGAN DAN PENGANGKUTAN.


i. KETIADAAN KELENGKAPAN BAGI PERBICARAAN DI LUAR DEWAN BICARA.


PERINTIS TELAH MEREKACIPTA MOBILE COURT KIT (MCK) IAITU SATU SET KELENGKAPAN BAGI

PERBICARAAN LUAR DEWAN BICARA YANG MENGANDUNGI SET PERALATAN YANG LENGKAP UNTUK

KEGUNAAN PERBICARAAN YANG MENGANDUNGI MEJA DAN KERUSI HAKIM, PEMBANTU SYARIAH DAN

SETIAUSAHA, RUANG PENYIMPANAN FAIL, LAPTOP DAN ALATULIS SERTA MENGANDUNGI RUANG

PENYAMBUNGAN WAYAR ELEKTRIK DAN PERALATAN AUDIO.

D. TANDA ARAS

BILIK BICARA MAHKAMAH BERGERAK SABAH DAN SARAWAK SERTA AMBULANS.


PENGURUSAN BAGI PERBICARAAN LUAR DEWAN BICARA SEMAKIN MUDAH DAN MENJIMATKAN KOS

PENGANGKUTAN, PENYEWAAN PERALATAN DAN MENGURANGKAN BEBAN KERJA KAKITANGAN.

PROJEK INI JUGA MEMPUNYAI PROSPEK YANG TINGGI UNTUK DIPROMOSIKAN BAGI KEGUNAAN

MAHKAMAH SYARIAH ATAU MAHKAMAH SIVIL DAN JABATAN- JABATAN LAIN SELURUH MALAYSIA.

PROJEK INI JUGA MAMPU MENJANA KEUNTUNGAN KEPADA JABATAN.


MENERIMA ANUGERAH EMAS DALAM KONVENSYEN TEAM EXCELLENCE WILAYAH UTARA 2017

MENYERTAI PERTANDINGAN MAJLIS PERSADA INOVASI PERKHIDAMATAN AWAM NEGERI SELANGOR

HARIKEDUA

NAMA KUMPULAN : SANMINA 4.0

ORGANISASI : SANMINA SCI PENANG

TAJUK PROJEK : UBERIZATION OF SMT SPLICING PROCESS

PENJIMATAN PROJEK : RM 250K


SANMINA PENANG PLANT II IS A PRODUCER OF PRINTED CIRCUIT BOARD (PCB) USING FULLY

AUTOMATIC SURFACE MOUNT EQUIPMENT.

DURING THE PLACEMENT OF COMPONENTS ON THE PCB, IT IS VITAL THAT FINISHING ELECTRONIC

COMPONENTS IN TAPE AND REEL ARE JOINT TOGETHER (CALLED SPLICING) TO ENSURE THE EQUIPMENT

DOES NOT STOP, DUE TO PART REPLENISHMENT.

THE CYCLETIME OF “SPLICING” IS AT 10 MINUTES PER SPLICE, THIS PROJECT IS TO REDUCE THE

CYCLETIME OF SPLICING OF OPERATORS AND TO INCREASE THE PRODUCTIVITY OF SMT OPERATORS.


WE CONDUCT A VALUE STREAM MAPPING EXERCISE AND IDENTIFIED SOME WASTE THAT IS ATTRIBUTED

TO WALKING AND INFORMATION GATHERING.


WE CONCLUDE THAT IF WE COULD PUSH THE SPLICING TIMING INFORMATION TO THE OPERATORS, WE

COULD REDUCE THE OPERATOR WALKING WASTE.

WE EVALUATED A NUMBER OF WEARABLE IN ORDER TO PUSH INFORMATION AND ALSO FREE UP THE

OPERATORS HAND TO MAKE EFFECTIVE WORK

THE MARKET PRICE FOR WRIST COMPUTER IS AROUND RM4200 PER UNIT. OUR TEAM CAME OUT WITH A

CREATIVE SOLUTION TO ACHIEVE THE PERFORMANCE OF WRIST COMPUTER WITH 90% COST

REDUCTION

THE WHOLE SYSTEM OF INFORMATION FLOW AND TASK ASSIGNMENT WAS BENCHMARK FROM THE E

HAILING SYSTEM OF UBER. THIS SYSTEM IS KNOWN AS UBR SPLICING.

THE INNOVATION IS NOT ONLY ON THE HARDWARE BUT ALSO THE GRAPHICAL USER INTERFACE (GUI)

WAS ALSO DEVELOP AND ALSO THE PROCESS TO MIMIC THE UBER SOLUTIONS.

D. TANDA ARAS

THE 1ST IMPLEMENTATION OF WEARABLE FOR OPERATOR PRODUCTIVITY IN SANMINA CORP


i. REDUCE THE SPLICING CYCLETIME BY 25% (10 MINS TO 7.5 MINUTES)

ii. USE OF INTERNET OF THINGS (IOT) TO FURTHER DRIVE PRODUCTIVITY

iii. ENABLE TRANSPARENT DATA ON NUMBER OF TASK COMPLETED BY OPERATOR (ENABLE

PERFORMANCE MANAGEMENT)


i. SHARING WITH UNIMAP, SIRIM, MITI AND MPC

ii. INTERNAL SHARING UNDER THE UMBRELLA OF INDUSTRIAL 4.0 SANMINA CORP

iii. 2ND RUNNER UP IN THE 2017 SANMINA PENANG TEAMING FOR EXCELLENT FINALS.

iv. GOLD MEDAL IN KONVENSYENTEAM EXCELLENCE WILAYAH UTARA 2017

NAMA KUMPULAN : MECHANICAL EYE


TAJUK PROJEK : TO IMPROVE PRODUCTIVE TIME AT TESEC MACHINE BY

REDUCTION OF SPEED LOSS FROM 5.84% TO 3%.

PENJIMATAN PROJEK : RM1,273,080


PLT LPL PRODUCTION LINE IN PLT SEGMENT IS ONE OF THE HIGH DEMAND PRODUCTION LINE

PRODUCING APPROXIMATELY ~16 MIO PIECES PER WEEK. UNFORTUNATELY INSTABILITY OF MACHINE

PERFORMANCE RESULTED LOW OUTPUT WHICH IS BELOW TARGET OF 6’615K PER WEEK. THIS IS DUE TO

HIGH SOCKET DISABLE AND NOT FULLY UTILIZED. TEAM WAS DECIDED TO PICKUP THE CHALLENGE TO

DRIVE THE IMPROVEMENT.


ACCORDING TO THE PARETO BREAKDOWN, SOCKET DISABLE FACTOR CONTRIBUTED 82.2% FROM

SPEED LOSS BY 4.8% OF LOSSES. UNSUITABLE CLEARENCE BETWEEN PACKAGE UNIT WITH HOLDER B PIN

SLOT HAS CAUSED BROKEN HOLDER B ARE FOUND WHILE DOING ANALYSIS STUDY.


USING 4R CONCEPT, THE TEAM INDENTIFIED CREATIVE SOLUTION REDESIGN HOLDER B BY ADOPT WIDER

ROAD AS A SUITABLE CLEARENCE BETWEEN PACKAGE UNIT AND HOLDER B PIN SLOT, THUS ELIMINATING

TEST SOCKET DISABLE. FINALLY WE MANAGED TO ACHIEVE BREAKTHROUGH RESULT 1.05%.

D. TANDA ARAS

WITH THE COMPONENT DESIGN MODIFICATION AT TEST SOCKET HOLDER B, TEST SOCKET UTILIZATION

SUSTAINED WITH ZERO LOSES AND ENABLE US TO GAIN MACHINE STABILITY. PRODUCTIVITY INCREASE

FROM 68.5% TO 73.3% AND SPEED LOSS REDUCED FROM 5.85% TO 1.85%. THUS, TEST PERFORMANCE

ABLE TO PRODUCE HIGHER OUTPUT INCREASE BY 5.6%. ALL THE EFFORTS ON CONTINUOUS

IMPROVEMENT DONE WAS ACKNOWLEDGE BY TOP MANAGEMENT AND RESULTED HIGHER COST

SAVINGS TO THE COMPANY.


i. SUCCESSFULLY ELIMINATED ALL THE ERROR DUE TO UNSUITABLE DESIGN OF TEST SOCKET HOLDER B.

ii. TEST SOCKET UTILIZATION SUSTAINED WITH ZERO LOSES.

iii. BREAKTHROUGH ACHIEVEMENT – SPEED LOSS REDUCED BY 4.8% FROM 5.85% TO 1.05%.

iv. BREAKTHROUGH ACHIEVEMENT – PRODUCTIVE TIME (PR) INCREASE BY 4.8% FROM 68.5% TO 73.3%.


i. GOLD AWARD GREEN SGA TEAM AT POWER LOGIC TEST SEGMENT CONVENTION 2017 AND 2ND

RUNNER-UP IN INFINEON MELAKA INTER-SEGMENT SGA CONVENTION 2017.

ii. GOLD AWARD IN ICC SOUTHERN REGIONAL

NAMA KUMPULAN : QUALITY GLADIATORS

ORGANISASI : SANMINA , BAYAN LEPAS PENANG

TAJUK PROJEK : VCT CYCLE TIME REDUCTION

PENJIMATAN PROJEK : RM137,056.00


AS A LEADING LEAN MANUFACTURING COMPANY IN OUR INDUSTRY, DOING A REDUNDANT

INSPECTION ACTIVITY IS A WASTE. WE HAVE TRANSFORMED THE CQA (CUSTOMER QUALITY

ASSURANCE) INSPECTION ACTIVITIES TO VIRTUAL CUSTOMER TEST (VCT) WHICH WILL SIMULATE THE

CUSTOMER APPLICATION AND ELIMINATE THE FINAL INSPECTION REPEATABILITY ACTIVITIES AND

REDUCTION OF QA INSPECTORS HEADCOUNT.

THE OBJECTIVE OF VCT ARE:

i. 1ST TO SURFACE OUT INFANT MORTALITY FAILURES DUE TO PIECE-PART VARIATIONS AND DESIGN

MARGIN

ii. 2ND TO ASSURE PRODUCT FUNCTIONALITY IN EXTREME OPERATING CONDITIONS AS CUSTOMER

VCT IS BEEN EXECUTED AS PROCESS, MATERIAL, DESIGN AND DEVELOPMENT VALIDATION TO ENSURE

PRODUCT MEETS CUSTOMER ESSENTIAL REQUIREMENTS

THE INCREMENTAL OF THE VCT SUBMISSIONS DAY BY DAY REQUIRED QUALITY OPERATION TO EMPHASIS

ON THE STANDARD HOUR STUDY FOR VCT CAPACITY COMMITMENT TO CUSTOMER.

DRC (DELIVERED RELIABILITY TEST) IS PART OF VCT DYNAMIC PROFILE. CURRENT DRC IS BEEN EXECUTED

IN EVERY NPI (NEW PRODUCT INTRODUCTION) STAGE STARTS FROM PROTO STAGE TILL PRODUCTION

RAMP.

EACH DRC PROFILE SHALL TAKE UP 26 HOURS TO COMPLETE ONE WHOLE CYCLE OF COMPREHENSIVE

DRC FOR QUANTITY OF 30 UNITS. WITH ADDITIONAL NEW REQUIREMENTS, THE CURRENT DRC PROFILE

REQUIRED TO BE REVISED AND SIMPLIFIED

THIS PROJECT WILL WALK THRU THE ANALYSIS OF EVERY STEP OF THE DRC PROCESS, REFINEMENT OF

INEFFICIENT STEPS AND REMOVAL OF STEPS UNNECESSARY TO THE PROCESS.


i. VCT IS A DYNAMIC PROFILE AND SAMPLING PLAN AS PER CUSTOMER REQUIREMENTS WHICH

INCLUDE COMPREHENSIVE DRC, QDRC (QUICK DRC), UI (USER INTERFACE), DROP TEST, FAI (FIRST

ARTICLE INSPECTION), OOB (OUT OF BOX).

ii. COMPREHENSIVE DRC CANNOT BE COMPLETED WITHIN THE COMMITTED DATELINE DUE TO DELAY

IN ELECTRICAL PARAMETRIC TESTING

iii. THIS PROJECT WILL IDENTIFY THE MAIN ROOT CAUSE OF THE ELECTRICAL PARAMETRIC TESTING

DELAY OF DRC PROFILE


i. TO HAVE A STANDARD CORRELATION TWO WAY RADIO (ALSO KNOWN AS GOLDEN RADIO USED

TO DESCRIBE THE PRECISION OF THE DEVICE TO STANDARD SPECIFICATIONS). THE GOLDEN RADIO

USED FOR COMPENSATE THE PATH LOSS DUE TO CABLE, ATTENUATOR, RF NUT AND OTHER

CONTRIBUTORS AT TEST STATIONS

ii. TRANSFORMATION OF TYPICAL VCT TEST STATION (CONFIGURATIONS OF 7 EQUIPMENTS AND

REQUIRED POWER SENSOR CALIBRATIONS). CHANGE TO ONLY ONE EQUIPMENT OF AEROFLEX IFR

3920 WHICH BE ABLE TO CATER ANALOG & DIGITAL RADIO TEST COVERAGE WHICH ELIMINATE

POWER SENSOR CALIBRATIONS

NAMA KUMPULAN : QUALITY GLADIATORS

ORGANISASI : SANMINA , BAYAN LEPAS PENANG

TAJUK PROJEK : VCT CYCLE TIME REDUCTION

PENJIMATAN PROJEK : RM137,056.00


i. TO HAVE A STANDARD CORRELATION TWO WAY RADIO (ALSO KNOWN AS GOLDEN RADIO USED

TO DESCRIBE THE PRECISION OF THE DEVICE TO STANDARD SPECIFICATIONS). THE GOLDEN RADIO

USED FOR COMPENSATE THE PATH LOSS DUE TO CABLE, ATTENUATOR, RF NUT AND OTHER

CONTRIBUTORS AT TEST STATIONS

ii. TRANSFORMATION OF TYPICAL VCT TEST STATION (CONFIGURATIONS OF 7 EQUIPMENTS AND

REQUIRED POWER SENSOR CALIBRATIONS). CHANGE TO ONLY ONE EQUIPMENT OF AEROFLEX IFR

3920 WHICH BE ABLE TO CATER ANALOG & DIGITAL RADIO TEST COVERAGE WHICH ELIMINATE

POWER SENSOR CALIBRATIONS

iii. ENHANCED VCT LABVIEW PROGRAM (LABORATORY VIRTUAL INSTRUMENT ENGINEERING

WORKBENCH (LABVIEW) IS A SYSTEM-DESIGN PLATFORM AND DEVELOPMENT ENVIRONMENT FOR

A VISUAL PROGRAMMING LANGUAGE FROM NATIONAL INSTRUMENTS. LABVIEW PROGRAM IS

BEEN CUSTOMIZED ONLY FOR VCT RF TEST PARAMETRIC MEASUREMENTS (SIMPLIFIED TEST

PARAMETERS FROM STANDARD TIA-603-E LAND MOBILE FM OR PM - COMMUNICATIONS

EQUIPMENT - MEASUREMENT AND PERFORMANCE STANDARDS). REFERENCE: PUBLISHED BY:

TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)

iv. LABVIEW AUTOMATIC PATHLOSS CORRELATION. (BACKGROUND OF THIS ALGORITHM: WHEN THE

POWER REFERENCE BEEN ENTERED IN THE LABVIEW PROGRAM AND MEASURE WITH CORRELATION

UNIT. THE LABVIEW WILL CAPTURED READING AND CONVERT TO DBM AND AUTO UPLOAD THE

DELTA IN THE PATHLOSS FILE. THIS PATHLOSS DELTA WILL AUTO COMPENSATE THE LOSSES OF THE

TEST STATION).

D. TANDAARAS / BENCHMARK

i. ADOPTED PRODUCTION CORRELATION RADIO

ii. BENCHMARK MSI PQRE (PRODUCT QUALITY RELIABILITY ENGINEERING) TEST LABVIEW SOFTWARE

PROGRAM

iii. BENCHMARK PRODUCTION TEST STATION IFR TEST STATION (AEROFLEX IFR 3920 ANALOG & DIGITAL

RADIO TEST EQUIPMENT)

E. PENCAPAIAN PROJEK & PENCIPTAAN NILAI / PROJECT ACHIEVEMENT & VALUE CREATION :

i. COST SAVINGS/AVOIDANCE OF RM137,056 PER ANNUM

ii. PENANG VCT LABVIEW WITH ENHANCED PROGRAM HAS BEEN CLONED TO REYNOSA SANMINA

iii. INNOVATION IDEA: IMPLEMENTED AUTO PATHLOSS CORRELATION

iv. DRC ATE CYCLE TIME REDUCTION 38%

v. INCREASED OF VCT PRODUCTIVITY BY 79%

vi. MEET SANMINA KPI FDQ (0 PPM IN JUL 2017) PPM=PARTS PER MILLION

F. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN / AWARD, REWARD & RECOGNITION :

i. 1ST RUNNER UP IN SANMINA TEAMING FOR EXCELLENCE IN 2016

ii. GOLD AWARD RECIPIENTS IN NORTH REGIONAL (LANGKAWI) MPC 2016

iii. GOLD AWARD RECIPIENTS IN NATIONAL (PUTRAJAYA) MPC 2016

iv. 1ST RUNNER UP IN SANMINA TEAMING FOR EXCELLENCE IN 2017

v. GOLD AWARD RECIPIENTS IN NORTH REGIONAL (BAYVIEW PENANG) MPC 2017

NAMA KUMPULAN :

ORGANISASI : MAJLIS PERBANDARAN KLANG

TAJUK PROJEK :

PENJIMATAN PROJEK : KOS PENTADBIRAN (RM / MASA SETAHUN : RM 74,570.88KOS OPERASI (RM/ TIMESAVING PERYEAR)


PERATUSAN KITAR SEMULA DI KLANG HANYA PADA KADAR 1% YANG MANA JAUH DARI PELAN

TINDAKAN SASARAN YANG DITETAPKAN OLEH KPKT IAITU 22% PADA TAHUN 2020. APA YANG MENJADI

MASALAH UTAMA BAGI PENDUDUK DI KLANG ADALAH KESEDARAN DALAM PELAKSANAAN PROGRAM

KITAR SEMULA. MAJLIS PERBANDARAN KLANG TELAH MENGORAK LANGKAH MAJU KE HADAPAN

UNTUK MENINGKATKAN KEMPEN KESEDARAN KITAR SEMULA DENGAN MEMBANGUNKAN SEBUAH

SISTEM KITAR SEMULA YANG MESRA PENGGUNA DAN MEMBERI MANFAAT KEPADA PENDUDUK YANG

TERLIBAT.

.


KESEDARAN PENDUDUK YANG RENDAH DI DALAM MELAKSANAKAN PROGRAM KITAR SEMULA.

JUMLAH SISA PEPEJAL YANG DIHASILKAN OLEH PENDUDUK YANG SEMAKIN MENINGKAT DAN

MEMERLUKAN LANGKAH SEGERA MELALUI AMALAN KITAR SEMULA SEBELUM SISA PEPEJAL TERSEBUT

DIKOMPOS, DITIMBUS ATAU DIHANTAR KE TAPAK PELUPUSAN SANITARI JERAM.


SISTEM DIGITAL ECOGEN RECYCLE MPKLANG SEBAGAI PEMUDAHCARA URUSAN REKOD DAN

DOKUMENTASI PENGURUSAN ALAM SEKITAR; DI MANA BERTINDAK SEBAGAI PENGKALAN DATA,

SUMBER RUJUKAN REKOD BARANGAN KITAR SEMULA OLEH PENDUDUK, PBT, KERAJAAN NEGERI DAN

KERAJAAN PERSEKUTUAN.

SELAIN ITU TURUT MEMBANTU PENDUDUK MEMBUAT PENANDAARASAN DENGAN PENDUDUK LAIN SERTA

MEWUJUDKAN PERSAINGAN DI DALAM PELAKSANAAN KITAR SEMULA BAGI MENDAPATKAN PAKEJ

INSENTIF YANG DISEDIAKAN OLEH MAJLIS PERBANDARAN KLANG.

D. TANDA ARAS

SISTEM ECOGEN RECYCLE MPKLANG AKAN MENJADI PENANDAARASAN KEPADA PIHAK BERKUASA

TEMPATAN DAN PENDUDUK DALAM MEWUJUDKAN KESEDARAN DAN PERSAINGAN PROGRAM 5R

(REDUCE, RECYCLE, REPAIR, REFUSE, REUSE) SELARAS DENGAN PELAN STRATEGIK MAJLIS

PERBANDARAN KLANG 2016-2020 (TERAS STRATEGIK 4), PELAN TINDAKAN TEKNOLOGI HIJAU

SELANGOR 2016-2018 (PENGURANGAN KOS PELUPUSAN) DAN PELAN STRATEGIK KEMENTERIAN

KESEJAHTERAAN BANDAR, PERUMAHAN DAN KERAJAAN TEMPATAN 2016-2020 (KRA 8).


DATA PENCAPAIAN PROGRAM KITAR SEMULA DI BANDAR BUKIT RAJA, KLANG

NAMA KUMPULAN :

ORGANISASI : MAJLIS PERBANDARAN KLANG

TAJUK PROJEK :

PENJIMATAN PROJEK : KOS PENTADBIRAN (RM / MASA SETAHUN : RM 74,570.88KOS OPERASI (RM/ TIMESAVING PERYEAR)


KEMENTERIAN KESEJAHTERAAN BANDAR, PERUMAHAN DAN KERAJAAN TEMPATAN (KPKT)

MAJLIS TELAH MENDAPAT PERTAULIAHAN SEBAGAI BANDAR MAMPAN OLEH KPKT MELALUI PROGRAM

MURNINETS PADA TAHUN 2015 DAN 2016. MAJLIS LAYAK MENERIMA PERTAULIAHAN INI SETELAH

MELEPASI MARKAH 80% SEPERTI YANG DISYARATKAN DALAM KRITERIA BANDAR MAMPAN.

MINI KONVENSYEN KUMPULAN INOVATIF DAN KREATIF, MAJLIS PERBANDARAN KLANG, 2017 PADA 25

MEI 2017

JOHAN (KATEGORI INOVASI SOSIAL)

KONVENSYEN TEAM EXCELLENCE/QE WILAYAH SELATAN 2017 PADA 1-2 OGOS 2017

ANUGERAH EMAS

MAJLIS PERSADA INOVASI PERKHIDMATAN AWAM PERINGKAT NEGERI SELANGOR, 2017 PADA 19-20 SEPT.

2017

JOHAN (KATEGORI INOVASI SOSIAL - PENAMBAHBAIKAN)

ANUGERAH INOVASI NEGERI SELANGOR 2017 PADA 9-12 OKTOBER 2017

GREEN APPLE AWARD 2017 PADA 6 NOVEMBER 2017 DI PARLIAMENT OF HOUSE, LONDON.

GREEN WORLD AWARD 2017 PADA DISEMBER 2017 DI ENGLAND.

NAMA KUMPULAN : ULTRA SENSORS

ORGANISASI : INFINEON TECHNOLOGIES (MALAYSIA) SDN BHD.

MELAKA

TAJUK PROJEK : CHIP KERKO & MISSING PROTRUSION IMPROVEMENT FOR

PSSO 2-53 BY NEW SINGULATION TOOL DESIGN.

PENJIMATAN PROJEK : RM 97.5K / MONTH

RM / MASA SETAHUN :RM 1.17 MILLION TIMESAVING PERYEAR


PGSSO 2-53 IS ONE OF INFINEON MELAKA SENSORS BEST-SELLING PACKAGES. WITH THE RAPID

INCREASE OF DEMAND FOR THE PACKAGE, A STEEP RAMP UP WAS NEEDED TO SECURE MARKET

POSITION. TEAM WAS FACING BIG CHALLENGE TO ENSURE DELIVERY ON TIME YET HIGH PRODUCT

QUALITY MUST BE GUARANTEED. TEAM HAD INTRODUCED A NEW INNOVATION IN PACKAGE

SINGULATION FROM LEADFRAME IN RESOLVING TWO MOST PAIN-POINT DEFECTS IN SENS

MANUFACTURING LINE, I.E. CHIP KERKO (CAPACITOR) AND MISSING PROTRUSION.THIS PROBLEM

CAUSED PRODUCTION TEST YIELD LOSS, HIGH REJECTION, HIGH MAN POWER AND POTENTIAL

CUSTOMER COMPLAINT.


i. SINGULATION PUNCHING TOOL WAS NOT OPTIMIZED WHEREBY THE SINGULATION DIE DID NOT

SUPPORT UNITS PROPERLY. THIS CAUSED CHIP KERKO FAILURE WHEN PUNCHING TOOL SINGULATED

THE UNITS.

ii. SINGULATION MECHANISM USING CONVENTIONAL METHOD WHICH CAUSED INCOMPLETE

SEPARATION BETWEEN LEAD FRAME AND COMPOUND.


SIMULATION SOFTWARE WAS USED TO PERFORM STRESS ANALYSIS TO PACKAGE DURING DOE TO

DEFINE THE OPTIMUM STRESS LEVEL IN MORE PRECISE AND SYSTEMATIC WAY.THIS ENABLED INNOVATIVE

AND CREATIVE SOLUTIONS IN 2 ASPECTS:

i. IMPROVEMENT IN SINGULATION BOTTOM DIE WIDTH TO OPTIMIZE SINGULATION PROCESS AND

SUPPORT UNITS EFFECTIVELY.

ii. INTRODUCTION OF PRE-BREAK SINGULATION METHOD WHICH TO IMPROVE SEPARATION BETWEEN

LEADFRAME AND COMPOUND

D. TANDA ARAS

SMART CONCEPT WAS USED TO BENCHMARK THE PROJECT

S: SPECIFIC - TO IMPROVE CHIP KERKO AND MISSING PROTRUSION AT LASER AND SINGULATION

PROCESS

M: MEASURABLE

A: ATTRACTIVE - BREAKTHROUGH IDEA OF NEW SINGULATION APPROACH IN SEMICONDUCTOR

INDUSTRIES.

FIRST PROJECT AT OPERATIONS TO USE COMPUTER SIMULATION TO STUDY THE BEHAVIOUR OF

PACKAGE.

R: REALISTIC - RISK ASSESSMENT WAS DONE AND RECORDED IN FMEA TO PREVENT ANY “SURPRISE”

EVENT..

T: TIMELY - TO COMPLETE THE PROJECT IN SEPT’16.

NAMA KUMPULAN : ULTRA SENSORS

ORGANISASI : INFINEON TECHNOLOGIES (MALAYSIA) SDN BHD.

MELAKA

TAJUK PROJEK : CHIP KERKO & MISSING PROTRUSION IMPROVEMENT FOR

PSSO 2-53 BY NEW SINGULATION TOOL DESIGN.

PENJIMATAN PROJEK : RM 97.5K / MONTH

RM / MASA SETAHUN :RM 1.17 MILLION TIMESAVING PERYEAR

E. . PENCAPAIAN PROJEK & PENCIPTAAN NILAI


1) TEAM OF THE QUARTER”, TOQ – ACHIEVEMENT: GOLD AWARD FOR INFINEON.

TOQ IS AN AWARD THAT HONORS TEAMS AND SMALL GROUPS WHO HAVE SET PRIORITIES AND HAVE

ACHIEVED OUTSTANDING RESULTS IN PROJECTS WITH FOCUS ON:

•CONTINUOUS IMPROVEMENT

•INNOVATION IMPROVEMENT BY NEW APPROACHES

•CUSTOMER FOCUS AND PROFITABLE GROWTH

2) YOUR IDEA PAYS, YIP – REWARD: RM12,000

YIP IS A TOOL TO COLLECT IDEAS, PROPOSALS AND THOUGHTS, TO DOCUMENT THEM AND TO FOSTER THEIR

EVALUATION. EVERYONE CAN CONTRIBUTE TO THE COMPANY THROUGH THIS TOOL AND HELP INFINEON

TECHNOLOGIES TO GET BETTER EVERY DAY WITH SMALL IMPROVEMENTS UP TO MOST SUFFICIENT IDEAS.

3) MAL TECHNICAL AND INNOVATION SYMPOSIUM” , MTIS – REWARD: RM300

MTIS IS A PLATFORM FOR YOU TO SHOWCASE AND SHARE NEW FINDINGS AND DISCOVERIES THAT HAVE

BEEN ACCOMPLISHED THROUGHOUT THE YEAR. EACH TOPIC THAT WAS SENT FOR MTIS HAVE TO GO

THROUGH A SCREENING SELECTION BY THE COMMITTEE AND ONLY THE SELECTED TOPICS WILL BE ALLOWED

TO PRESENT AT THE MTIS

4) BEST COLLABORATION POSTER AWARD IN 36TH INTERNATIONAL ELECTRONIC MANUFACTURING

TECHNOLOGY(IEMT) CONFERENCE WITH MMU UNIVERSITY.PROJECT ARTICLE UPLOADED IN IEEE WEBPAGE

5) CHAMPION IN INFINEON MELAKA SGA COMPETITION (SMALL GROUP ACTIVITY) 2017-REWARD:

RM1000 + TROPHY

6) GOLD AWARD IN MPC TEAM EXCELLENCE SOUTHERN REGION 2017

7) PROJECT SHARING WITH OTHER GLC COMPANY MALAYSIA AIRPORT BERHAD IN INFINEON MELAKA

SEPT’2017

NAMA KUMPULAN : APX TROOPERS

ORGANISASI : SANMINA (MALAYSIA) SDN BHD

TAJUK PROJEK : APX8500 MOBILE QUALITY IMPROVEMENT

PENJIMATAN PROJEK : 4 MONTHS

RM 1,715,582 (COST AVOIDANCE)

RM 114,057 (LABOR SAVING)

RM -10323 (IMPLEMENTATION COST)

RM 1,819,316 (TOTAL SAVING)

RM / MASA SETAHUN : RM 5,457,946


APX8500 MOBILE RADIO IS THE MOST EXPENSIVE AND HIGH DEMAND PRODUCT BUILD IN THE FACTORY.

HOWEVER, DURING THE RAMP BUILD OF APX8500 MOBILE SINCE JAN 2017, THERE ARE FEW ISSUES

OCCURRED AND ONE THE MAJOR ISSUE WAS POWER AMPLIFIER (PA) DAMAGED/BURNT WHICH LEAD

TO PRODUCTION STOP BUILD. BUILT RADIO HAS BEEN RETURNED TO THE FACTORY FOR REWORKING.

IN ORDER TO SUSTAIN PROFITABLE REVENUE AND HIGHEST QUALITY PRODUCT, THE TEAM NEEDS TO

DRIVE THE INVESTIGATION AND IDENTIFY THE ROOT CAUSE OF THE ISSUE. ALSO, TO FURTHER IMPROVE

THE YIELD PERFORMANCE FOR APX8500 MOBILE RADIO.


THE ROOT CAUSE OF POWER AMPLIFIER (PA) DAMAGED/BURNT WAS DUE TO MISSING RADIO

FREQUENCY (RF) BULLET BOARD TO BOARD CONNECTOR DURING RADIO ASSEMBLY.


BASED ON ISHIKAWA DIAGRAM AND CAUSE SCREENING ANALYSIS, THE TEAM HAD IDENTIFIED FEW

POSSIBLE POTENTIAL CAUSES WHICH COULD LEAD TO PA DAMAGED/BURNT. THE TEAM HAD

IMPLEMENTED A RF BULLET GAUGE WHICH HAS LEAD TO AN INNOVATION OF THE TRANSMITTER AUTO

ASSEMBLY FIXTURE AND FINALLY BEEN UPGRADED WITH A LASER SENSOR AS THE IMPROVEMENT.

D. TANDA ARAS

i. WE HAVE BENCHMARKED NXP SEMICONDUCTOR.

ii. WE ALSO BENCHMARKED HEWLETT-PACKARD


i. ELIMINATE PA BURNT/DAMAGE DEFECT

ii. OUTPUT IMPROVEMENT FROM 280 TO 330 UNITS/DAY

iii. IMPROVE PRODUCT ON TIME DELIVERY FROM 85% TO 100%

iv. IMPROVE YIELD BY 23.4%

v. PRODUCTIVITY IMPROVEMENT BY 17.8%

vi. IMPROVE POTENTIAL CUSTOMER RETURN FROM YELLOW ZONE TO GREEN ZONE


i. SANMINA-SCI SEMI FINAL PRESENTATION TOP 15 (JUNE, 2017)

ii. SANMINA-SCI FINAL PRESENTATION TOP 5 (JULY, 2017)iii. MPC REGIONAL, EMAS (AUG, 2017)

HARIKETIGA

NAMA KUMPULAN : OZONE

ORGANISASI : FINISAR (M) SDN BHD

TAJUK PROJEK : PROMOTE ENVIRONMENT MANAGEMENT PROGRAM (EMP)

THROUGH REDUCTION OF INDIRECT MATERIALS

PENJIMATAN PROJEK : RM / MASA SETAHUN : RM188 019.00


FINISAR (M) SDN BHD IS AN ISO 14001 COMPLIANT COMPANY. MAIN STORE IS A PLACE WHERE WE

HAVE MANY MATERIAL USED FOR PACKAGING AND STORING MATERIALS. TEAM OZONE HAD LOOKED

AT THIS AREA FOR ANY ENVIRONMENTAL IMPROVEMENT. SO, OZONE TEAM WAS FORMED TO

SPEARHEAD THE COST REDUCTION, WASTE ELIMINATION AND ENVIRONMENT FRIENDLY EFFORTS.

HAVING THE CORE ENVIRONMENT IN MIND THE TEAM HAD IDENTIFIED SEVERAL MEASURES TO HAVE

KAIZEN ACTIVITIES IN MAIN STORE.

REDUCING PRINTER RIBBON AND CELLOPHANE TAPE IS TWO OF THE ACTION BASED ON PARETO

ANALYSIS. THE TEAM HAD BRAINSTORM, USED LEAN METHODOLOGY AND VARIOUS QCC TOOLS TO

COME UP WITH WIN WIN SOLUTION FOR THE COMPANY.







THE ROOT CAUSE OF POWER AMPLIFIER (PA) DAMAGED/BURNT WAS DUE TO MISSING RADIO

FREQUENCY (RF) BULLET BOARD TO BOARD CONNECTOR DURING RADIO ASSEMBLY.







USING THE LEAN APPROACH LIKE PROCESS AT A GLANCE, WORK STANDARDIZATION, FISH BONE, WHY-

WHY, 5S AND PERIODIC MONITORING, WE HAD COME UP WITH A FEW ACTION.






D. TANDA ARAS








OZONE FINISAR WAS CROWNED AS CHAMPION UNDER PRIVATE SECTOR IN APIC 2016 AT PICC.

NAMA KUMPULAN : FANTASTIC 5


TAJUK PROJEK : PRODUCTIVITY ENHANCEMENT BY REDUCING/ELIMINATING

COSMETIC DEFECT IN FLAG SHIP PRODUCT TO MAXIMIZE PROFIT MARGIN

GAIN TO THE COMPANY



FINISAR (M) SDN BHD HAD MANY TECHNOLOGICALLY ADVANCED AND BREAKTHROUGH PRODUCTS

FOR PHOTONICS INDUSTRY. AS A LEADER IN THE INDUSTRY THAT IS FULL OF COMPETITION, OUR

COMPANY STRIVES TO SERVE THE MAXIMUM QUANTITY OF MODULE TO MARKET BASED ON EVER

GROWING CUSTOMER NEEDS. OUR COMPANY’S NEWEST ENTRY INTO 100GIGABYTES MARKET’S

PRODUCT IS VERY MUCH SOUGHT AFTER PRODUCTS BY LEADING CORPORATION LIKE MICROSOFT,

APPLE, CISCO AND GOOGLE.

AS COMPETITION GROWS, SURVIVAL OF THE FITTEST APPLIES, AND PER YEARLY COMMITMENT TO

INCREASE VALUE TO CUSTOMER, FINISAR ALSO NEEDED TO REDUCE THE SELLING PRICE AND INCREASE

THE QUALITY OF PRODUCTS CONTINUOUSLY. THIS EVENTUALLY WILL ERODE OUR PROFIT MARGIN. IN

ORDER TO CONTINUOUSLY STAY ABOVE THE REST OF THE COMPETITIONS, WE NEED TO MAINTAIN THE

CURRENT MARGIN BY LOWERING COST OR INCREASE THE VOLUME. THIS CAN BE DONE BY IMPROVING

OUR PRODUCTS YIELD AND REDUCE MATERIAL SCRAP.

THE TEAM HAD LOOKED AT VARIOUS WAYS AND MEANS TO TAKE THIS CHALLENGE AND FOUND OUT TO

REDUCE OR ELIMINATE COSMETIC DEFECTS IS LOW COST OR NO COST SOLUTION. THE COSMETIC

DEFECTS CONTRIBUTE 8% OF THE PRODUCE.





GAIN TO THE COMPANY



100GIGABYTES GOES TO VARIOUS PROCESSES FROM ASSEMBLY TILL TESTING AND LABELLING. THE

FANTASTIC 5 TEAM HAD DONE PROCESS MAPPING, BRAIN STORMING, GENCHI GENBUTSU (GO & SEE)

AND CAUSE SCREENING METHOD TO FIND POSSIBLE ROOT CAUSES. ONE OF THE MAIN CONTRIBUTORS

FOR THE FAILURE IS SCRATCHES ON THE SURFACE OF MODULE WHILE TESTING IN TEMPBOX.





GAIN TO THE COMPANY



AFTER MUCH DELIBERATIONS AND DISCUSSION WITH MANAGEMENT AND OPERATION LEVEL

PERSONNEL, FANTASTIC 5 DECIDED TO MODIFY THE CURRENT TEMP BOX TO ALLEVIATE THE

SCRATCHING OF MODULE SURFACE. MANY FOLLOW THROUGH BRAINSTORMING ACTION HAD TAKEN

PLACE TO FIND AND EVALUATE THE BEST DESIGN.





GAIN TO THE COMPANY


D. TANDA ARAS

1. COSMETIC DEFECTS REDUCTION IN 100GIGABYTES



i. FANTASTIC 5 EMERGED WINNER IN QUARTERLY INTERNAL LEAN TEAM COMPETITION.

ii. THE TEAM ALSO WON GOLD AWARD IN MINI CONVENTION IN PENANG 2017.

iii. THE TEAM TOOK GOLD AWARD IN REGIONAL AT BATU FERRINGHI PENANG

8.01

4.00% 1.14%

0.00%

5.00%

10.00%

WW18-22 WW23-27 WW28-32

Average cosmetic defects

Average cosmetic defects

NAMA KUMPULAN : RENAISSANCE


TAJUK PROJEK : MAXIMIZING PROFIT MARGIN OF PRODUCTS BY REDUCING

SCRAP TO GAIN MORE IMPACT FOR THE COMPANY



FINISAR IS COMMITTED TO QUALITY AND REACT POSITIVELY TO ANY INITIATIVE TO INCREASE THE

QUALITY LEVEL. AS AN INNOVATIVE AND OWNER OF MANY BREAKTHROUGH PRODUCT AND

TECHNOLOGY, WE EXPLORE MANY WAYS TO INCREASE OUR PRODUCT’S RELIABILITY. THIS IS INCLUDING

MAKING DESIGN CHANGE AND IMPROVEMENT.

THE TEAM HAD LOOKED AT HIGH VOLUME PRODUCTS TO EMBARK ON THIS MEASURE SO THAT THE

IMPACT WILL BE HIGH. THE TEAM HAD IDENTIFIED 14 GIGABYTES LONG WAVE ROSA (RECEIVER OPTICAL

SUB ASSEMBLY) WHICH HAS 200K VOLUME PER QUARTER.


IN THE PRODUCT 14GIGABYTES LONG WAVE ROSA WE HAD IDENTIFIED ONE TYPE OF FAILURE THAT

CONTRIBUTED TO YIELD LOSS AND HIGH SCRAP.

THIS PHENOMENON MAY DUE TO THE DESIGN OF THE HOUSING OF THIS PARTICULAR ROSA. THE TEAM

HAD LINED UP A FEW MEASURE TO VERIFY THIS AND COME UP WITH COUNTER MEASURES


6.154%

0.022% 0.016% 0.010% 0.008% 0.005% 0.005% 0.001%0.000%

1.000%

2.000%

3.000%

4.000%

5.000%

6.000%

7.000%

0100020003000400050006000700080009000

10000

14G LW ROSA - Q3'16_Defect Pareto

NAMA KUMPULAN : RENAISSANCE


TAJUK PROJEK : MAXIMIZING PROFIT MARGIN OF PRODUCTS BY REDUCING

SCRAP TO GAIN MORE IMPACT FOR THE COMPANY


D. TANDA ARAS



i. RENAISSANCE WAS CROWNED AS CHAMPION IN OUR INTERNAL LEAN TEAM COMPETITION

ii. THE TEAM WAS THE 7TH PLACING WINNER IN APIC 2016 HELD IN PICC.

NAMA KUMPULAN : KAIZEN


TAJUK PROJEK : PRODUCTIVITY ENHANCEMENT BY INCREASING PROCESS

YIELD FOR OUR HIGH VALUE 6 PIN PRODUCT.



FINISAR (M) SDN BHD HAD MAINTAINED A GOOD QUALITY, DELIVERY AND COST STRUCTURE TO BETTER

SUPPORT EVERYONE IN INDUSTRY AND COMMUNITY AT LARGE. BY DOING THIS OUR COMPANY

NEEDED TO MAKE SURE THE PRODUCTION COST DO NOT GO HIGHER THAN TARGETED LEVEL. AS PER

OUR KPI, KAIZEN TEAM NEEDED TO FIND OUT WAYS AND MEANS TO CONTAIN THE COST INCREASE.

AS PER YEARLY COMMITMENT TO INCREASE VALUE TO CUSTOMER, FINISAR NEEDED TO REDUCE THE

SELLING PRICE AND INCREASE THE QUALITY OF PRODUCTS CONTINUOUSLY. THIS EVENTUALLY WILL

ERODE OUR PROFIT MARGIN, THEREFORE WE NEED TO MAINTAIN THE CURRENT MARGIN OR INCREASE

THE VOLUME BY IMPROVING OUR YIELD AND REDUCE MATERIAL SCRAP.

THE TEAM HAD LOOKED INTO PRODUCT FAMILY OF 6PINS WHICH HAS THE HIGHEST YIELD LOSS

COMPARED TO MANY OTHER PRODUCTS. THE HIGHEST CONTRIBUTION COMES FROM

CONTAMINATION.







6PIN PRODUCT FAMILY GOES TO VARIOUS PROCESSES FROM ASSEMBLY TILL TESTING AND LABELLING. THE

KAIZEN TEAM HAD DONE PROCESS MAPPING, BRAIN STORMING, GENCHI GENBUTSU AND CAUSE

SCREENING METHOD TO FIND POSSIBLE ROOT CAUSES. ONE OF THE MAIN IMPACTS FOR THE

CONTAMINATION FAILURE IS OPTICAL PATH NOT REFLECTED ACCORDING TO SPECIFICATIONS.







THIS TEAM HAD EVALUATED MANY ACTIONS PUT FORWARD BY MEMBERS. THIS INCLUDES USING ALL THE

TOOLS PROVIDED BY LEAN MANAGEMENT.






D. TANDA ARAS

Yield tracking in our shopfloor execution systems








MUNCUL SEBAGAI ANTARA 10 PASUKAN TERBAIK SEKTOR SWASTA DALAM APIC 2016

NAMA KUMPULAN : BRAINSTORMER


TAJUK PROJEK : WORK STANDARDIZATION IN FINISHED GOODS BY

INCORPORATE TRAY LABEL INTO SHOPFLOOR EXECUTION SYSTEMS.PENJIMATAN PROJEK : RM / MASA SETAHUN : RM 72 432


FINISAR’S CUSTOMERS ARE VARIED AND ANY REQUIREMENT BY CUSTOMER IS OUR UTMOST PRIORITY.

WE IN FINISHED GOODS STORE OFTEN REQUIRED TO REPACK INTO CUSTOMIZED PACKAGING. THE

PRODUCT PART NUMBER REPRESENTS A DIFFERENT PRODUCT TYPE. IT IS NEEDED TO BE CHANGED BASED

ON CUSTOMER. IN ORDER TO DO THIS EACH PACKAGING STYLE DIFFERS BY TRAY, UNITS IN A PACKAGE,

INSTRUCTION AND SIZES. TO IDENTIFY EACH, WE GENERATE PART NUMBERS. BUT THE LIST OF PART

NUMBERS HAD GROWN TOO LONG. MANAGING PART NUMBERS BECOME ANOTHER HEADACHE AS

THE PRODUCTS BECOME MORE VARIED.

TO EASE OUR OPERATION, WE INCORPORATE THIS FEATURE INTO EXISTING SHOP FLOOR EXECUTION

SYSTEMS TO. EARLIER SYSTEM WAS EASY TO USE BUT EVENTUALLY IT BECOME COMPLEX WITH MORE AND

MORE CUSTOMER REQUEST CAME IN. THE FINISHED GOODS DEPT. FORMED “BRAINSTORMER” TO

1) ELIMINATE ANY UNNEEDED STEPS,

2) COMBINE WHERE NEEDED BASED ON FEASIBILITY OF OPERATOR’S MOVEMENT

3) REARRANGE LOGISTICS OR MOVEMENT ERGONOMICALLY

4) AND, SIMPLIFY THE WHOLE PROCEDURE OR METHOD OF RETRIEVAL, STORAGE AND DISPLAY


THE WHOLE OPERATION OF DOING CUSTOMIZED PACKAGING INVOLVES

i. A LOT OF MOVEMENT,

ii. TRANSACTIONS IN SYSTEMS AND MANUAL,

iii. HARDCOPIES OF CUSTOMER ORDER FORMS,

iv. INVOLVES TOO MANY HANDLING BETWEEN FG STORES OPERATORS AND SHIPPING PERSONNEL

v. CONSUME TOO MUCH TIME IN PROCESSING.

THIS HAD CREATED A DELAY IN EXECUTING AN ORDER FROM CUSTOMER


USING THE LEAN APPROACH LIKE PROCESS AT A GLANCE, WORK STANDARDIZATION, FISH BONE, WHY-

WHY, 5S AND WITH PERIODIC MONITORING, WE HAD STREAMLINED THE OPERATION.

NAMA KUMPULAN : BRAINSTORMER


TAJUK PROJEK : WORK STANDARDIZATION IN FINISHED GOODS BY

INCORPORATE TRAY LABEL INTO SHOPFLOOR EXECUTION SYSTEMS.PENJIMATAN PROJEK : RM / MASA SETAHUN : RM 72 432

D. TANDAARAS / BENCHMARK

i. NUMBER OF JOB HANDLED BY THE DEPT IN A WEEK.

E. PENCAPAIAN PROJEK & PENCIPTAAN NILAI / PROJECT ACHIEVEMENT & VALUE CREATION :

i. THE OPERATOR’S WORK WAS EASED UP BY THE REDUCTION OF STEPS – 70%

ii. OPERATION COST REDUCED BY RM72K PER YEAR

iii. OPERATORS WERE RETRAINED AND REASSIGNED TO SHIPPING DEPT. FOR 5 HOURS PER DAY.

F. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN / AWARD, REWARD & RECOGNITION :

i. BRAINSTORMERS WAS CROWNED AS CHAMPION IN OUR INTERNAL LEAN TEAM COMPETITION

ii. WE WAS ALSO TOOK GOLD IN MINI CONVENTION IN PERAI 2017.

NAMA KUMPULAN : LEKIR


TAJUK PROJEK : TSXP BROKEN ARRAY YIELD LOSSES IMPROVEMENT

PENJIMATAN PROJEK : RM / MASA SETAHUN : RM 1JUTA


YIELD IS ONE OF THE LEADING KPI METRIC IN ORDER TO MEASURE PRODUCT’S QUALITY. THE TEAM

REALIZED THAT TSXP PLATING YIELD IS NOT ABLE TO ACHIEVE YIELD TARGET OF 99.95% WITH TOTAL OF

0.33% LOSSES WHICH ARE MAINLY CONTRIBUTED BY 0.29% OF BROKEN ARRAY REJECTS.


THERE ARE SEVERAL ROOT CAUSES TO THE PROBLEM BASED ON 4M ANALYSIS SUCH AS MISSED

HANDLING(MAN), RINSING NOZZLES (MACHINE), BLOWER (MACHINE), STATIONARY ARM (METHOD),

GOLD POST PIPING (METHOD), IMMERSION CARRIER HANGER (MATERIAL) AND IMMERSION CARRIER

(MATERIAL). ALL OF THE POSSIBLE ROOT CAUSES NEED TO BE VERIFIED BY ANALYSIS IIN ORDER TO

TACKLE THE TRUE ROOT CAUSES WITH BIG IMPROVEMENT IMPACT TO THE OBJECTIVE.


THROUGH ANALYSIS ON THE POSSIBLE ROOT CAUSES, ACTIONS HAVE BEEN TAKEN ON THE TRUE ROOT

CAUSES (BLOWER, GOLD POST BOTTOM PIPING AND IMMERSION CARRIER) THAT CAUSING THE

REJECTS. YIELD AND REJECTS CASES HAVE BEEN SIGNIFICANTLY REDUCED BUT STILL INSUFFICIENT BASED

ON THE YIELD AND REJECT CASES TARGET SETTING. THEREFORE, FURTHER INNOVATIVE SOLUTION

(ETCHING TRAY) HAS BEEN CARRIED OUT IN ORDER TO MEET THE TARGET SETTINGS

D. TANDA ARAS

YIELD (99.95%)

BROKEN ARRAY CASES (1 LOT / WEEK)


YIELD (99.95%) AND BROKEN ARRAY CASES (1 LOT/WEEK) TARGET HAVE BEEN ACHIEVED.

COST SAVINGS OF RM 1 MILLION AFTER PROJECT COMPLETION (APPROVED BY FINANCE)


i. YIP AWARD (RM 3K)

ii. GOLD AWARD IN INFINEON MAL SGA COMPETITION

iii. GOLD AWARD IN MPC SOUTHERN REGION TEAM EXCELLANCE CONVENTION

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