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ECU
Kaizen Consulting
bringing
you a profit
Cost reduction and quality improvements
Design and manufacturing approach
MarkLines
is pleased to introduce its Kaizen Consulting Service and its Design
& Manufacturing Engineering Service for Automotive Electronic
Systems, Devices, Components and ECU (Electronic Control Unit) Production.
MarkLines' over-20-years experienced consultants, who were all managers
and engineers at Japanese automotive and/or electronic manufacturers,
can assist you to improve the QCD (Quality, Cost and Delivery) at
your production sites.
Our unique consulting service will result in increasing your business
profits in the Automotive Electronics Sector.
For further details on MarkLines Consulting
Service,
please send an inquiry email.
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(CONTENT)
1.FEATURES OF MARKLINES' CONSULTING SERVICE
2.TRACK RECORDS
3.KAIZEN DIRECTIONS FOR AUTOMOTIVE ELECTRONICS PRODUCTION
4.WHAT CAN GO WRONG IN QCD IMPROVEMENT
5.STEPS FOR QCD IMPROVEMENT
6.SHORTCUTS FOR ERADICATING DEFECTS
7.DETERMINANT FACTORS FOR QUALITY IMPROVEMENT
8.A CASE OF FAULT ANALYSIS TO ENGINE ECU
9.CONSULTING SCENES FOR AN ECU MANUFACTURER
10.AN EXAMPLE OF IMPLEMENTATION PLAN
11.EXAMPLES OF THE DELIVERABLES
INQUIRY
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FEATURES
OF MARLINES' CONSULTING SERVICE
DOMAIN:
Overall Development and Manufacturing processes for Automotive Electronic
Systems, Devices, Components and ECU (Electronic Control Unit) Production.
CONCEPT: Overall Diagnosis from
both the business and technology side, then providing effective instructions
and advice to achieve actual improvements and benefits.
IMPLEMENTATION: Offering consulting
based on the "3 Gen-ism" (Genba [on site], Genbutsu [in
kind], and Genjitsu [in fact]).
TRACK
RECORDS
|
Client
|
Description
|
Electronic
Equipment Supplier
("A" company listed on the TSE)
|
Instructions
of Upgrading the ECU related standards, creating the map to select
ECU subcontract makers, and implementing the measures against
problem correction etc. |
Electronic
Equipment Supplier
("B" company listed on the TSE)
|
Instructions
of Making the procurement procedure to the Chinese ECU component
makers, and of Drawing up the purchase specifications and Quality
Control manuals etc. |
Board
Supplier
("C" company )
|
Technical
support to Sales and Engineering sectors. Instructions of Publishing
in academic journals, and of Applying for patents etc. |
Board
Supplier in China
("D" company )
|
Instructions
of Improving the yield of large-sized board and the plating thickness
variation in outer layer etc. |
Material
Manufacturer
("E" company listed on the TSE)
|
Instructions
of Developing prototypes of the device embedded board, and of
Making the development plans etc. |
Board
Manufacturing Subcontract Maker ("F" company )
|
Instructions
of Introducing the production control system etc. |
Auto
Manufacturer
("G" company listed on the TSE)
|
Survey
of the Electronic Platform-based Development Process, and Technical
support to explore improvements in the Process etc. |
Auto
Manufacturer
("G" company listed on the TSE)
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Survey
of the Digital Design and Engineering System for Mass-production,
and Technical support to develop the Vehicle Specification System
etc. |
Electronic
Equipment Supplier
("H" company listed on the TSE)
|
Instructions
of Reforming the Electronic Design Process, and of Implementing
the Circuit Design CAD, Board Design CAD and PDM systems etc. |
Semiconductor
Makers
("J"& "K" company listed on the TSE)
|
Technical
support to implement the Digital Development Collaboration System
covering all design, analysis, examination, and inspection processes
etc. |
Electric
Component Supplier
("L" company listed on the TSE)
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Technical
support to implement the Circuit Design CAD, Board Design CAD
and PDM systems for the Automatic Transmission Control ECU etc. |
Measuring
Instrument Maker
("M" company listed on the TSE)
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Instructions
of Developing the base software for measuring instruments (Gold
medal of the president software prize). |
Electric
Component Supplier
("N" company listed on the TSE)
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Instructions
of the Software Development Process Improvement based on CMMI
Model etc. |
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KAIZEN
DIRECTIONS FOR AUTOMOTIVE ELECTRONICS PRODUCTION
1. Eliminating
Defects in the Devices (Semiconductors, Electronic Parts, Boards and
Sensors etc.)
- Much of the total volume of electronic devices is not self-manufactured
but purchased.
- QCD Improvement comes from the engineering ability of Tier 1 manufacturers.
- Kaizen in the Circuit Design greatly increases the level of QCD
improvement.
2. Eliminating
Defects in the Device Solder-Mounting on the PCBs (Printed Circuit
Boards)
- These are the most serious problems in the ECU manufacturing process.
- QCD Improvement comes from improving operators' soldering and mounting
skills.
3. Eliminating
Defects in the PWBs (Printed Wiring Boards)
- Much of the total volume of printed wiring boards are purchased.
- QCD Improvement comes from the manufacturing ability of Tier 2 manufacturers.
- Kaizen in the Board Design greatly increases the level of QCD improvement.
WHAT
CAN GO WRONG IN QCD IMPROVEMENT
STEPS
FOR QCD IMPROVEMENT
[Quality Statement]
Quality is created in the manufacturing process. If the causes leading
to defects are eliminated beforehand, the burden to eliminate defects
are not passed on during the respective processes.
[Procedure]
| Education
& Training |
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1
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Check
the on-site data. Analyze the emerging pattern. Understand why
defects come out. [Literature Review]
- Experiment Design & Data Survey. (Refer to Fig.1. as below)
- Practical Use of Test Boards. |
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2
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Visualization
of Defects.
- Practical Use of your Digital Camera. |
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3
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Microscopic
Observation of Faulty Points. (Refer to Fig.2. as below)
- Practical Use of Analysis Tools (e.g. Microscope) |
| Cultivation
of Self-prescription |
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4
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Feedback
Nonconformance Reports to the Mfg. Process.
- Accumulation of Fault Examples |
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5
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Revision
of Checklists & Manuals on site. |
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6
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Launch
the Site-Remediation Movement.
- Review the Authority & Time Allocation of Operator
- OK if "Shorter working hours" less than "Existing".
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7
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Follow
up the Improvement Actions. |
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8
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Supervise
the Tier 2 Suppliers' Improvement Actions.
- Defects in Board Manufacturers have large influence. |
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SHORTCUTS
FOR ERADICATING DEFECTS
DETERMINANT
FACTORS FOR QUALITY IMPROVEMENT
|
Types
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Determinant
Factors
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| Tools |
-
Carrier machine
- Dressing board
- Cleaning roller
- Die & mold
- Screen for printing
- Film for printing
- Drill & Router bit |
| Operation |
-
Work Instructions
- Level of skill
- Work Environment
- Trouble shooting
- Workload, Fatigue
- Relationship |
Manufacturing
Conditions
|
-
Conveyer speed
- Flow rate
- Drilling (rotation, feed speed etc.)
- Light exposure
- Temperature Profile
- Chemicals (temperature, concentration, PH etc.) |
| Manufacturing
Equipments |
-
Chemical polishing
- Exposure, Development, Etching, Exfoliation
- AOI
- Roughening, Lamination etc.
- Boring, Grinding
- Panel Plating
- Silk, Resist
- Finishing
- Routing
- Handling |
| Materials |
-
Copper thin film
- Prepreg
- Copper clad laminate
- Silk, Resist ink
- Dry film
- Plugging ink
- Copper, Silver paste
- Solder. Ni Au
- Carbon ink |
| Secondary
Materials |
-
holder, panel
- Polishing agent
- Filter
- Roughening & Plating chemical
- Dry film
- Etchant
- Surface treatment chemical
- Drill, Router bit
- Exfoliate paper |
Manufacturing
Environment
|
-
Breath
- Dust
- Contamination
- water quality, bacteria
- Floor vibration prevention
- Indoor illuminance
- Indoor temperature and humidity |
| Administration |
-
Process manufacturing control
- Quality control
- Traceability
- Material control
- Standard, Criterion Control
- Cost control
- Labor control
- Tool accuracy control |
| Board
Specifications |
-
Layer number
- Board thickness, Dimension
- Minimum hole diameter
- Minimum line width, Clearance
- Resist clearance
- Through-hole structure
- Special Material
- Required reliability |
| Factory
Buildings |
-
Building structure
- Clean room
- Floor withstand load, vibration control
- Duct work
- Water treatment plant
- Power supply
- Work space
- Temperature and humidity control |
| Others |
-
Subcontract control
- Acceptance check capability
- Manager leadership
- Curiosity & problem finding capability
- Communication between Manager and Operators
- Turnover ratio of employee
- Corporate culture & practice |
A
FISHBONE DIAGRAM FOR QUALITY IMPROVEMENT
A
CASE OF FAULT ANALYSIS TO ENGINE ECU
CONSULTING
SCENES FOR AN ECU MANUFACTURER
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AN
EXAMPLE OF IMPLEMENTATION PLAN
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EXAMPLES
OF THE DELIVERABLES
Assessment
Reports
(on individual site)
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MarkLines
will document the results of survey, on-site assessment, and cause-and-effect
analysis and the Manufacturing Implementation Plans for the individual
site.
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[Contents
of the reports (examples)]
- Manufacturing process flowchart
- Cause-effect diagram of problems
- Solutions & Implementation
- Improvement Results etc. |
Manufacturing
Technology & QC Checklists
(on individual Mfg. process)
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Since
there are determinants of the quality for every mfg. process,
MarkLines will improve the checklists used on site, which will
be more useful for the improvement on manufacturing technology
and quality control. MarkLines will teach the fault analysis theory
and practices to key persons and operators, who can do improvement
activities spontaneously by themselves.
The documented record of MarkLines instruction activities is a
deliverable.
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[Check items
(examples)]
- Operation
- Administration
- Mfg. Conditions
- Manufacturing Equipment / Process
- Manufacturing Environment
- Factory Bldg.
- Tools
- Parts / Material
- Secondary Material
- Parts Mounting Specification
- Board Spec.
- Others etc.
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A
Supplier guidance manual
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MarkLines
will prepare the manual to summarize the vital points on supplier
selection, order issue and technical guidance etc.
|
[Contents
of the manual (examples)]
- Supplier selection & order issue
- Acceptance Inspection
- Technical Guidance etc. |
A
Proposal for ECU Design Improvement
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MarkLines
will organize the measures to improve the Board Design of which
effects are large for the quality improvement in ECU mfg. process.
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[Contents
of the proposal (examples)]
- Improvement on the Board Design
- Improvement on the Circuit Design and Bill of Material etc. |
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For further details
on MarkLines Consulting Service,
please send an inquiry email.
MarkLines Co., Ltd.
Consulting Department
General Manager
Hiromi Fujikawa
Phone: +81-3-5114-8710
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