應用六標準差改善Y公司疊層站疊層良率

Applying Six Sigma Technique to Improve the Yield of the Stacking Process in Y Company

10.6132/JCM.2013.7.1.12

盧瑞琴(Lai-Chin Lu)；馬崧獻(Sung-Hsien Ma)

六標準差 ； 製程能力 ； Six sigma ； Process capability

商業現代化學刊

7卷1期（2013 / 03 / 01）

237 - 261

繁體中文

積層陶瓷電容MLCC（Multilayer Ceramic Capacitor）的生命週期在全球的競爭壓力之下越來越短的趨勢，會往高容、高頻、高壓、小尺寸發展，若可以縮短新產品研發到量產甚至到販售的時間，將有助於提升產品在市場上的競爭力。六標準差（Six Sigma）接續全面品質管理（TQM）後的一個新興追求卓越品質的管理方法。六標準差為運用策略、企業文化的改變及各種管理與統計工具的運用，執行專案計畫及目標，並從工作流程中減少失誤，追求最小變異，以達到節省成本和時間的一種哲學。本研究採取個案研究法，以個案公司為例，在了解研究目的及六標準差（Six Sigma）之內容及真正精神後，配合個案公司之文化與制度，擬定適合的改善方法及策略導入於企業中，並找出成功導入精實生產的程序步驟及運作方法導入於企業中，以評估、驗證其改善成效。在界定階段透過SIPOC流程圖將改善方向界定在疊層製程；衡量階段則透過柏拉圖分析現行不良率發生的工作流程與發生模式的分佈狀況；分析階段則根據生產及維修報表，統計良率變化，並透過DOE、要因分析及實驗分析，得出可能導致線不良的原因進行探討；改善階段則透過分析的結果進行對策，並小量投入產線試作，以驗證改善對策是否有效；控制階段則引用分析階段所擬定的對策，進行長期追蹤，並結算對策成效。研究結果顯示以DMAIC模式導入後，現不良率有明顯低減，直接衍生的改善的效益為：每月不良率從5.49%降至4.03%，節省73萬元左右的維修及材料成本。

The life cycle of the MLCC (Multilayer Ceramic Capacitor) is getting shorter and shorter due to the competition in the world. The MLCC will develop into the high capacity, high frequency, high voltage, and small size for this trend. It will increase the competitive strength if we narrow the time of the new products from design to marketing. The philosophy of the 6σ is a strategy which changing the company culture and a variety of management and statistical tools for saving time and costs. In this case, we found the best result to combine the system of the 6σ and culture of the company. The improvement used SIPOC and was being in stacking process at the definition stage. The mode of and the rate of the defective production would be analyzed with Pareto chart at measure stage. At analysis stage, the variation of the yield would be investigated by the production, the maintain record, and the DOE in order to figure out the root cause. We tested and verified the action of these factors at improvement stage. At last, we confirmed the long-term effects of stacking at control stage. The results of this study showed the obviously decreased defective rate after introducing the DMAIC process. That is, the costs for maintenance and materials were decreased 0.73 million per month.