Introduction

A new wire bonding machine was purchased

and installed in January.
The company has marketed their product as
better than military standards.
The company top management are very
insistent on quality which is a good sign.
Problems
The machine has started to behave erratically.

If this continues it will fail to deliver.

No proper initial analysis done by Regan.
Problems continued
Quality problems cropping up in customer
side.

They cannot increase capacity of their entire
operation this plant is needed to ensure that
they can deliver to customers.

GME standards
The company has maintained good quality.

That is when the Military only requires 4
grams of break force they continue to produce
with 7 grams of break force.

Fewer than 10 ppm fail.
Situation in quality checks
GME quality checks are manual they are not
automated.

The management reasons that it is done in all
other companies of their size.
CAN THEY DO IT?
Capability
They can produce quality goods.

They can meet their own quality standards.

Although their quality standards are much
more than required.
Findings
However in the sample observation that was
conducted 80 of 1008 wire connections failed
the test.

Although most are spread in 5 particular
Samples it is still a matter of concern.
The real problem
Their machines seems to give products they
are not uniform in nature even the ones close
to each other seem to be far apart.

The standard deviation in each sample is too
high and this is posing a great threat to the
quality of the product.
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
147
1
0
1
3
1
6
1
9
2
2
2
5
2
8
3
1
3
4
3
7
4
0
4
3
4
6
4
9
5
2
5
5
5
8
6
1
6
4
6
7
7
0
7
3
7
6
7
9
8
2
8
5
8
8
9
1
9
4
9
7
1
0
0
1
0
3
1
0
6
1
0
9
1
1
2
1
1
5
1
1
8
1
2
1
1
2
4
Std Deviation of Observation of each sample
Std Deviation
Some of the worst cases
Why was it bad?
The red ones point to some of the most erratic
behaviour in the same sample.

The yellow ones represent the worst as a
sample.
What is it that we want?
We want high averages and low standard
deviation.

To do this we need Design of Experiments.
4 Factors
Temperature.

Force.

Time.

Power.
The effects
What did we see?
Temperature was the most influential of all
the factors.

Followed by force.

Recommendations
Why?
They offer high average and low standard
deviation.

In fact combination 6 is the best by far
offering lowest standard deviation with high
average but it takes twice the amount of time
as combination 2 does.
Conclusion
Choose Combination 2.
Verify it by increasing number of quality checks
for the next 2 months.
Maintain log of the settings used from here on for
all the machines and maintain statistical data on
all machines even if they are running well.
If possible repeat this with at least 3 options in
each factor to get a better idea on the whole
problem and consider this for future problems as
well.
THANK YOU