Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process

Hard defect failures in hard disk drives are detected from the first level failure analysis of the Final Quality Assurance failed drives at Company AB. The hard defect failures are then send for second level failure analysis to determine the potential root cause of the failure. High hard defect fail...

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Main Author:	Ramachandran, Eswari Devi
Format:	Thesis
Language:	English English
Published:	2014
Subjects:	TS Manufactures
Online Access:	http://eprints.utem.edu.my/id/eprint/14749/1/Productivity%20Improvement%20Preventive%20Actions%20For%20Hard%20Defect%20Failure%20Reduction%20At%20Hard%20Disk%20Drive%20Assembly%20Prosecc%2024pages.pdf http://eprints.utem.edu.my/id/eprint/14749/2/Productivity%20improvement%20preventive%20actions%20for%20hard%20defect%20failure%20reduction%20at%20hard%20disk%20drive%20assembly%20process.pdf
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spelling	my-utem-ep.147492022-12-29T15:32:27Z Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process 2014 Ramachandran, Eswari Devi TS Manufactures Hard defect failures in hard disk drives are detected from the first level failure analysis of the Final Quality Assurance failed drives at Company AB. The hard defect failures are then send for second level failure analysis to determine the potential root cause of the failure. High hard defect failures causes low lot acceptance rate which delays drives shipment due to long lead time and also deliver poor quality drives to customer. The recovery activity for FQA failure lots also requires additional space and tester. The aim of this project is to reduce hard defect failure at Final Quality Assurance through three objectives; (i) to identify and analyze potential root causes of the hard defect failures, (ii) to develop a model of prevention action and (iii) to validate the preventive action model effectiveness. The analysis of data is based on six weeks Final Quality Assurance failed tested data of product 'A' trend analysis using QUALITY DATABASE system and sampling of two drives per week for Aslab second level FA for continuous five weeks. 5 Whys and FMEA are performed to determine the potential preventive action and preventive action model is developed. Pre and post DPPM and lot acceptance rate results are monitored and compared to validate the effectiveness of the preventive actions after one month. Results show the actuator component from U supplier show significant trend from QUALITY DAT ABASE analysis as well as the AsLab results. Three potential root causes of hard defect failures have been determined as incoming material cleanliness, poor screening at backend test and assembly cleanliness. The main actions implemented are temporary stop U actuator supplier; introduce hard defect long test screen REV Q at backend and briefing and awareness on assembly related findings. From the implementation the main actions, observed 92.8% hard defect failure dppm reduction and LAR above 70% is achieved. The benefits of this project are the reduction of failed lots due to hard defect failures, minimiz.e the rework activity and also improve customer satisfaction. The result is based on comparable sample size and show significant with P value <0.05. For the future work, the proposed model can be improved using the application of Fuzzy Logic for data storage and data retrieval. 2014 Thesis http://eprints.utem.edu.my/id/eprint/14749/ http://eprints.utem.edu.my/id/eprint/14749/1/Productivity%20Improvement%20Preventive%20Actions%20For%20Hard%20Defect%20Failure%20Reduction%20At%20Hard%20Disk%20Drive%20Assembly%20Prosecc%2024pages.pdf text en public http://eprints.utem.edu.my/id/eprint/14749/2/Productivity%20improvement%20preventive%20actions%20for%20hard%20defect%20failure%20reduction%20at%20hard%20disk%20drive%20assembly%20process.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=92236 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering Ebrahim, Zuhriah
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Ebrahim, Zuhriah
topic	TS Manufactures
spellingShingle	TS Manufactures Ramachandran, Eswari Devi Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
description	Hard defect failures in hard disk drives are detected from the first level failure analysis of the Final Quality Assurance failed drives at Company AB. The hard defect failures are then send for second level failure analysis to determine the potential root cause of the failure. High hard defect failures causes low lot acceptance rate which delays drives shipment due to long lead time and also deliver poor quality drives to customer. The recovery activity for FQA failure lots also requires additional space and tester. The aim of this project is to reduce hard defect failure at Final Quality Assurance through three objectives; (i) to identify and analyze potential root causes of the hard defect failures, (ii) to develop a model of prevention action and (iii) to validate the preventive action model effectiveness. The analysis of data is based on six weeks Final Quality Assurance failed tested data of product 'A' trend analysis using QUALITY DATABASE system and sampling of two drives per week for Aslab second level FA for continuous five weeks. 5 Whys and FMEA are performed to determine the potential preventive action and preventive action model is developed. Pre and post DPPM and lot acceptance rate results are monitored and compared to validate the effectiveness of the preventive actions after one month. Results show the actuator component from U supplier show significant trend from QUALITY DAT ABASE analysis as well as the AsLab results. Three potential root causes of hard defect failures have been determined as incoming material cleanliness, poor screening at backend test and assembly cleanliness. The main actions implemented are temporary stop U actuator supplier; introduce hard defect long test screen REV Q at backend and briefing and awareness on assembly related findings. From the implementation the main actions, observed 92.8% hard defect failure dppm reduction and LAR above 70% is achieved. The benefits of this project are the reduction of failed lots due to hard defect failures, minimiz.e the rework activity and also improve customer satisfaction. The result is based on comparable sample size and show significant with P value <0.05. For the future work, the proposed model can be improved using the application of Fuzzy Logic for data storage and data retrieval.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Ramachandran, Eswari Devi
author_facet	Ramachandran, Eswari Devi
author_sort	Ramachandran, Eswari Devi
title	Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
title_short	Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
title_full	Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
title_fullStr	Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
title_full_unstemmed	Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
title_sort	productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2014
url	http://eprints.utem.edu.my/id/eprint/14749/1/Productivity%20Improvement%20Preventive%20Actions%20For%20Hard%20Defect%20Failure%20Reduction%20At%20Hard%20Disk%20Drive%20Assembly%20Prosecc%2024pages.pdf http://eprints.utem.edu.my/id/eprint/14749/2/Productivity%20improvement%20preventive%20actions%20for%20hard%20defect%20failure%20reduction%20at%20hard%20disk%20drive%20assembly%20process.pdf
_version_	1776103080317681664

Productivity improvement preventive actions for hard defect failure reduction at hard disk drive assembly process

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