Operator efficiency improvement through thinking 6 Sigma + Lean problem solving approach in IFX OP BE — A case study

In this paper, Thinking 6 Sigma and Lean problem solving techniques are adopted for the solution development to improve operator efficiency on Mal DS TSxP Taping Process. The conventional Six Sigma tools are replaced with lean tools to enhance the effectiveness of the design, methodology, and approach for value and waste analysis. This newly developed approach has systematically identified insufficient and poorly defined operator job contents that are the root cause for low personnel efficiency. The successful implementation of this technique has resulted in ~RM200k annual saving without any unwanted implications on overall machine performance, OEE and product quality. This newly developed value and waste analysis approach has proven to be effective for personnel efficiency improvement at TSxP taping process. Also, it has opened up many other opportunities at back-end manufacturing environment to further strengthen its competitiveness.