6시그마 방법론을 적용한 렌즈 사출공정 최적화
Optimization of Lens Injection Process Using 6 Sigma Methodology
6시그마 방법론 렌즈 사출공정 최적화;
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In this thesis, the basic philosophy and features of Six Sigma program were reviewed. The 5 phases of DMAIC roadmap and tools used in each phase were explained in detail. Furthermore, phase by phase, we compared DMAIC and DMADOV roadmaps in terms of its application areas and activities to do. A case study for lens injection process is given to show how DMAIC roadmap can be applied to a real situation. In spite of the technical advances in lens injection process, it is still controlled by an intuitive and ad-hoc method to assure the quality of the final products. The FTY (first time yield) of lens injection process is usually less than 56.5 % and for a specific purpose lens its yield goes down under this level. Many process improvement projects have been done by far to result in some minor effects. In this situation, we applied Six Sigma methodology, that is, DMAIC roadmap to improve lens injection process. Three CTQ's of lens injection process were identified and the current level of each CTQ measured through DMA phases. After finding 8 vital few X's, we used Taguchi method to optimize the process in improvement phase. By maximizing the signal- to-noise ratios for each CTQ, the optimum condition of X's was obtained and verified through confirmative experiments. In Control phase, the control plan for vital few X's was established. We found that it was helpful in keeping the lens injection process in statistical control. The proportion of nonconforming injected lenses reduced dramatically from 434,686DPMO to 22,132 DPMO. The successful results of this Six Sigma project will be push-leveraged to the other injection processes.
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