Lean six sigma in scrap cost improvement an application in electronics manufacturing system

VIET NAM NATIONAL UNIVERSITY HO CHI MINH CITY HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY TRAN NGOC QUYNH LEAN – SIX SIGMA IN SCRAP COST IMPROVEMENT: AN APPLICATION IN ELECTRONICS MANUFACTURING SYSTEM Major: Industrial Engineering Major ID: 8520117 MASTER THESIS HO CHI MINH CITY, January 2023 THIS RESEARCH IS COMPLETED AT: HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY – VNU HCM Instructor: Assoc Prof PhD Do Ngoc Hien ………………………………………………… Examiner 1: PhD Nguyen Vang Phuc Nguyen………………………………………………… Examiner 2: PhD Nguyen Van Thanh………………………………………………………… Master’s Thesis is defended at HCMC University of Technology, VNU-HCM on January 08, 2023 The Board of The Master’s Thesis Defense Council includes: Chairman: PhD Do Thanh Luu ……………………………………………………… Secretary: PhD Le Song Thanh Quynh………………………………………………… Counter-Argument Member: PhD Nguyen Vang Phuc Nguyen…………… Counter-Argument Member: PhD Nguyen Van Thanh……………………………… Council Member: Assoc Prof PhD Do Ngoc Hien …………………………………… Verification of the Chairman of the Master’s Thesis Defense Council and the Dean of the Faculty of Mechanical Engineering after the thesis is corrected (if any) CHAIRMAN OF THE COUNCIL (Full name and signature) DEAN OF FACULTY OF MECHANICAL ENGINEERING (Full name and signature) VIETNAM NATIONAL UNIVERSITY HCMC SOCIALIST REPUBLIC OF VIETNAM VNUHCM UNIVERSITY OF TECHNOLOGY Independence – Liberty – Happiness MASTER’S THESIS ASSIGNMENTS Full name: TRAN NGOC QUYNH Learner ID: 2070328 Date of birth: 29th October, 1998 Place of birth: Ca Mau Major: Industrial Engineering Major ID: 8520117 I – TITLE: LEAN – SIX SIGMA IN SCRAP COST IMPROVEMENT: AN APPLICATION IN ELECTRONICS MANUFACTURING SYSTEM/ NGHIÊN CỨU ỨNG DỤNG LEAN SIX - SIGMA VÀO GIẢM CHI PHÍ PHẾ PHẨM: TRƯỜNG HỢP ĐIỂN CỨU TẠI NHÀ MÁY LẮP RÁP HÀNG ĐIỆN TỬ ASSIGNMENTS AND CONTENT: Assignments:     Investigate a production system to identify the quality and productivity-related problems and their root causes Collect the information and data to prove the problem Propose a Lean Six Sigma framework to reduce the scrap cost rate in an EMS factory Reduce the scrap cost rate to meet the company target Content:      Chapter gives a general introduction to the research object and problem The research objectives, limitations and scope of the study, the content to be performed, and layout of the study will also be briefly presented in this chapter Chapter presents the theories used in the research will be presented, including the Lean concept, Six Sigma methodology, in-process kanban (IPK), Maynard operation sequence technique (MOST) and related studies Chapter introduces a research methodology with step to step to carry out this study Chapter presents an overview of the research object, such as process, layout, traceability systems, etc The Define, Measure and Analyze phases will be discussed in this chapter All data collected is analyzed to identify the improvement opportunity and form a research problem As a result, this session will also conduct improvement actions to solve the problem's root cause Moreover, the control plan will also be defined to maintain the improvement actions and their results Chapter reports the conclusion of the thesis The remaining shortcomings will be pointed out, and possible developing directions for the future will be suggested i II – ASSIGNMENT DELIVERING DATE (based on the Decision on Assignments Delivering): September 05, 2022 III – ASSIGNMENT COMPLETING DATE (based on the Decision on Assignments Delivering): December 18, 2022 IV – INSTRUCTOR: Assoc Prof PhD Do Ngoc Hien Ho Chi Minh City, December 23, 2022 INSTRUCTOR (Full name and signature) HEAD OF DEPARTMENT (Full name and signature) DEAN OF FACULTY OF MECHANICAL ENGINEERING (Full name and signature) ii ACKNOWLEDGEMENT "Lean – Six Sigma in scrap cost improvement: an application in Electronics Manufacturing System" is a result of whale time at the Department of Industrial Systems Engineering, HCMC University of Technology This thesis would not have been feasible without the untold amount of encouragement from numerous people who enabled me to complete the study First and foremost, I would like to express my heartfelt appreciation and deepest gratitude to my primary advisor – A/Prof Đỗ Ngọc Hiền for his guidance over the course of this thesis study I am grateful beyond words that he is ready to discuss issues with vast information I have had no chance to be shared before I could not have asked for a better advisor for my thesis study Besides, thanks for the enthusiastic support from colleagues at Jabil company In the process of implementing as well as collecting data, I have received very enthusiastic support from both teachers and brothers and sisters in the company I would like to especially thank Mr Danh Võ – IE Functional Manager and Ms Nhi Trần – IE Engineer who facilitated and supported me directly in this project I would also like to thank the IE support team members who have always enthusiastically supported me in my work and searching for orientation for graduation thesis topics in the company In addition, I would like to thank the friends who have helped me through the difficulties and also the joys Thank you for making my life more colourful Last but not least, I would like to express my sincerest thanks to my greatest source of motivation and inspiration: thank you to my parents for always supporting me in every way Thank you, my brother – Trần Quốc Công, PhD for advice and guidance I would not have gotten to where I am today without your support In the process of working and reporting, mistakes will inevitably be made, and I would like to ask for your comments and corrections so that I can improve my knowledge as well as future orientation Trần Ngọc Quỳnh iii ABSTRACT This research presents six sigma implementation conducted in an EMS enterprise to reduce scrap cost rate and thereby increase its sigma level The study has gone through the problem that the factory is facing: the percentage of scrap cost is higher than the target (actual 0.03% vs goal 0.02%) Using the DMAIC methodology, the root cause was defined as product handling, tool-using and IPK identification between stations Then, three improvement actions were taken to address the three identified causes The solutions are to change the board handling trays, add a mandatory scan step when using a screw jig, and determine the number of IPKs between stations After applying improvement solutions, the line performance is significantly improved The sigma level improved from 2.91 to 3.43 for the download station and from 2.6 to 3.19 for the wintest station Since then, the rate of products passing the first time (FPY) has also improved, from 98.31% to 98.55%, compared to the factory's target is 98.54% Furthermore, the research's target was also achieved when improving the scrap cost ratio from 0.03% to 0.014% This result proves the effectiveness of the study, meeting the research objectives and the company's expectations Keywords: Lean Six – Sigma, scrap cost reduction, MOST, FlexSim simulation, IPK iv TÓM TẮT LUẬN VĂN Nghiên cứu trình bày việc triển khai Six - Sigma doanh nghiệp EMS để giảm tỷ lệ chi phí phế phẩm từ tăng mức sigma hệ thống Nghiên cứu sâu vào vấn đề mà nhà máy gặp phải: tỷ lệ chi phí phế phẩm cao so với mục tiêu (0.03% thực tế so với mục tiêu 0.02%) Bằng việc sử dụng chu trình DMAIC, nguyên nhân gốc rễ xác định thao tác di chuyển sản phẩm, thiếu công cụ hỗ trợ thao tác IPK trạm chưa xác định rõ ràng Sau đó, ba giải pháp cải tiến thực để giải ba nguyên nhân xác định Các giải pháp thay đổi khay dùng dể vận chuyển bo mạch, thêm bước quét bắt buộc sử dụng đồ gá xác định số lượng IPK trạm Sau áp dụng giải pháp cải tiến, hiệu suất dây chuyền cải thiện rõ rệt Mức sigma cải thiện từ 2.91 lên 3.43 cho trạm Download từ 2.6 lên 3.19 cho trạm Wintest Từ đó, tỷ lệ sản phẩm đạt lần (FPY) cải thiện, từ 98.31% lên 98.55%, so với mục tiêu nhà máy 98.54% Ngoài ra, mục tiêu nghiên cứu đạt cải thiện tỷ lệ chi phí phế liệu từ 0.03% lên 0.014% Kết chứng tỏ tính hiệu nghiên cứu, đáp ứng mục tiêu nghiên cứu kỳ vọng công ty v DECLARATION I hereby declare that this is my own research All the data and the results used in this research are honest and have not been published in other studies I will be totally responsible for my research if it is incorrect as mentioned above The research’s author TRAN NGOC QUYNH vi CONTENTS MASTER’S THESIS ASSIGNMENTS I ACKNOWLEDGEMENT III ABSTRACT IV TÓM TẮT LUẬN VĂN V DECLARATION VI CONTENTS VII LIST OF FIGURES VIII LIST OF TABLES X LIST OF ABBREVIATIONS XI CHAPTER INTRODUCTION 1.1 BACKGROUND 1.2 RESEARCH OBJECTIVE AND SCOPE .2 1.4 THESIS STRUCTURE CHAPTER LITERATURE REVIEW 2.1 LEAN SIX SIGMA 2.2 IN-PROCESS KANBAN (IPK) .3 2.3 MAYNARD OPERATION SEQUENCE TECHNIQUE (MOST) CHAPTER THE DMAIC METHODOLOGY CHAPTER CASE STUDY 4.1 RESEARCH OBJECT .9 4.1.1 Overall process 4.1.2 Scrap definition, FPY dashboard and EDMR system 4.2 DMAIC RESULTS .11 4.2.1 Define 11 4.2.2 Measure 14 4.2.3 Analyze 17 4.2.4 Improve 26 4.2.5 Control 36 CHAPTER CONCLUSION AND DISCUSSION 39 5.1 CONCLUSION 39 5.2 DISCUSSION 40 LIST OF PUBLICATIONS 41 REFERENCES 42 APPENDIX 44 PROFILE 58 vii LIST OF FIGURES FIGURE EXAMPLE OF IPK FIGURE MOST DATA CARD FIGURE DMAIC METHODOLOGY FRAMEWORK FIGURE RESEARCH METHODOLOGY FIGURE OVERALL PROCESS FIGURE THE LAYOUT OF THE ASSEMBLY LINE FIGURE FPY DASHBOARD INTERFACE 11 FIGURE EMDR SYSTEM INTERFACE 11 FIGURE BB SCRAP COST IN 10 WEEKS 13 FIGURE 10 %CONTRIBUTION OF SCRAP ISSUES 13 FIGURE 11 %SCRAP COST TREND CHART 14 FIGURE 12 SIPOC OF THE PROJECT 14 FIGURE 13 BB SCRAP BY DEFECTS 15 FIGURE 14 DEFECTS BREAKDOWN BY PROCESS 16 FIGURE 15 BB FPY AND SCRAP TREND CHART 16 FIGURE 16 CTQS OF THE PROBLEM 17 FIGURE 17 DESCRIPTIVE REPORT FOR THE SCRATCH DEFECT RATE 18 FIGURE 18 DESCRIPTIVE REPORT FOR SCRATCH DEFECT RATE (REMOVED OUTLIERS) 18 FIGURE 19 PROCESS CAPABILITY ANALYSIS FOR DOWNLOAD STATION 19 FIGURE 20 DESCRIPTIVE REPORT FOR THE DEFORMED CABLE DEFECT RATE 20 FIGURE 21 DESCRIPTIVE REPORT FOR DEFORMED CABLE DEFECT RATE (REMOVED OUTLIERS) 20 FIGURE 22 PROCESS CAPABILITY ANALYSIS FOR THE WINTEST STATION 21 FIGURE 23 AUTO QUALITY MATRIX 21 FIGURE 24 PROCESS MAPPING 22 FIGURE 25 CHI-SQUARE TEST FOR DEFECT RATE OF 12 OPERATORS 23 FIGURE 26 FISHBONE DIAGRAM FOR SCRATCHES AND DEFORMED CABLE DEFECTS 24 viii APPENDIX Table A1 Summary of scrap cost in 10 weeks Week Total scrap cost Total BB Scrap cost %BB scrap/Total scrap Process issue scrap Other issue (PI count, Clear Aging WIP…) scrap BOM cost %BB Scrap/ BOM cost %BB Scrap/ BOM cost due to Process Issue %Process issue %Other issue 10 11 12 13 14 15 Avg $32,155 $2,797 $43,248 $3,460 $60,903 $5,481 $99,329 $8,840 $72,543 $6,311 $68,439 $6,023 $98,379 $8,461 $106,650 $9,065 $85,329 $7,594 $103,236 $8,775 8.7% 8.0% 9.0% 8.9% 8.7% 8.8% 8.6% 8.5% 8.9% 8.5% $2,401 $3,051 $4,474 $3,840 $3,490 $4,094 $4,163 $4,233 $3,945 $4,463 $397 $409 $1,007 $5,001 $2,821 $1,928 $4,297 $4,832 $3,650 $4,312 $8,322,119 0.03% $10,345,93 0.03% $13,748,38 0.04% $16,348,71 0.05% $14,129,56 0.04% $15,658,71 0.04% $14,695,76 0.06% $13,252,02 0.07% $14,142,99 0.05% $13,851,45 0.06% 0.05% 0.03% 0.03% 0.03% 0.02% 0.02% 0.03% 0.03% 0.03% 0.03% 0.03% 0.03% 85.82% 88.19% 81.63% 43.43% 55.30% 67.98% 49.21% 46.70% 51.94% 50.86% 62.11% 14.18% 11.81% 18.37% 56.57% 44.70% 32.02% 50.79% 53.30% 48.06% 49.14% 37.89% 8.7% 44 Table A2 Defect by operators Operator 1086860 1218818 1476908 2269548 2300802 2451111 2455929 2495152 2711909 2717937 2800227 PhamP1 Total Defect 5 4 47 Tested 5321 8351 3951 810 6370 7361 1110 3853 7201 3276 2150 1520 51274 Table A3 Production plan for Flexsim model input Or der Bay B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BB LINE6 B2INGENICO BB LINE12 Famil y Ty pe Qua ntity Project edstart Project edend Delay hour Or der LANE 8000 DESK 3200 MOV E2500 LANE 7000 200 85 360 820 86 360 2304 87 240 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 2952 88 Bay B2INGENICO BB LINE6 B2INGENICO BASE LINE B2INGENICO BB LINE7 B2INGENICO BASE LINE Fa mil y IUC 250 IUC 250 IUC 250 IUC 250 Ty pe Qua ntity Project edstart Project edend Delay hour 360 200 360 200 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 82224 9/12/20 22 9/12/20 22 9/12/20 22 9/13/20 22 82800 84300 87120 45 10 11 12 13 14 15 16 17 18 19 20 B2INGENICO BB LINE7 B2INGENICO BB LINE9 B2INGENICO BB LINE7 B2INGENICO BB LINE8 B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BB LINE9 B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BB LINE6 B2INGENICO BASE LINE B2INGENICO BB LINE7 DESK 3200 MOV E2500 MOV E2500 DESK 3200 LANE 7000 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 160 360 360 299 240 200 56 360 300 200 200 240 200 360 200 360 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 6900 89 9744 90 12300 91 12340 92 13752 93 24120 94 24120 95 24144 96 24220 97 24252 98 24492 99 24552 10 10 10 10 10 24612 24624 25920 26700 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BB LINE6 B2INGENICO BB LINE9 B2INGENICO BB LINE7 B2INGENICO BASE LINE B2INGENICO BASE LINE IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 200 200 200 240 200 92 200 200 200 360 200 360 161 360 200 200 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 87612 87852 87972 89352 91440 93264 93372 93612 93732 94060 95760 96624 96864 98700 99132 99372 46 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BB LINE8 B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE9 B2INGENICO BB LINE6 B2INGENICO BB LINE7 B2INGENICO BASE LINE B2INGENICO BASE LINE IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 200 120 200 200 200 120 360 240 200 200 200 360 360 360 200 200 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 27720 27720 30012 30252 30372 34920 35020 35352 35772 36012 36132 38544 39024 41100 41532 41772 10 10 10 10 10 11 11 11 11 11 11 11 11 11 11 12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BB LINE6 B2INGENICO BASE LINE IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 200 200 240 360 200 360 200 200 200 200 200 200 240 200 360 200 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 99492 10008 10015 10226 10440 10486 10489 10513 10525 10872 11065 11089 11095 11101 11102 11304 47 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BB L9 LINE1 B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 200 120 200 240 200 200 200 200 120 308 200 117 360 200 200 200 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 41892 42120 43920 46152 47292 47532 47652 48240 49320 49420 52560 52920 52944 53052 53292 53412 12 12 12 12 12 12 12 12 12 13 13 13 13 13 13 13 B2INGENICO BB LINE7 B2INGENICO BB LINE9 B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE6 B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BB LINE9 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 360 360 360 200 200 200 200 200 240 200 200 200 360 200 360 360 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 11310 11450 11566 11641 11665 11677 11736 12168 12175 12217 12241 12253 12542 12600 12646 12674 48 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 B2INGENICO BB LINE6 B2INGENICO BB LINE7 B2INGENICO BB LINE10 B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE10 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE9 B2INGENICO BB LINE12 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 320 360 120 200 240 200 200 200 200 81 200 200 200 200 367 240 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 53424 55500 56520 56880 56952 58812 59052 59172 61200 63720 64572 64812 64932 65520 67344 67752 13 13 13 14 14 14 14 14 14 14 14 14 14 15 15 15 B2INGENICO BB LINE7 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE6 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 360 200 200 200 200 240 200 200 200 360 200 200 360 200 200 360 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 12750 12793 12829 13032 13033 13255 13369 13405 13464 13726 13825 13896 13898 13945 13981 13982 49 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 B2INGENICO BB LINE6 B2INGENICO BASE LINE B2INGENICO BB LINE7 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 IUC25 360 200 360 200 200 200 200 200 200 200 200 240 360 200 200 200 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/12/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 67824 69840 69900 70332 70572 70692 74160 76092 76332 76452 78480 78552 81744 81852 82092 82212 15 15 15 15 15 15 15 16 16 16 16 16 16 16 16 16 B2INGENICO BB LINE7 B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE8 B2INGENICO BASE LINE B2INGENICO BB LINE9 B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BASE LINE B2INGENICO BB LINE12 B2INGENICO BB LINE6 B2INGENICO BASE LINE IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 IUC 250 360 200 240 200 200 200 200 360 200 360 200 200 200 240 360 200 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 9/13/20 22 14190 14328 14335 14521 14557 14617 14760 14806 15097 15122 15133 15192 15409 15415 15422 15624 50 16 B2INGENICO BB LINE7 IUC 250 360 9/13/20 22 9/13/20 22 15630 Table A4 Throughput from simulation model and from MES system for top products Product type 5 5 5 5 5 5 5 5 5 5 15 15 Throughput From model 57 59 60 60 58 57 57 57 57 58 57 57 57 57 58 60 60 59 57 58 21 28 Throughput From MES 53 45 55 50 57 55 54 50 63 65 62 64 38 60 60 59 58 57 38 58 26 27 Product type 7 7 7 7 7 7 7 7 7 7 10 10 Throughput From model 21 22 32 38 16 28 17 16 39 17 36 23 15 46 49 22 27 21 25 45 16 43 Throughput From MES 45 28 20 38 49 50 18 41 44 31 25 41 11 44 46 22 30 47 19 35 37 46 Product type 3 3 3 3 3 3 3 3 3 3 Throughput From model 43 28 23 20 19 28 32 28 20 32 29 25 28 27 31 20 43 23 20 28 Throughput From MES 26 25 19 41 23 48 35 14 54 17 45 34 43 39 20 22 39 48 20 50 51 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 39 27 30 28 72 21 23 67 11 23 38 66 25 30 13 13 82 68 51 25 31 37 78 62 97 40 61 67 31 42 14 25 12 49 55 58 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 20 25 16 15 15 24 80 15 80 44 27 43 16 15 23 44 43 43 14 37 14 51 31 44 82 43 65 80 33 40 25 59 22 47 15 40 Table A5 Scratches defect rate before and after improvement Phase Date Scratches defects count Total test Defect rate PPM Before Before Before Before Before 24-Dec 25-Dec 26-Dec 27-Dec 28-Dec 12 14 11407 14005 12522 12011 12955 0.11% 0.10% 0.07% 0.02% 0.03% 1052 1000 719 250 309 52 Before Before Before Before Before Before Before Before Before Before Before Before After After After After After After After After After After After After 29-Dec 30-Dec 31-Dec 1-Jan 2-Jan 3-Jan 4-Jan 5-Jan 6-Jan 7-Jan 8-Jan 9-Jan 18-Jan 19-Jan 20-Jan 22-Jan 23-Jan 24-Jan 25-Jan 26-Jan 28-Jan 9-Feb 11-Feb 12-Feb 10 11 18 11 18 4 3 14011 11979 11060 2828 6926 10918 10507 11468 13229 11823 12452 10806 24784 25659 30367 21704 21075 27457 28669 19698 21902 17521 13185 11953 0.04% 0.01% 0.08% 0.04% 0.14% 0.06% 0.08% 0.10% 0.06% 0.15% 0.09% 0.17% 0.01% 0.02% 0.01% 0.02% 0.02% 0.01% 0.01% 0.02% 0.01% 0.01% 0.02% 0.03% 428 83 814 354 1444 641 761 959 605 1522 883 1666 121 156 66 230 190 109 70 203 137 114 228 335 53 After After After After After After After After After After After After After After After 15-Feb 18-Feb 23-Feb 25-Feb 26-Feb 27-Feb 28-Feb 1-Mar 5-Mar 6-Mar 7-Mar 8-Mar 9-Mar 11-Mar 13-Mar 2 2 5 5 19574 23147 22294 17179 19055 19650 16102 14769 21506 17003 21495 30003 39485 27321 24233 0.02% 0.01% 0.00% 0.01% 0.02% 0.01% 0.01% 0.01% 0.03% 0.03% 0.00% 0.01% 0.01% 0.02% 0.02% 153 86 45 116 157 102 124 68 279 294 47 67 127 183 206 Table A6 Deformed cable defect rate before and after improvement Phase Date Deformed defect count Total tested Defect rate PPM Before Before Before Before Before Before 24-Dec 25-Dec 26-Dec 27-Dec 28-Dec 29-Dec 13 11 12 18 11466 13834 12424 11858 12709 13703 0.11% 0.08% 0.10% 0.06% 0.14% 0.07% 1134 795 966 590 1416 657 54 Before Before Before Before Before Before Before Before Before Before Before After After After After After After After After After After After After After 30-Dec 31-Dec 1-Jan 2-Jan 3-Jan 4-Jan 5-Jan 6-Jan 7-Jan 8-Jan 9-Jan 18-Jan 19-Jan 20-Jan 21-Jan 22-Jan 23-Jan 24-Jan 25-Jan 26-Jan 27-Jan 28-Jan 7-Feb 8-Feb 16 13 14 21 18 10 10 14 3 12 11892 11084 2842 6750 10688 10314 11158 13254 11783 12378 10709 24127 25397 29824 29832 21423 20792 27333 28069 19295 32784 21687 10915 15601 0.13% 0.08% 0.11% 0.19% 0.13% 0.20% 0.16% 0.08% 0.08% 0.11% 0.07% 0.04% 0.02% 0.02% 0.02% 0.02% 0.01% 0.01% 0.02% 0.06% 0.02% 0.02% 0.02% 0.06% 1345 812 1056 1926 1310 2036 1613 754 849 1131 654 373 236 168 235 233 144 110 178 622 153 184 183 577 55 After After After After After After After After After After After After After After After After After After After After After After After After 9-Feb 10-Feb 11-Feb 12-Feb 13-Feb 14-Feb 15-Feb 16-Feb 17-Feb 18-Feb 19-Feb 20-Feb 21-Feb 22-Feb 23-Feb 24-Feb 25-Feb 26-Feb 27-Feb 28-Feb 1-Mar 2-Mar 3-Mar 4-Mar 13 8 15 10 17 13 6 17477 18673 14075 11550 10893 18558 19885 20228 15111 23019 14990 12998 25414 21421 23957 22521 17019 18451 19423 15958 13783 21430 23250 29348 0.04% 0.02% 0.09% 0.07% 0.06% 0.03% 0.04% 0.03% 0.05% 0.01% 0.03% 0.03% 0.06% 0.03% 0.03% 0.04% 0.03% 0.05% 0.09% 0.08% 0.01% 0.03% 0.03% 0.01% 401 161 924 693 643 323 402 346 529 130 334 308 590 327 250 444 294 488 875 815 145 280 258 136 56 After After After After After After After After After After After After After After After After After After After After After After 5-Mar 6-Mar 7-Mar 8-Mar 9-Mar 11-Mar 12-Mar 13-Mar 14-Mar 15-Mar 16-Mar 17-Mar 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar 25-Mar 26-Mar 27-Mar 11 11 10 15 11 5 3 21234 16507 21571 29569 39918 26803 26652 23852 28479 27931 23475 30167 35104 22009 14072 24529 12135 14976 15578 22065 16253 15798 0.03% 0.03% 0.05% 0.01% 0.01% 0.04% 0.04% 0.03% 0.01% 0.02% 0.03% 0.01% 0.04% 0.05% 0.04% 0.02% 0.04% 0.02% 0.02% 0.03% 0.02% 0.03% 283 303 510 101 100 410 375 335 70 179 256 99 427 500 355 204 412 200 193 272 185 253 57 PROFILE Full name: Tran Ngoc Quynh Date of birth: 29th October, 1998 Birthplace: Ca Mau Address: 78 Duong Thi Sau Street, Ward 1, Bac Lieu city, Bac Lieu Province EDUCATIONAL PROCESS  2016 – 2020: Bachelor of Industrial Systems Engineering, HCMC University of Technology  2020 – 2022: Master of Industrial Engineering, HCMC University of Technology WORKING PROCESS  9/ 2020 – now: Industrial Engineer, Jabil Vietnam TRẦN NGỌC QUỲNH 58