Flat Panel Display Operations Improvement

I took the initiative and responsibility of the operation with guaranteed result delivery within requested window and turned the business that was planned for decommissioning around.

Summary

Meeting production goals and capacity entitlement

I was leading a R&D operation focused on solution development in flat panel display area. One of our projects was deployed for production and after qualification was transferred to operation organization.

After a few weeks of production and going through the ramp-up phase, it was widely believed that designed capacity was unachievable and the operation organization was going to permanently stop the line of business unless there was a guarantee on the results per design criteria and in a short period of time.

Construciton layer of an OLED display

Process Capability Analysis used for fixtures qualification

Liquid adhesive robotic application process

Approach

Resource Deployment
1. Entered into this unbiased
2. Entire R&D team mobilized to the production floor to better understand the problem
Issues with Shop Floor Management System
1. Re-educate the team on concept of natural process variation and process capability
2. Established SPC to monitor performance of key process steps
3. Revised the quality procedure to follow SPC output as the trigger point to stop and make process adjustments
4. Prevented over correction on equipment settings
5. Separated induced noise from over adjustments
Quality problem related to vertical alignment in lamination process
Established Ishikawa Diagram to establish causal relationship for parameters affecting misalignment
1. Cure Process- ruled out
2. Lamination process- ruled out
Analysis
1. Volume of adhesive showed variation
2. There was a correlation established between time and variations
3. correlation between temperature change and time
A facility event was causing temperature fluctuation in the clean room impacting the viscosity of the adhesive in the transfer tube line
Problem fixed in 1 week
Elimination of process variation- Application of liquid adhesive (robotic process)

Results

Alignment related failures reduced by over 98%

Production goal was met in first day (from 50 to 300 units per per shift)

Production rate increased to 450 units per shift 3 days after changes applied and without adding any equipment

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