Michael Script_ _ _

Slide 1
Good Afternoon Honorable judges, distinguish guests and ladies & Gentlemen.
We are from GPS2 from Penang representing Sanmina Pulau Pinang.
Slide 2
On 1st Feb 2016, manufacturing has been transition to Sanmina with no change on process, quality
and people.
Slide 3
We have 76 manufacturing plant in 25 countries and this is our vision.
Pose 1..2..3..4
Slide 4
We produce two way radios for all the professions throughout the world.
Slide 5
This is our team profile and our commitment is to continue ship flawless product, on time delivery
and good quality.
Slide 6
We use the DMAIC approach to discover the best practices to continuous improvement. Lets start
with DEFINE.
Slide 7
The team list down Area Of Opportunity from every department
Improve cost of poor quality (COPQ)
Improve Yield On Leak Test
Improve Operator Training Lead Time.
Overcome high turn over of contract operator.
Slide 8 :
We decided to select High CQA Failure Rate as the team project base on decision matrix
Slide 9 :
Our Project Title is To Reduce CQA Failure Rate Due To Human Assembly Error
Hafsah what is CQA?

Hafsah Script_ _ _
CQA is Customer Quality Assurance. protect our customer brand and our companys reputation by
minimizing customer complaints.
Slide 10
This is overall Process map of Sanmina Manufacturing. CQA Buy off is done at backend at the last
stage prior to shipment.
Slide 11
At Front End, there is NO CQA gate is required as all system are built in with poke yoke quality
control.
In Backend, QA will sample check and ONLY allow good products been shipped

Michael Script_ _ _
Slide 12
HafsahYES as a production manager, I strongly agreed the importance of the Quality.
But we also need to look into our delivery KPI
This slides shows our Portable Mid Tier demand which clearly show the spike in every quarter end.

Slide 13
Simultaneously, the headcount is increased during high ramp been shown in Operator Balance
Chart (OBC) in quarter end.
Slide 14
Although we plan for additional HC, we have difficulties to manage training for newly hired and
transferred employees.
Slide 15 :
Due to the poor operator competency, Quality team continued to feedback on the defect escapee on
human assembly error which impact our delivery.
Slide 16 :.
The huge challenge for us is to ensure we deliver the year demand without any quality issue
although with the serious retention rate and new board Indonesian workers
Slide 17 :

All Members----Lets act Now!!

Slide 18 :
Our Team Charter.
Is aligned with corporate goal to continue improve our Quality, Cost and OPERATOR competence.
- The goal is to Reduce CQA Failure Rate by 60% on Human Assembly Error by June 2016
- The project scope is on human assembly error and OPERATOR competence on critical
operations mainly on Portable Mid Tier.
Slide 19 :
The Project is align with Sanmina Corporate believe on the quality towards good Resource
Management.
Slide 20 :
Hafsah..how is our current quality performance????

Hafsah Script_ _ _
Slide 21 :
Ladies & gentlement..
I have compile the CQA data from CQA database.
The data will include product name, defect mode and quantity and date.
Slide 22 :
From the data, we found CQA trend showing spike on every quarter end average of 2.5% compare
to normal demand ,the failure rate is only 1.0%.

Slide 23 :
.And the highest contributors is mid tier production line which contribute 39%.
Slide 24 :
The Cost of Poor Quality and Delivery delay has impact to internal stakeholder .
Slide 25 :
And external Stakeholder
Slide 26 :
With the team capability and commitment, we set our aggressive goal:
Reduce CQA Failure Rates By 60%
Slide 27 :
Nisha Hafsah!! Can you explain the CQA test stage?
Slide 28 :
There are 3 main stages been tested..
1st Product functional to test product user interface.
2nd We measure electrical parametric to ensure we meet the product design requirements.
3rd We check for the cosmetic inspection to ensure meet customer expectations .

Nisha : Are these defect able to captured by production?

Slide 29 :
Yes
All the test are similar to factory testing which included Funtional Test ,Final Inspection gate and
Compro label printing stage.
Slide 30 :
Nisha : What is the defects escaped?
From the CQA Defect list ,80 % of human Assembly Errors is able to be detected at final
inspection gate.
Slide 31 :
Nisha : How about Functional Failures escapee?
80% of CQA functionality failure are able to be detected at production functional test.
20% of the CQA defects were contributed from the environmental stress.
Slide 32 :
Nisha : BEST test is fully control by Shop Floor Control system. stage. Why still electrical failure
escaped?

Hafsah Script_ _
We dont capture any electrical failures at initial stage. CQA electrical failures were contributed
from the environmental stress.

Fatimah
Slide 33 :
Hasnida--.Why Escapee Factory Testing although testing is similar with CQA?
We identified, insufficient skillful OPERATOR, training program not effective, no process
classification, poor resource management & SOP procedure not comprehensive are the possible
causes contribute to CQA escapee.
Slide 34 :
From fishbone diagram, team brainstorm 18 possible causes & conclude the 9 possible causes are
TRUE cases base on the team validation.
Lets look into 1st validations
Slide 35
Ladies & gentlement..
In a BEL product, it will required the operator to test manually all the product button functionality.
During validations, I observed that most of the new & transfer operators not familiarize with
products features cause them:
- Not following the test sequence and Skip process
Slide 36
2nd validations done on RESOURCE MANAGEMENT
We will required ONLY skillful and experience operator to perform at Functional, Inspection and
compro stage.
But from the CQA compliance results, it show operator competence is highest contributor which is
45%
Slide 37 :
Hasnida..Who is Big Sister?
Big sister are the senior operators who have been certified to perform a job.
In Sanmina, we appoint big sister to assist and closely monitored the newly hired during on-job
training.
During the normal demand, the ratio of big sister is 1 to 3 new operator under training.
Slide 38 :
Hasnida.. Do we have enough big sister at CQA escapee point?
No..BIG SISTER certification on the CQA escapee point is less than 50%.
Furthermore, only 30% of the populations is been certified to perform >7 processes.
This has cause the limitation to mobilize these operators during quarter end.
This conclude the 2nd validation is true.
Slide 39 :
Hasnida..Why we are always getting newly hired operators?
As EMS company, the manufacturing operating model works as 60% contract workers and 40%
permanent OPERATORs. The resignation of contract workers are not able to control due to contract
nature.
This conclude the 3rd Validation is true.

Slide 40 :
Hasnida.. Fatimah..we use SOP as reference to teach new operator. Whats wrong?
The current SOP is very product specific and does not emphasis the critical quality control of each
process
Therefore we conclude that the 4th validation is true.
We brainstorm on the alternative solutions to overcome the causes.
Slide 41 :
This is the alternative solutions matrix. By brainstorming the advantage and disadvantages of each
possible solutions, the team conclude to explore the experiments on these 4 mains solutions:
1. To Have guided Semi Automated Test system
2. Classification of Each Process
3. Increase the reservoir pool of big sister and certified OPERATORs
4. Training Cook Book by process
Slide 42 :
Nisha What need to be improve

Putt
Slide 43 :
We try to Benchmark on other production line best practices. By looking at CQA defect by
production line, we found that the ASTRO product is having the lowest CQA defects which less
than 10%
NIshaPutt what ASTRO DO Different?
Slide 44 :
ASTRO functional checking station is equipped with embedded instructions.
The monitor screen will prompt a sequence of instruction in order to teach operator how to perform
the test.
The unit will ONLY consider PASS once all the buttons are been pressed and flag as pass in each
every test.
This will eliminate operator from skip process.
Slide 45 :
Fatimah..wow..it would be easy for the operator to test. Lets benchmark.
We begin to clone this poka-yoke feature into the B E L product and did a pilot run..
Fatimah...Pls share the CQA results.
Slide 46 : Fatimah Script
Putt.. We successfully reduce Functional failures from 28% to 3% within a month.
Slide 47 :
With the implementation of Embedded Functional Test at BEL Product, two units of radios be able
to be tested at the same time. This has increase the productivity and reduce cycle time by 50%.
Slide 48 :
With the encouraged positive results, we proliferate and implement across Mid Tier eight products.
Slide 49 :
The team studies the second escapee level at 4 different production lines
There is no significant different on CQA failure rate across these lines bocos these stages required
experienced operators.
We then look into the human development improvement..
Slide 50 :
By looking at process stage, validate 90% of the process are the same.
Slide 51 :
We have sampled 5 newly hired operators (with experience of 2 weeks) to study the manual
inspection effectiveness even with the big sister coaching.
With the collaboration with the Master Black Belt, we study the Attribute Agreement Analysis and
conclude operator still unable to provide consistent results

Hamidah
Slide 52 :
Our second solution, Classifications of the process.
Nisha: Hamidah why we need to classify the process?
Those days min requirements to hire as operator must be a SPM holders.
Today in actual world due to the direct labour limitation, manufacturing industry recruit employee
with ONLY 3M Let me quote in Malay 3M means Membaca, Menulis dan Mengira.
Slide 53 :
The classification of this process been validate by engineering , training and quality team base on
PFMEA method.
From these process breakdown in BEL Product, we conclude 54% process is been classified as
Level1
Operator will 100% fully fixture guided to assembly or test radio.
Slide 54:
3 process under level 2 which is semi guided by fixture / system and required some manual
judgement.
Slide 55:
And 3 processes which required 100% manual judgment with very limited system or fixture guide
fall under level 3.
Slide 56 :
Hasnida..These are the CQA Escapee point right?
Yes..Since process under level 3 contribute highest CQA escape, it was labelled as " Critical
Operations.
Slide 57 :
Hasnida: Hamidah!! What is learning curve
Learning curve is the cycle time required for an operator to learn a process and produce build in
product quality and output efficiently.
In Level1, new operator will able to produce product within an hour
3 days for those products which clasified as level 2.
Min 7 days with additional training to perform process under level 3 which is critical operations.
Slide 58 :
3rd solutions will focus on opportunity to increase reservoir pool. BEFORE..
Only 30% of the populations is been certified to perform >7 processes.
Slide 59 :
Hasnida..What we have done?
Manager done a motivation talk session and explain the benefits to all senior employees to
encourage them to be multi skills.
Some of the benefits include:
Big Sister Club_ Collecting points for every employee been buddy with them
Ist priority for any upgrade

Slide 60 :
After the motivation talk , we can see drastic improvement which is 73 % of employees able to
perform more than 8 processes.
Slide 61 :
Backup pool of critical operations is very important to ensure consistent flawless product shipped.
We achieve minimum required reservoir pool by 3 times back up
Slide 62 :
Hasnida.. Hamidah!!! Any Enhancement done to training processs flow?
Yes. We emphasize the process allocation by level for new hires and condition to allow Operators to
perform level 3.
Slide 63 :
IN our 4th Solutions, the process engineering team compile all the lesson learnt in each process and
develop a cook book by process.
Hasnida.. What is COOK BOOK? Nasi Kandar recipe?
Hahah!! This is NOT a recipe for cooking but recipe to perform job at a each process and uploaded
in Sanmina Web for easy retrieval.
Slide 64 :
This is one of the example of cook book which emphasis do & donts
Hafsah..How is our governance process?
Slide 65 :

Hafsah Script_ _ _
Hamidah..Impressive results.
When we audited the line after the Process classifications, we see drastic improvements.
The task Leader be able to locate the newly hired OPERATOR at level 1 and ONLY certified
OPERATORs is been placed at Critical operations
Slide 66 :
Allow me to re-cap the improvement done. We have successfully implemented:
Embedded Functional Test
Classifications Of Process
Increased Reservoir Pool
Cook Book
Hafsah..How is the current CQA trend?.
Slide 67 :

Hafsah Script_ _ _
Hamidah, we successfully reduce the CQA failure rate by 80%..which exceeded our initial goal of
60%..

Michael Script_ _ _
Slide 68 :
We have save cost avoidance of total RM128K on COPQ improvement & training hours
Slide 69 :
Hasnida..Are we prepared for next quarter end with 65 OPERATORs end contract this Sept?
Hasnida.. Michael..YES WE DO
I dont have to worry about this any more!
Since our process break into Level category and Level 1 contribute 53%, I dont have to spent much time to
train them.
Slide 70 :
These are the Benefit Gain by Stake holder. They are happy with flawless quality delivery on time
Slide 71 :
With great teamwork, we manage to gain lots of valuable knowledged
Slide 72 :
The spider chart shows that Our Team member Capability capability are increased after the project
completion.
Slide 73:
These are some of intangible benefits gained by team. Depth understanding on DMAIC approach,
implementation of Kaizen and enhance our knowledge on human development training.
Slide 74 :
Hasnida.. How Do We Guarantee Performance
Slide 75 :
We continue motivate other shift and increase the reservoir pool
QA team will continue their routine audit and provide feedback.
Slide 76 :
We also implement Color badge by each level certification for visual identifications.
Slide 77 :
We proliferate these project across all the 4 crews and clone to other production lines.
Slide 78 :
Before end the project, let us re-cap the project summary.
We defined through team charter, measure through base line, analyze through Digital Six Sigma
Tools, Improve through process and control through standardize process
Slide 79 :
Thank You.