Abstract
The case company is a professional connector supplier, proving design and manufacture of connectors to world famous ODM in Taiwan, Mainland China, Korea, United States and etc. These ODM produces consumer electronics products like note book, mobile phone, camera, LCD TV, and so forth. Power jack connector is the breadwinning product of S company, which owns over 50% world -wide market share of notebook. In 2009, a new-developed connector, power jack with wire, encountered malfunction problem, causing whole note book shut down. It was a crisis, 3.2 million NT dollars of quality lost per month, customer threatened cancelling the order. Top management had immediately joined the crisis control and led a Six Sigma team to work out the solution. This thesis introduces the process of the case company using DMAIC approach to improve the malfunction of wired power jack connector. In this case, not only 3.2 million NT dollars quality lost per month was saved, but also gained extra 15million NT dollars order per month. The Six Sigma team initially utilized CTQ tree to determine the critical-to-quality characteristics based on customer’s requirements, hence found the measurable main process output variables accordingly. Consequently, performing Measurement System Analysis to make sure that the data obtained in the case study was convinced, and reviewed existed process capability. Through methodology analysis, main process input factors were determined and improved, the defect rate was reduced from 1433 dppm to 564dppm (dppm represents defect part per million). Further ahead, poke-yokes were applied and lowered the defect rate to 68dppm, customer was satisfied. Herein, the fool proof “low pressure molding technique” applying on the wired power jack connector got poor yield rate in the beginning, the Six Sigma team adopted Taguchi methods to work out the optimal molding parameter combination, successfully promote the yield rate to 99% and above. Finally, the Six Sigma team recommended the case company to launch DFSS approach in the beginning of product development. Designing customer’s requirements into products in early development stage so that quality lost will be saved.