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OptimizeNewAIOCMFDesignProcess

LeanSixSigmaGreenBeltProject

ProjectLeader:WebberGuo

ProductivityChampion:JudyJiang

ProjectSponsor:HongLeiZhu

ProjectMentor:WesleyWang

ProcessOwner：

Finance:YanChenProjectKick-offJuly24,2014TRACtionProjectID#528-927886-UpCharterProjectBasics:BusinessFunction:

DTDLInnovationFunctionalGroup:LenovoDesktopSchedule:June172014toNov2015Leader:

WebberGuoManager:ZhuHongleiTollgateApprover:WesleyWangProblemStatement:RepeatingtechnicalproblemswithnewCMFresultedinprojectsscheduledelay.TheseproblemscannotbedetectedinDevelopmenttestingwithoutpre-study&validation.CurrentlythereisnodefinedandutilizedE2EprocessutilizingnewCMFdesignprocess.SMARTGoal:ThepurposeofthisprojectistoimplementannewAIOCMFdesignprocesswhichphaseinallnewFY14/15PCDAIODesktopproductsbyJanuary2015.InScope:DTAIOwNewCMFOutofScope:DTAIOw/oNewCMFPrimaryMetric(Y)andDefectDefinition:Y=NewCMFMEPartSVTYieldRateYisadefectwhenYislessthan60%Benefits:

ImprovedproductQualityReducedcostandresourcestofixdefectsLowerriskofprojectsscheduledelay2014LENOVOconfidentialALLRIGHTSRESERVEDCoreandExtendedTeamMembers

CrossFunctionNamesRoleResponsibility

R&DDTInnovationProjectLeaderWebberGuoProjectLeaderLeadOptimizeNewAIOCMFDesignProcessProject

R&DDTSLVincentGongProcessOwnerSetupandleadteamforNewProductCMFDesign&maintainprocess

R&DDTTPMZhaoChenxiangCoreTeam

ManagementfortheNewProductDesignQualityrisk

ManagementfortheNewProductDesignAssurancerisk

R&DDTPAYangBaofeng

Quality(PQE)DTWangJD/ZhaoYuGCoreTeamManagementfortheNewCMFProductDesignQualityrisk

ManagementfortheNewCMFMEPartsQualityrisk

MEPEBaiTao

IDCIDZhangJunCoreTeam

ManagementfortheNewProductCMFIDDesign

R&DDTMELiXiaozhongCoreTeam

ManagementfortheNewProductCMFMEDesign

R&DDTMELiuJinpengCoreTeam

ManagementfortheNewProductCMFMEDesign

DefineBackgroundsTomeeteachcycletimeincludingBTS,Holidaycycle,andSpringcycle,NewCMFcan’tbetheprojectgatingissueatSITExitorSVTphase.ProblemsInordertoincreasetheconsumerAIOcompetitiveness&enhanceleadership,marketingrequireconsumerAIOphaseinnewCMF.Buttherearemanyunexpectedissueshappened&egatingissuesofproductdevelopment&TTM/TTV.ProblemsDefinition2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSInScopeAIOProjectsNewIDProjectsNewCMFProjectsOutofScopeTraditionalDTProjectsOldIDProjectsW/ONewCMFProjectsScope2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSSIPOC2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSSuppliersInputsProcessOutputsCustomersInnovationRDN+2/3InnoPlanEarlySystemDesignPlanID/MESLProductStructureNewCMFopportunitySL/MEID/CMFTeamCMFSolutionSystemPlacement

IDSL/MESystemPlacementNewCMFPre-studyReportSLMEMEPre-designTestToolingReportSLODTPre-conceptKOSystemSpecTPMInnoLandingPlanTechSolutionSurveyDraftDesignDetailDesignEngineeringRFIVOCandCTQ2014LENOVOconfidentialALLRIGHTSRESERVED#CustomersRankedVOCCTQs1MarketingPMMarketingandPMhavecomplainedthathaloproductswithnewCMFoftendelayschedule.ProductTTM/TTV2TPMNewCMFofteneprojectgatingissues&can’tbedefectedbeforeSVT.NewCMFrelatedriskmitigation&designcontrol3ODTNeedtomeeteveryprojectschedulekeymilestone.ProductTTMDMAICSSchedule2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSLSSPhaseStartFinishDefineJune17,2014June30,2014MeasureJune30,2014July21,2014AnalyzeJuly21,2014September30,2014ImproveSeptember30,2014Aug15,2015ControlAug15,2015Oct30,2015ShareOct30,2015Nov20,2015StakeholderAnalysis2014LENOVOconfidentialALLRIGHTSRESERVEDStakeholderCommunicationStrategyLevelofInfluenceActionFrequencyR&DDTMEWeeklymeetingHighNewCMFPre-study&TestToolingReportWeeklyIDCIDWeeklymeetingHighNewCMFIDopportunityWeeklyQuality(PQE)E-mailHighQualitySpecBi-WeeklyR&DDTPAE-mailHighTestCaseBi-WeeklyR&DDTTPME-mailHighProjectManagementBi-WeeklyMEPEE-mailMediumManufactureEvaluationBi-weeklyDMAICSCommunicationPlan2014LENOVOconfidentialALLRIGHTSRESERVEDRolesCadenceMethodCoreTeamWeeklymeetings,conferencecalls,andworkshopsasrequiredemails,meetings,interviews,workshops,conferencecallsExtendedTeamMeetings,conferencecalls,andworkshopsasrequiredemails,meetings,workshops,conferencecallsManagementSummaryateachphaseexitProjectupdatesasrequestedemailsandmeetingsBULeadersSummaryateachphaseexitemailsDMAICSMeasureProjectMetric“Y”YisNewCMFMEPartSVTYieldRateY=NewCMFMEPartSVTYieldRateBalanceMetricnewCMFMEpartsqualityshouldmeetLenovoqualityrequirementkeepEarlySystemDesignleadtimeMetricDefinition2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSNewCMFMEPartSVTYieldRateweremeasuredbyPEfromSVT,thedatawascapturedBYMEPEMeasureSystemDMAICSSothesystemisstableandtrusted!DataCollectionPlan2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSDataCollectionPlanMeasureDataSourceHowisDatacollectedWhoCollectstheDataWhenwillDatabeCollectedHowisDataUsedNewCMFMEPartSVTYieldRateMEPESVTAPIMEPE8/10–8/31ComparativeDataCollectionResult2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSNewCMFMEPartSVTYieldRateA740/A540RearCoverHorizon2RearCoverHorizon2sRearCoverYieldRate35%38%50%BaselineandSMARTGoal2014LENOVOconfidentialALLRIGHTSRESERVEDDMAICSNewCMFMEPartSVTYieldRateFinancialBenefitForecast2014LENOVOconfidentialALLRIGHTSRESERVEDSoftSavingSoftSavings=ReduceTime(day)*Human(R）*HRrate（people*year）/workdaySoftSavings=3days*1*20*78K$/Y=18.6K$DMAICSAnalyzeMethodMeasureProcessMaterialManIQCLackofnewCMFexperienceIDLackofCMFexperienceSampletoolingdon’tbuildworkingsampleBottleneckofmeasuremethodIQC&reliabilityspectoolateLackoftesttoolSupplyChainistoolongSDVMachinedon’thavefinishingVendorbaselimitedIDInsistIDrequirementRDinvolvePEStoolateDMAICSSampletoolingquantityisnotenoughRFQassignvendorw/oscoreV–VerylikelyS–SomewhatlikelyN–NotlikelyV–VeryeasyS–SomewhateasyN–NoteasyFishboneDiagramYieldRateIstoolowVendormissT1/T2issuesCauseScreeningDMAICS#ItemHowlikelyisthecausetobeamajorSourceofVariation(SOV)?V–VerylikelyS–SomewhatlikelyN–NotlikelyHoweasywoulditbecontrolledbyR&D?V–VeryeasyS–SomewhateasyN–NoteasyResult1IDLackofCMFexperienceVVVV2IDInsistIDrequirementVVVV3IQCLackofnewCMFexperienceVSVS4VendormissT1/T2issuesVNVN5SampletoolingquantityisnotenoughVSVS6Sampletoolingdon’tbuildworkingsampleVSVS7SDVMachinedon’thavefinishingVSVS8SupplyChainistoolongSNSN9VendorbaselimitedSSSS10BottleneckofmeasuremethodSSSS11LackoftesttoolSVSV12IQC&reliabilityspectoolateVSVS13CMF&RDinvolvePEStoolateVSVS14RFQassignvendorw/oscoreVSVS15161718CauseScreeningDMAICS#ItemHowlikelyisthecausetobeamajorSourceofVariation(SOV)?V–VerylikelyS–SomewhatlikelyN–NotlikelyHoweasywoulditbecontrolledbyR&D?V–VeryeasyS–SomewhateasyN–NoteasyResult1IDLackofCMFexperienceVVVV2IDInsistIDrequirementVVVV3IQCLackofnewCMFexperienceVSVS4SampletoolingquantityisnotenoughVSVS5Sampletoolingdon’tbuildworkingsampleVSVS6SDVMachinedon’thavefinishingVSVS7IQC&reliabilityspectoolateVSVS8RDinvolvePEStoolateVSVS9RFQassignvendorw/oscoreVSVSNeedfindoutrootcause5WhysDMAICSIssue/Cause:IQC&reliabilityspectoolateWhyIQC&reliabilityspectoolate?>Teammemberinvolvetoolate.WhyTeammemberinvolvetoolate?>Definespecatconceptphase.WhyDefinespecatconceptphase?>IDfixedCMFatconceptkickoff.WhyIDfixCMFatconceptkickoff?>PESCMFengineeringpreparationisnotready.WhyPESCMFengineeringpreparationisnotready?>NewCMFCprojecttesttoolingonlycovermanufacture.RootCause:NewCMFCprojecttesttoolingonlycovermanufacture.Issue/Cause:RDinvolvePEStoolateWhyRDinvolvePEStoolate?>IDdon’tinvolveRDuntildraftdesign.WhyIDdon’tinvolveRDuntildraftdesign?>IDonlyinputCMFinforfromCMFteam.WhyIDonlyinputCMFinforfromCMFteam?>ThereisnoCMFengineeringpreparationforPES.WhythereisnoCMFengineeringpreparationforPES?>NewCMFengineeringpreparationafterPES.WhynewCMFengineeringpreparationafterPES?>RDengineeringcprojectkickoffafterPES.RootCause:RDengineeringCprojectkickoffafterPES.2014LENOVOconfidentialALLRIGHTSRESERVEDSummaryofRootCausesDMAICSProblemRootcause1IDLackofCMFexperienceLackofworkshop&informationsharingbetweenteams.2IQCLackofnewCMFexperienceNonewCMFtraining&introductionbeforeDPR.3SampletoolingquantityisnotenoughLimitedresourceatCproject.4Sampletoolingdon’tbuildworkingsampleCurrentCprojectnotdeepenough.5SDVMachinedon’thavefinishingSchedulelimitation.6IQC&reliabilityspectoolateNewCMFCprojecttesttoolingonlycovermanufacture.7CMF&RDinvolvePEStoolateRDengineeringCprojectkickoffafterPES.8RFQassignvendorw/oscorePoorvendorbase&surveytoolate.ImproveorDesignImprove-SolutionsDMAICSProblemRootcauseSolution1IDLackofCMFexp

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