Improving installing time for new machine by lean application: A real case study in Intel VNAT

Abstract

Viet Nam Assembly and Test (VNAT) factory started to produce chipset products for Intel Global since 2010. Currently, VNAT is considered as a ramp up site delivering 70% finish-good across a virtual factory of Intel over the world. In order to increase the factory capacity, several factors need to be considered, including shifting tools from another Intel site to VNAT. Once the new tool arrives, it needs to go through the installation and qualification (IQ) process as fast as possible. This thesis is dealing with the IQ process of ACL tool, one of the most critical tool used in the production. While ME (module engineer) from another Intel site performed IQ for ACL (a special tool used for the function of loading production substrates from trays into carriers operation at Intel) within approximately 7000 minutes (116 hours), VNAT spent 8100 mins doing the same job. Thus, this thesis applied Lean tools and techniques to help VNAT ME shorten the IQ time for the ACL tools. 5S, Single-Minutes-Exchange of Dies (SMED), Standard Work Instruction (SWI), Process Mapping have been applied successfully in this thesis project. Keywords: Lean, SMED, SWI, Installation, Qualification, 5S, Manufacturing. Tool ACL module Material Handling System (MHS) is specific area to do a study.