DFM Improvement Ideas

Index

1 Improvement Ideas
2. MEETING MINUTE

9.Jan.2020
IVI PD ME
 Ideas Improvement
PD ME
CI2VMAFDAG0.BEVNT
Line Daimler OMS Section Assembly Model CI2VMARDAG0.BEVNT Improve Team
Designer

Process TOP & BOTTOM Assembly PIC Due Date

Before After Effect New

 Improvement Point Idea Generation Principle  Effect Unit :person
- Method 2: Divide,Separate (2.1 Divide Separate parts(function)
Ideas Improvements in the process of supplying mechanical
materials to the model Front & Rear camera line Daimler OMS / Skip process
 Improvement Content
MinMax
- Requires supplier separation to 2 this part is 2 different
 Issue materials be store in 2 different boxes and then give line
Loss time to separate materials before assembly

Before After

Signal status
Processing
Complete
Delay

9/1 16/1
 Progress 14/11 8/1

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly Model Improve Team
DC17RTT-DEH.BEVNT1 Designer
New
Process Main label attachment and Packing PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method 5: Change parameter (5.8change thickness,area & size)
Ideas Improved pads for products Daimler E2H
 Improvement Content ST Process Reduction
- Design more handle for pads
 Issue
4.6%↓
Loss time to peel off the pads before boxing (10s)

216

206

Signal status
Processing
Complete
Delay

8/1 9/1 16/1

 Progress 19/11

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly Model Improve Team
DC17RTT-DEH.BEVNT1 Designer
Complete
Process Rear Frame Control PCB Assembly PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method 5: Change parameter (5.4Change direction,angle)
Ideas Improvements in the process of supplying mechanical materials
on the line Daimler E2H  Improvement Content ST Process Reduction
- Redesigned the shape of the car by rotating vehicles from
 Issue horizontal to vertical
2%↓
Worker have to bend over to get supplies and workability difficulties (11s)

536

525

Signal status
Processing
Complete
Delay

8/1 9/1 16/1

 Progress 19/11

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly Model Improve Team
DC17RTT-DEH.BEVNT1 Designer
New
Process Main PCB & FFC Assembly PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :ea
- Method 12: Standardize,Modularize (12.1Let’s modularize
Minimize type for screws on line Daimler E2H
type,size,shape spec of material)
Equipment Reduction
 Improvement Content
 Issue - Minimize the type of screws at assembly stations 50%↓
There are too many types of screws on the product. (1ea driver)
Therefore, the assembly became complicated and cricket confused

Signal status
Processing
Complete
Delay

8/1 9/1 16/1

 Progress 18/11

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly Model Improve Team
DC17RTT-DEH.BEVNT1 Designer
New
Process VCM Membrane Camera assem PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :ea
- Method 13: Prevent (13.3 Prolems occurred in previout step , remove
Preventing the shortage of sensor numbers on LCD assemblies of Increase Quality
or block by filtering)
Daimler E2H products with sensors
 Improvement Content
12ea
 Issue -Add sensor system to detect the number of VCM (sensor detect)
Although the number of VCM is lacking, the system pressure cannot
be detected

12
0

Signal status
Processing
Complete
Delay

8/1 16/1
 Progress 19/11 9/1

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line Daimler OMS Section Assembly Model CI2VMAFDAG0.BEVNT Improve Team
Designer

Process Attach IR Cover Protection Film PIC Due Date New

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method 13: Prevent (13.3 Prolems occurred in previout step , remove
Ideas Improved for sheet patch on line Daimler OMS or block by filtering) ST Process Reduce

 Improvement Content
 Issue - Re-design handle for pads 6.3%↓
Loss time to peel off the pads (3s)

47

44

Signal status
Processing
Part No:RAB35750301
Complete
Delay

8/1 9/1 16/1

 Progress 28/11

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line VW Section Inspection Model OCU3,MQB37W,OCU4 Improve Team
Cold

Process Power PIC Due Date New

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method :17.1 Use intermediaries to complete the function
Improved mounting for scanning guns at Power station
 Improvement Content

- installing a fixed scan gun bracket to auto scan

 Issue
- Fixed Jig 6.8%↓
- Time (6s) (4s)
Workers must use manual the scanner to scan the Wip ID so the scanning
process takes longer. Time (10s)
58.26
sec
54.26
sec

Signal status
Processing
Complete
Delay
13/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
OCU3,MQB37W
Line VW Section Inspection Model Improve Team
OCU4,T-Module Cold
New
Process PinVision PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :
- Method :17.1 Use intermediaries to complete the function
Install more air guns
 Improvement Content

- install more air guns at pinvision

 Issue

There is no air gun at pinvision station Workers must use their mouths to
blow when there are foreign objects.

Signal status
Processing
Complete
Delay
14/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-
Line Daimler E2H Section Assembly Model DEH.BEVNT1,DC17RTT- Improve Team
DEH.BEVNT1 Cold
New

Process Assembly 1 PIC Due Date

 Improvement Point Before Idea Generation Principle After  Effect Effect Unit :
- Method :4.2 Convenient structure change for screw firing
Change the structure of the screw gun
 Improvement Content

- Change screwdriver with guide coordinates

 Issue

Screw gun at Assembly 1 station without guide screw firing coordinates

Signal status
Processing
Complete
Delay
18/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
CF101B-
Line Daimler MPC5.5 Section Inspection Model Improve Team
DAE0.BE1DP72 Cold
New
Process Inspection Image quality PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :
- Method :8.3 Change topology object structure
Add ground wire for the table to wait for product
inspection,Add product layout OK NG and must divide  Improvement Content
each cell clearly - Clear layout from the color of the product that
is waiting to be checked is yellow
 Issue - NG product is red and clearly divided one by
one so that the product does not get bumped
Product table when assembled, there is no clear layout.The NG test into each other.
product does not have a clear location and layout, the NG product is put - Add grounding wires to the table to allow the
together with the finished product. product to wait for inspection

Signal status
Processing
Complete
Delay
20/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-
Line Daimler E2H Section Assembly Model DEH.BEVNT1,DC17RTT- Improve Team
DEH.BEVNT1 Cold
New
Process Scan Out PIC Due Date
 Improvement Point Before Idea Generation Principle After  Effect Effect Unit :sec
- Method :4.2 Convenient structure change for screw firing
Change the location of the scan gun and fix it
 Improvement Content

- Change the location of the Scan gun from

 Issue
under the table, Attach a mount to fix the scan 2,3%↓
Workers have to scan Wip and Main label with their hands, so the
gun (5s)
- Transfer signals from wip stamp scanner to
operation takes a lot of time. Time (20s)
main label stamp scanner. Time (15s)
216s
211s

Signal status
Processing
Complete
Delay
18/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line VW HUD Section Inspection Model HSW01-VW.BEU1 Improve Team
Cold

Process Scan Out PIC Due Date New

Before After Effect
 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method :4.2 change position
Fix scan gun at OOB station for easy operation
 Improvement Content
- Fix the scan gun to the mirror holder to automatically
 Issue scan the main label stamps. Time (3s)
2s
Workers must use their hands to scan the main label stamps. Time (5s)
%

5s
3s

Signal status
Processing
Complete
Delay
21/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
CF101B-
Line Daimler MPC5.5 Section Assembly Model Improve Team
DAE0.BE1DP72 Cold
New
Process Assembly module camera PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :
- Method :6.3 Change Position
Move the tray holder to 7 cm and place the Top Cover
tray at 45 degrees angle  Improvement Content
- Move the stand to 7cm and place the top cover trayin the
direction of 45 degrees
 Issue

Workers must put the top cover tray down at a angle of 0 degrees making
the trayTop cover is easy to fall and hard to get top cover worker. The
distance of the support bar is 10cm, so when placing the tray diagonally at
45 degrees, it will not be placed.

Signal status
Processing
Complete
Delay
26/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
CF101B-
Line Daimler MPC5.5 Section Assembly Model Improve Team
DAE0.BE1DP72 Cold
New
Process All station Assembly PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method :4.4 Change the curved shape
Change the structure of fixed Jig when manipulating
 Improvement Content
- Change the screw fixing position and check the cable on the
conveyor beltenter the 4 concave positions to make sure
 Issue Jig's 4 balls are fixed .Time (2s) 4s
Workers must use pegs and stoppers to fix Jig when firing screws orcable
6.5%
testing takes a lot of time and is difficult for workers.Time (6s)
61s
57s

Signal status
Processing
Complete
Delay
28/11/2019 8/1/2020 9/1/2020 16/1
 Progress
Day of idea Internal DFM Idea Apply plan Date of
found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line Hyundai (IVI_11) Section Assembly Model Hyundai`YBI Improve Team
H.Hung

Process Cable insert & Key PCBA fixing PIC Due Date New

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit : EA
Method 12 Standardize , Modularize (12-1)

Ideas Improvement to improve productivity The Tray in  Improvement Content

Material 157%
Request 4P Supplier Must modularize type, size, shape,spec of
 Issue material / product 66ea/ 1 TRAY

Model: Hyundai`YBI the Tray size is not suitable for

storing PCB Key
4*27=
108
EA/1tray
3*14=42ea
/1tray

3cm
5cm
Record Signal status
Gap
Processing
Complete
Delay

 Progress
12-12-2019 8-1-2020 9-1-2020 16/1

Day of idea found Internal meeting date DFM Idea Meeting date Apply plan recieved Date of application
 Ideas Improvement
PD ME
Line VW AR-HUD ( IVI 24) Section Inspection/Assembly Model HSW01-VW.BEU1 Improve Team
H.Hung

Process Cover Top assembly & Mirror Housing assembly PIC Due Date New

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
Method 5 Change Parameter:5-8 Change thickness, area&size!
Ideas Improvement Change Jack to Materials at Input station  Improvement Content

Change the design size Jack to Material hew down, Woker easy
 Issue assembly Total 2 Station 5%↓
8(s)
Model: HSW01-VW.BEU1 at Input Station using hard input Materials in
assembly. Jack Materials keep out of reach to worker Cover
130s
Cover
Housing 125s
Cover Top assembly Cover Top assembly Mirror Housing assembly
Cover Top assembly Cover Top assembly Mirror Housing assembly 123s
Housing
120s

Signal status
Processing
Complete
Delay

 Progress
21-11-2020 8-1-2020 9-1-2020 16/1

Day of idea found Internal meeting date DFM Idea Meeting date Apply plan recieved Date of application
 Ideas Improvement
PD ME
Line Hyundai (IVI_11) Section Inspection/Assembly Model Hyundai`SP2I Improve Team
H.Hung

Process Input assembly PIC Due Date New

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
Method 1 Delete:1-2 Eliminate function that do not affect the required properties
Ideas Improvement ` protect film hard for Assembly` at  Improvement Content
Input station
Request Supplier Delete-shortcut protect film, Workers easy assembly
 Issue
5%↓
Model: Hyundai`SP2I Reasion using hard protect film (4s)
length, worker open manual input
74s
70s

Signal status
Processing
Complete
Delay

 Progress
13-11-2019 8-1-2020 9-1-2020

Day of idea found Internal meeting date DFM Idea Meeting date Apply plan recieved Date of application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly 1 Model DC17RTT-DE- Improve Team
H.BEVNT1 Roy
New
VCM,Membrace,Camera Assembly
Process PIC Due Date

Before After  Effect Effect Unit :

 Improvement Point Idea Generation Principle
- Method 4 : Change color
1. Change color in screw on camera

 Improvement Content
 Issue
1. Change color in screw for each camera
1. One camera use for 2 Model 2. Mark the position on the Rear Frame with a sticker
3.Easy to see

Signal status
Processing
Complete
? Delay

08/1/2020 16/1 ?
 Progress 28/11/2019 09/1/2020

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly Model DC17RTT-DE- Improve Team
H.BEVNT1 Roy
New

Process VCM,Membrace,Camera Assembly PIC Due Date

 Improvement Point Before Idea Generation Principle After  Effect Effect Unit :(ea)
- Method 4 : Change shape
1. Change from Tray to Car

 Improvement Content

 Issue 1. Set is not redundant outside the Tray

2.Change Tray To Car
1. Set was broken by someone bumping into 3. It's easy to move
2. Dirt may fall into the set 4. Set will be protected better

↓1%
1/100
0%

Signal status
Processing
Complete
?
Delay

08/1/2020 16/1 ?
 Progress 19/11/2019 09/1/2020

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line Daimler MPC 5.5 Section Assembly Model Improve Team
Roy

Process Insert Main Label PIC Due Date New

Before After Effect

 Improvement Point  Effect Unit :sec
Idea Generation Principle
1. The main label area must be correct - Method 5 : Change direction and angle

 Improvement Content
 Issue

1. Insert position on Set with Label must be the same 7s

1. Labeling area does not mark the location of the stickers 20.5%
then will not wrong direction
2. Label may be wrong or in the opposite direction
34s
27s

Signal status
Processing
Complete
Delay

 Progress 28/11/2019 08/1/2020 09/1/2020 16/1 ?

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
DC17LTT-DEH.BEVNT1
Line Daimler E2H Section Assembly 2 Model DC17RTT-DE- Improve Team
H.BEVNT1 Roy
New
Process Rear Frame, Control PCB assembly PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method 4 : Change shape
1. Change color in material

 Improvement Content
 Issue 20s
3.7%
1. Change color in cables(case 1)
1. Same on both cables 2. Mark the position on the Rear Frame with a
sticker(case2)
536s
516s

Signal status
Processing
Complete
Delay

 Progress 14/11/2019 08/1/2020 09/1/2020 16/1 ?

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Damler CF101B-
Line Section Assembly Model Improve Team
MPC5.5 DAE0.BE1DP72 Elsu
New
Process Camara module assy PIC Due Date

Before After Effect

 Improvement Point  Effect Unit :sec
Idea Generation Principle
Resize line - Method 5-6 : Distance change distance
 Improvement Content

 Issue - Design separator bar to

2.1%↓
reduce impact distance
The distance between Jig and the pass is too big (1.3s)

61.
3s
60
s

Signal status
Process-
ing
Complete
Delay
09/01/202
 Progress 20/11/2 08/01/202
0
16/1
019 0

Apply Date of
Day of Internal DFM Idea plan applicati
 Ideas Improvement
PD ME
Damler CF101B-
Line Section Assembly Model Improve Team
MPC5.5 DAE0.BE1DP72 Elsu
New
Process Bottom case fixing PIC Due Date

Before After Effect

 Improvement Point  Effect Unit :sec
Idea Generation Principle
Add a trash can - Method 17.1 : Use intermediaries to
complete the function
 Improvement Content
 Issue 4.1%↓
add carrying case camara
(2s)
No position yet camara protective cap protective cap

48. 46
5 .5
s

Signal status
Process-
ing
Complete
Delay
26/11/2
 Progress 019
08/01/202 09/01/202 16/1
0 0

Apply Date of
Day of Internal DFM Idea plan applicati
 Ideas Improvement
PD ME
Damler CF101B-
Line Section Assembly Model Improve Team
MPC5.5 DAE0.BE1DP72 Elsu
New
Process Assembly PIC Due Date

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec

- Method 17.1 : Use of intermediaries to

add screw tray
complete the function
 Improvement Content
 Issue 40%↓
Tray design for extra screws
(4s)
There is no room for extra screws

10
s 6s

Signal status
Process-
ing
Complete
Delay
26/11/2
 Progress 019
08/01/202 09/01/202 16/1
0 0

Apply Date of
Day of Internal DFM Idea plan applicati
 Ideas Improvement
PD ME
DC17LTT-DE-
Line E2H-Damler Section Assembly Model Improve Team
H.BEVNT1 Elsu
New
Process boxed PIC Due Date

Before After Effect

 Improvement Point  Effect Unit :sec
Idea Generation Principle
Improve safety when handling - Method 17.1 : Use of intermediaries to
complete the function
 Improvement Content
 Issue
one more stop 1.8%↓
(4s)
Boxes are easy to fall off
21
8
21
4

Signal status
Process-
ing
Complete
Delay
18/11/2 09/01/202
 Progress 019
08/01/202
0
16/1
0

Apply Date of
Day of DFM Idea
Internal plan applicati
Meeting
 Ideas Improvement
PD ME
Damler CF101B-
Line Section Assembly Model Improve Team
MPC5.5 DAE0.BE1DP72 Elsu
New
Process Camara module assy PIC Due Date

Before After Effect

 Improvement Point  Effect Unit :sec
Idea Generation Principle
Change Jig fixation pin - Method 17.1 : Use intermediaries to
complete the function
 Improvement Content
 Issue
Replace with auto latch 16.3%↓
Workers take time to lock deadbolt (10s)

61.
3
51.
3

Signal status
Process-
ing
Complete
Delay
20/11/2 09/01/202
 Progress 019
08/01/202
0
16/1
0

Apply Date of
Day of DFM Idea
Internal plan applicati
idea
 Ideas Improvement
PD ME
Line IVI 37 Section Inspection/Assembly Model DC17LTT-DEH.BEVNT Improve Team
John

Process Top case & Heat Sink Assembly 1 PIC Due Date Complete

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method 4: Change shape.4-3 :Change shape,
structure and type
- Change the structure of containers
 Improvement Content

- Design the baby tray back to fit with

 Issue
camera 0,5%↓
- The camera in the tray is down and tilted. Workers have (3s)
difficulty managing to remove the camera from the tray.
536s
533s

Signal status
Processing
Complete
Delay
13/11/2019 8/01/2020 9/01/2020
 Progress 16/1

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line IVI 37 Section Inspection/Assembly Model DC17LTT-DEH.BEVNT Improve Team
John

Process Top case & Heat Sink Assembly 1 PIC Due Date Complete

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method5:Parameter change 5-8: Change thick-
ness, area and size
- Design extra handles for the camera’s stickers
 Improvement Content
- Supplier additional handle at the protective sticker for workers
 Issue to easily manipulate 40%↓
(0.9s)
Workers have difficulty removing protective stickers from cameras.

536s
531s

Signal status
Processing
Complete
Delay
19/11/2019 8/01/2020 9/01/2020
 Progress 16/1

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
 Ideas Improvement
PD ME
Line IVI 37 Section Inspection/Assembly Model DC17LTT-DEH.BEVNT Improve Team
John

Process Main PCB & FFC Assembly PIC Due Date Complete

Before After Effect

 Improvement Point Idea Generation Principle  Effect Unit :sec
- Method4:Change the shape 4-3 :Change shape,
structure and type
- Change the structure of the cable  Improvement Content
 Issue - The supplier folds the cable before
delivering it to LG 2,26%↓
- This stage, workers have to fold the cable. Workers
(10s)
folding cable can be deflected, broken.

442s
432s

Signal status
Processing
Complete
Delay
18/11/2019 8/01/2020 9/01/2020
 Progress 16/1

Day of idea Internal DFM Idea Apply plan Date of

found meeting date Meeting date recieved application
Meeting Minutes 10/1(Fri)

Date/Location • Date: 9/1/2020 (Thur) 10:00 – 11:50

• Location : IVI PD Investigate Room

• Attendee: 14 People
• 1: IVI PD:- Part leader: Mr. Duong
• ME member: Truong, Ha Hung, Manh Hung,
Linh, Minh, Dinh (6 명 )- Mr. Jowoon, Ms. Thanh
Attendee
• 2 : ME MFG Team: Ms. Bui Thi Thao (thao.bui)
PE Team: Mr. Nguyen Hong Son (hongson.nguyen)
Mr. Pham Van Hung (vanhung.pham)
Procument Team: Ms. Bui Mai Linh (linh.bui)
IVI Production team: Mr. Cao Tien Dat (dat.cao
• Meeting Contents: Reviewing DFM Improvement Ideas
to discuss validity and PIC of the ideas.
PIC review ideas then give comment,PD ME summary comment
then follow
Date Jan 9th, 2020
Contents Time 10 AM
Content DFM Idea review
Location IVI R&D Investigation room
(at corridor Besides IVI PD)
Participant IVI PD, IVI MFG, IVI Proc.
IVI MAT, IVI PE, IVI QA