Characterization of the server repair process in a manufacturing plant

Abstract

This research presents the characterization of the repair process followed for the server PCB component by the production department, the results of the determination of a false failure and its impact on the DPPM metric in its NFF categorization. After the use of the DMAIC methodology, value flow maps and the characterization of variables, it was possible to identify physical differences between the test methods executed by the different departments involved in order to obtain a false failure result at the end of the process. It is inferred in the results of the DPPM measurable and its NFF categorization after performing the actions of the DMAIC methodology reviewed in the research. In determining the sample size, the two-year history was taken into account as a decisive factor. An action plan was developed for each difference situation, new control documents were added to existing processes, and measurement tools and test methods were standardized across all departments to reduce the possibility of variation in the final results of false failure determination. These changes generate benefits such as improved information recording, improved repair process, increased repair assertiveness effectiveness, improved repair times, improved DPPM metrics in the NFF portion, minimized storage costs and reduced waiting times in a return and repeat environment.