Improve Yield of the Replication Line for DVD9/DVD5 for a Technology Company

Abstract

Abstract ⎯ Replication process is used to mold the disc via injection molding, this process is used for high volume runs due to process stability. Currently the yield of the replication line is around 85-90%, the objective of this project is determine why the line can’t operate at a yield of 90% or greater, if the process is qualified to operate at a 90% process yield in a 4 hours job. The Company needs to determine if the process yield variation shown by the replication line are due to a manufacturing model that forces the equipment operates within transient (unstable) zone for most of the orders processed. The frequency and extend of technology changes, order size and idle time between jobs could be major factors within manufacturing model that affects the process yield. Key Terms ⎯ Injection Molding, Replication process, Transient Zone, Yield.