From Paper to Pixels: Improving RF Productivity with Digital Check Sheets and DMAIC

Vollständiger Abstract

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Manufacturing documentation often contributes to process inefficiencies, human error, and productivity constraints within the RF brazing workflow. This study aimed to improve manufacturing documentation at NGK Electronics Devices by replacing manual check sheets with a digital RF Brazing Checksheet System. Guided by the Lean Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework, the study adopted a mixedmethods approach involving observation, time tracking, and user feedback to evaluate the existing process. The main issues identified included lengthy documentation, inaccurate data entry, limited traceability, and inefficient retrieval of historical records. A digital check sheet incorporating autofill, field validation, and expiry alerts was subsequently developed and piloted over four weeks. Following implementation, form completion time decreased by more than 60%, error rates fell by over 80%, and technician workload was reduced. In addition, integrating real-time dashboards and feedback loops strengthened continuous improvement in line with Kaizen principles. The success of the system has prompted plans for broader deployment across additional product lines, including optical parts, as well as possible integration with digital work instructions (WORKI) to support fully paperless operations. The findings demonstrate that lean-driven digital transformation can modernize legacy documentation practices, improve data quality and accessibility, and enhance RF brazing throughput in manufacturing settings. This study also confirms the value of the DMAIC framework for designing, piloting, and sustaining digital interventions on the shop floor, resulting in measurable gains in accuracy, efficiency, and operator experience. Future work will evaluate cost savings, quality yield, and long-term sustainability metrics.