PV chart management innovation based on production balance ratio: a case study of Company S's GaAs process improvement for compound semiconductors

In today's highly competitive manufacturing environment, continuous improvements in production efficiency play a crucial role in enhancing engineering value. This research paper presents a case study of Company S, a global leader in the production of gallium arsenide, to investigate methods for improving production efficiency. The study utilizes the eliminate, combine, rearrange, and simplify methods along with the line balancing rate to identify bottlenecks and minimize abnormalities in the manufacturing process. Furthermore, process management theories are employed to develop and implement the production value (PV) chart, which visualizes process management for improved production balance rates and reduced operating costs. The results indicate a significant increase in monthly production capacity (42%), a reduction in labor costs (20%), and a decrease in lead time (5 working days) through the adoption of the PV chart. This research demonstrates that the combination of the PV chart and process management theories provides a valuable tool for visualizing and improving process management not only in the semiconductor industry but also in other industries. The proposed method offers opportunities for reducing lead time, direct processing costs, direct material costs, and increasing productivity.