# data[].attributes.headline
Packing Method Change for QT01004-187-CE

# data[].attributes.subject
Packing Method Change for QT01004-187-CE

# data[].attributes.body
Improved productivity by eliminating cable bending and simplifying material handling.

# data[].attributes.headline
37°C Match-Point Routing Optimization in QT06020-151

# data[].attributes.subject
37°C Match-Point Routing Optimization in QT06020-151

# data[].attributes.body
Elimination of non-value-added operations while maintaining compliance with customer requirements.

# data[].attributes.headline
Kaohsiung: Improvement of 291 washer and shaft pressing workstation

# data[].attributes.subject
Kaohsiung: Improvement of 291 washer and shaft pressing workstation

# data[].attributes.body
Issue： When the washer and shaft are inserted and stamped together, sometimes the locating pin may come loose, causing dimensional defects.

Solution： Change the flat locating pin to a threaded locating pin.

Result： After the improvement, it is not only easy to fine-tune the size but also prevents it from becoming loose.

# data[].attributes.attachment_link.title
Quality improvement of 291 washer and shaft pressing workstation

# data[].attributes.headline
Kaohsiung: 500&003 Element scanning process changed from manual to automated

# data[].attributes.subject
Kaohsiung: 500&003 Element scanning process changed from manual to automated

# data[].attributes.body
500&003 Element scanning process require 1 operator to perform manual work. The SC & AD team identified a cost-saving opportunity by automating the feeding process of the sensor element scanner, reducing manual labor.

Result:

With an annual demand of 1720K pcs, this transformation resulted in total cost savings of USD 21.7K.

# data[].attributes.attachment_link.title
500&003 Element scanning process changed from manual to automated

# data[].attributes.headline
Eliminating motion waste at the point of use

# data[].attributes.subject
Eliminating motion waste at the point of use

# data[].attributes.body
With a simple improvement, we eliminated unnecessary trips, reduce non- productive time and ensured that the material was organized, identified and available exactly where it is needed.

An activity that generated daily trips was identified, and from a Lean perspective, we found a clear motion waste (MUDA), as it was an activity that did NVA to the product.

The solution was to bring the materials to the Point of Use (POUS) by placing bins for each packaging model.

# data[].attributes.attachment_link.title
Kaizen_Card___AUG26 -L3 L1-Bins for bags

# data[].attributes.body
PZT quality improvement

# data[].attributes.body
The Kaizen project from design team

# data[].attributes.attachment_link.title
Kaizen Card  MCD Design& Process development

# data[].attributes.body
Objective:

• Improve detection of TPA connector

Process Risk:

• Send TPA closed to customer, this affects their assembly process.

Solution:

•Change current mechanical detection of TPA for a height sensor.

# data[].attributes.headline
Elimination of Non-Value-Added Parylene Coating Operation

# data[].attributes.subject
Elimination of Non-Value-Added Parylene Coating Operation

# data[].attributes.body
Eliminated a non-value-added coating process, reducing cost and improving manufacturing efficiency without impacting product functionality.

# data[].attributes.attachment_link.title
Elimination of Non-Value-Added Parylene Coating Operation

# data[].attributes.headline
Point-of-Use Bin System for Part Segregation and Defect Stratification

# data[].attributes.subject
Point-of-Use Bin System for Part Segregation and Defect Stratification

# data[].attributes.body
Introduced a point-of-use bin system to improve part segregation, eliminate unnecessary motion, and provide defect stratification to support scrap reduction initiatives.

# data[].attributes.attachment_link.title
Point-of-Use Bin System for Part Segregation and Defect Stratification

# data[].attributes.body
An effort to create an organized area to dispense cable efficiently for multiple jobs.

# data[].attributes.body
Use this format to upload Kaizen Activity.

Preference use English language.

# data[].attributes.headline
Modification of the painting process for polyamide tubes used in products for Flextronics.

# data[].attributes.subject
Modification of the painting process for polyamide tubes used in products for Flextronics.

# data[].attributes.body
After mapping the production process during Libor's visit, we implemented improvements that have increased efficiency and shortened the one-piece flow cycle time.

# data[].attributes.attachment_link.title
Modification of the painting process for polyamide tubes used in products for Flextronics

# data[].attributes.headline
Matamoros - 702 Line Uptime Improvement Through Reliability Enhancements

# data[].attributes.subject
Matamoros - 702 Line Uptime Improvement Through Reliability Enhancements

# data[].attributes.body
Kaizen 702 – Improve 5% Uptime

By applying Lean Manufacturing principles and focusing on equipment reliability, this Kaizen eliminated recurring sources of unplanned downtime on Line 702. Through targeted improvements to critical stations, the team increased process stability, improved Overall Equipment Effectiveness (OEE), and unlocked additional production capacity without capital investment. This initiative not only supports Operational Excellence objectives but also delivers sustainable cost savings through higher throughput and waste reduction.

#LeanManufacturing #OperationalExcellence #Reliability #OEE #ContinuousImprovement #CostReduction #Kaizen

# data[].attributes.attachment_link.title
702 Line Uptime Improvement Through Reliability Enhancements

# data[].attributes.headline
Matamoros - 781 Capacity Increase Through Cycle Time Reduction

# data[].attributes.subject
Matamoros - 781 Capacity Increase Through Cycle Time Reduction

# data[].attributes.body
Kaizen 781 – Improve Capacity

This Kaizen demonstrates how Lean thinking can drive significant capacity gains through cycle time reduction and motion optimization. By eliminating bottlenecks, improving workstation design, and streamlining machine sequences, the team increased hourly output while maximizing the use of existing resources. The result is a more efficient process, improved productivity, and a direct contribution to Operational Excellence and cost competitiveness.

#LeanManufacturing #CycleTimeReduction #CapacityImprovement #OperationalExcellence #Productivity #ContinuousImprovement #CostImprovement #Kaizen

# data[].attributes.attachment_link.title
781 Capacity Increase Through Cycle Time Reduction

# data[].attributes.headline
Matamoros - Reduce Frequency of destructive test on 648 due CAN revision

# data[].attributes.subject
Matamoros - Reduce Frequency of destructive test on 648 due CAN revision

# data[].attributes.body
Optimizing Quality Controls Through Data-Driven Decisions

Since 2018, CTS-MAT maintained a containment action consisting of one destructive inspection per shift to verify the integrity of the connector terminal assembly and CAN-L trace. After nearly eight years of monitoring, no recurrence of the original quality issue and no PCA-related defects were identified.

Based on this proven process stability, the inspection frequency was optimized from one sample per shift to two samples per week, maintaining quality assurance while eliminating unnecessary destructive testing.

This improvement reduces quality sample scrap, optimizes inspection resources, and generates an estimated $6,000 USD in annual savings, demonstrating how periodic review of legacy controls can uncover opportunities for continuous improvement without compromising product quality.

Results:

✅ Maintained process control and product quality
✅ Reduced destructive test scrap
✅ Optimized quality resources
✅ Annual savings of $6,000 USD
✅ Data-driven continuous improvement initiative

#Kaizen #ContinuousImprovement #Quality #CostReduction #OperationalExcellence #CTSMatamoros

# data[].attributes.attachment_link.title
Reduce Frequency of destructive test on 648 due CAN revision

# data[].attributes.headline
Matamoros - Reduction of Energy Consumption in All Areas

# data[].attributes.subject
Matamoros - Reduction of Energy Consumption in All Areas

# data[].attributes.body
Driving Sustainability Through Operational Excellence

A plant-wide effort focused on eliminating unnecessary energy consumption resulted in a 5.1% reduction in electricity usage while maintaining production performance. The combined efforts of all departments helped save more than 208 MWh and $52,000 USD in six months, reinforcing our commitment to Operational Excellence, cost competitiveness, and environmental sustainability.

# data[].attributes.attachment_link.title
Reduction of Energy Consumption in All Areas

# data[].attributes.body
Kaizen from the event we held on July 17th for the Hydrophone line.

Thank you, everyone, for your engagement, active participation, and passion for continuously improving our processes. Your teamwork and commitment were key to the success of this Kaizen event, and the results reflect the great effort made by everyone involved.

Let's keep the momentum going and continue driving improvements together!

# data[].attributes.headline
Automation of RJ45 Cable Jacket Stripping to Improve Safety and Productivity

# data[].attributes.subject
Automation of RJ45 Cable Jacket Stripping to Improve Safety and Productivity

# data[].attributes.body
Cable jacket stripping for RJ45 cables (H814, H824, H611, H933, and H953) was previously performed manually using cutter blades. This process was time consuming, limited productivity, and exposed operators to the risk of hand injuries while also causing inconsistent stripping quality that could lead to rejects.

To mitigate these issues, an automatic cable stripping machine was implemented to automate the cable jacket removal process. The improvement increased productivity from 40 UPH to 150 UPH, reduced processing time by 173.25 hours per year, improved stripping consistency and product quality, enhanced operator safety by eliminating cutter blade use, and generated annual labor savings of $1,701.32 plus $32.40 in reject cost savings.

# data[].attributes.headline
Kaohsiung: 291 PCB & COVER heat sealing changed from manual to automated

# data[].attributes.subject
Kaohsiung: 291 PCB & COVER heat sealing changed from manual to automated

# data[].attributes.body
291 PCB & COVER heat sealing require 2 operators to perform manual work. The SC & AD team members find a cost saving opportunities, add an automated conveyor mechanism to allow one person to operate two workstations.

Result:

Reduce one operator and cost saving USD 8.9K per year.

# data[].attributes.attachment_link.title
291 PCB & COVER heat sealing changed from manual to automated

# data[].attributes.headline
Kaohsiung: Improvement of Base-rail tin plating defects

# data[].attributes.subject
Kaohsiung: Improvement of Base-rail tin plating defects

# data[].attributes.body
Analysis confirmed that the tin plating process was replaced with a heating system. The titanium rod, due to heating, lengthened and deformed into an arch shape, leading to a significant reduction in contact area and causing a circuit break.

Result：The titanium rod was shortened by 2mm and the surface was re-polished. Production continued and the problem of incomplete plating was not observed again after half a month of monitoring. Please refer to next four pages for illustration.

# data[].attributes.attachment_link.title
Improvement of Bserail tin plating defects

# data[].attributes.body
During 2025 Albuquerque plant had to remodeling bathrooms and we went in may to implement different items that support our employees working in Foundry area, to maintain the cleanness and the organization in the new bathrooms

# data[].attributes.headline
5 S tooling set organization - Albuquerque

# data[].attributes.subject
5 S tooling set organization - Albuquerque

# data[].attributes.body
Albuquerque team were focused to improve the tooling organization on pressing area

# data[].attributes.headline
ZHO-Punch fixture linear encoder setting improvement to prevent safety accident

# data[].attributes.subject
ZHO-Punch fixture linear encoder setting improvement to prevent safety accident

# data[].attributes.body
Enlarged molding pin punch fixture linear encoder to eliminate the gap between linear encoder and working table to prevent operator injury.

# data[].attributes.attachment_link.title
Molding punch fixture of pin insertion error-proof improvement

# data[].attributes.body
Review scan data, optimized the SSPSS setting from 80/40 to 81/40.5

, eliminated the failure and scrap

# data[].attributes.headline
ZHO-551 series pedal output correlation failure improvement

# data[].attributes.subject
ZHO-551 series pedal output correlation failure improvement

# data[].attributes.body
Defect description：

From March 2026, 551 output correlation with high defect rate continuously, On index position, the correlation sudden drop 0.2°-1°(see the below picture) and exceeded the idle SPEC ±1%.

Result:

After improved the rotor convex position, the total output correlation defect rate will be reduced to 0.05%.

# data[].attributes.attachment_link.title
551 Output Correlation Failure improvement - ^6.17)

# data[].attributes.headline
Guide Mide to optimize plating process for KSN6888A

# data[].attributes.subject
Guide Mide to optimize plating process for KSN6888A

# data[].attributes.body
Yield continuous improvement

# data[].attributes.attachment_link.title
Kaizen_Card___Guide Mide to optimize plating process for KSN6888A

# data[].attributes.headline
Process Optimization for Composite PZT KSN300141A of Wuhan United Imaging

# data[].attributes.subject
Process Optimization for Composite PZT KSN300141A of Wuhan United Imaging

# data[].attributes.body
Process continuous improvement!

# data[].attributes.attachment_link.title
Kaizen_Card___Composite PZT KSN300141A of Wuhan United Imaging Process Optimization

# data[].attributes.attachment_caption
CER0398A laser defects reduction by Precise PVA spraying volume control

# data[].attributes.headline
CER0398A laser defects reduction by Precise PVA spraying volume control

# data[].attributes.subject
CER0398A laser defects reduction by Precise PVA spraying volume control

# data[].attributes.body
Time Waste reduction by digital way

# data[].attributes.attachment_link.title
Kaizen Card  RF CER0398A laser defects reduction by precise PVA spraying volume control

# data[].attributes.headline
Reduction of Terminal Misplacement Through Fixture-Based Assembly Guidance

# data[].attributes.subject
Reduction of Terminal Misplacement Through Fixture-Based Assembly Guidance

# data[].attributes.body
Enhanced assembly consistency by providing clear terminal positioning guidance

# data[].attributes.attachment_link.title
Reduction of Terminal Misplacement Through Fixture-Based Assembly Guidance

# data[].attributes.headline
Washing baskets with internal lining for Brandsonic

# data[].attributes.subject
Washing baskets with internal lining for Brandsonic

# data[].attributes.body
This result not only represents a 32.6% reduction in scrap and approximately $900 USD in monthly savings, but also reflects our employees’ commitment to continuous improvement.

The opportunity was identified during Gemba Walks focused on detecting Lean wastes, and the solution was developed and implemented by the production team itself. This Kaizen demonstrates how employee engagement can drive meaningful business improvements without capital investment, while strengthening a culture where everyone is empowered to identify opportunities, eliminate waste, and continuously improve our processes every day.

# data[].attributes.headline
ZHO-Re-use obsolete 706 recycle-bin for urgent delivery and cost saving

# data[].attributes.subject
ZHO-Re-use obsolete 706 recycle-bin for urgent delivery and cost saving

# data[].attributes.body
Re-used 600pcs obsolete 706-99-047GD recycle bin to 706-99-047ID through removed and re-printed CTS Code defined by customer, cost saving $9,972. this action was completed by ZHO WH and line operators.

# data[].attributes.attachment_link.title
Kaizen Card - Re-used obsolete 706 recycle bin for cost saving

# data[].attributes.headline
ZHO-810 over-molding valve pin lifecycle improvement 

# data[].attributes.subject
ZHO-810 over-molding valve pin lifecycle improvement 

# data[].attributes.body
The over-molding valve pin lifecycle improved from 20-30k cycles to more than 100k cycles through sourcing new supplier with different raw material and new surface coating material.

# data[].attributes.attachment_link.title
810 over-molding Valve Needle Improvement

# data[].attributes.headline
ZHO-551/552 contactor feeding abnormal improvement 

# data[].attributes.subject
ZHO-551/552 contactor feeding abnormal improvement 

# data[].attributes.body
Through modification to the contactor vibration feeder to eliminate the gap to improve unstable feeding from 5% to 1%

# data[].attributes.headline
ZHO-330 cover slight collision with rotor improvement

# data[].attributes.subject
ZHO-330 cover slight collision with rotor improvement

# data[].attributes.body
Through adding guiding mechanical device to improve cover slight collision between cover and rotor during cover loading process, occurrence frequence improved from 5% to 0%

# data[].attributes.body
Safety is Our Priority!

# data[].attributes.attachment_link.title
Kaizen Card - Lack of exhaust ventilation for the oven in  Knock Sensor area

# data[].attributes.body
Safety is Our Priority!

# data[].attributes.attachment_link.title
Kaizen Card - Lack of exhaust ventilation for the oven in the element room area

# data[].attributes.body
Use this format to upload Kaizen Activity.

Preference use English language.

# data[].attributes.body
Design, production and implementation of a new visual quality control board. Defines production workstations, catalogs ceramic defects, and identifies their point of origin. The modular solution allows for the rapid addition, removal, or replacement of any images and cards.

# data[].attributes.body
The problem with the planets sticking to the grinding plate was solved by adding protrusions to the planet.

# data[].attributes.body
It was necessary to do a general cleaning and set up a regular weekly cleaning due to the increase in reworks due visual defects (hairs, fibers and other impurities in the electrode on the ceramic). At the same time, a new standard for clothing was introduced.

The cleaning was finished in one section and will continue across the entire production, regularly and repeatedly.

# data[].attributes.headline
Kaohsiung: Reduce Cost of resin for plating lines

# data[].attributes.subject
Kaohsiung: Reduce Cost of resin for plating lines

# data[].attributes.body
Installed a dedicated DI water purification unit in the QA laboratory (NT$38,300 investment). This reduces dependency on the plating line resin system and achieves an estimated annual maintenance cost saving of NT$93,350.

# data[].attributes.headline
Kaohsiung: 206-OPF Safety Improvement for Automated Equipment

# data[].attributes.subject
Kaohsiung: 206-OPF Safety Improvement for Automated Equipment

# data[].attributes.body
Issue： When an operator uses manual mode for product retesting, the oven sensor may incorrectly trigger the discharge gripper, resulting in unintended movement and a potential safety risk.

Solution： The AD team modified the control program and added an HMI option that allows the oven discharge gripper to be disabled during manual retesting.

# data[].attributes.attachment_link.title
206-OPF Safety Improvement for Automated Equipment

# data[].attributes.headline
Return Mechanism Implementation – Terminal Bender (P/N 7310)

# data[].attributes.subject
Return Mechanism Implementation – Terminal Bender (P/N 7310)

# data[].attributes.body
The operation required a full 180° lever movement, adding unnecessary motion, operator fatigue, and inefficiency.

This Kaizen reduced the lever travel to the minimum required range, eliminating excess motion and enabling a more efficient Standard Work.

As a result, cycle time was reduced by 20%, while improving ergonomics, consistency, and operator performance.

# data[].attributes.body
Use this format to upload Kaizen Activity.

Preference use English language.

# data[].attributes.body
6S Kaizen added.

Libor, thank you for your advice.

# data[].attributes.headline
Pneumatic tool for the “MicroWelder” welder.

# data[].attributes.subject
Pneumatic tool for the “MicroWelder” welder.

# data[].attributes.body
Another simple tool created by our maintenance department to improve the quality of welding operations. We are reducing the number of steps performed by the operator, which speeds up the welding process.

# data[].attributes.attachment_link.title
Pneumatic tool for the “MicroWelder” welder

# data[].attributes.headline
Replacement of High Temp Tape with Mechanical Stopper

# data[].attributes.subject
Replacement of High Temp Tape with Mechanical Stopper

# data[].attributes.body
The use of high temperature tape as a measurement starting reference has been eliminated and replaced with a reusable mechanical stopper (magnetic ruler stopper). This improvement removes repetitive tape application, reduces operator handling, and standardizes the measurement reference point across all operators.

As a result, the process achieved 100% elimination of tape usage for this application, reducing consumption by approximately 475.54 meters per month (9.51 rolls/month).

Overall, the improvement expected to generates an estimated annual savings of $111.30, consisting of both material and labor cost reductions, while also enhancing process standardization and stability.

# data[].attributes.headline
High Motion Waste During Tube Issuance (Stockroom)

# data[].attributes.subject
High Motion Waste During Tube Issuance (Stockroom)

# data[].attributes.body
The tube issuance process was improved by introducing a modified tube rack with an integrated table and hanger for fast moving tubes to reduce unnecessary movement from stockroom personnel. Previously, the process required multiple trips between the tube rack and working table, resulting in a total cycle time of 91.80 sec/ft.

Based on the total tube issuance volume of 16,104 ft record, the improvement generated an estimated annual labor time saving of 222.87 hours, equivalent to approximately $372.20.

This improvement enhanced operational productivity by minimizing travel distance, reducing motion waste, and shortening tube issuance lead time.

# data[].attributes.body
Making a better drying rack for buckets. Larger capacity, faster loading, moveable to be wherever you do the cleaning.

# data[].attributes.body
Basic kaizen activity to improve efficiency when manipulating tools and parts at spray dryer.

# data[].attributes.body
Improvement of 6S conditions by securing and repositioning bins to enhance organization and reduce contamination risk.

# data[].attributes.headline
Visual Management and 6S Bin Support for Temperature Bath Module

# data[].attributes.subject
Visual Management and 6S Bin Support for Temperature Bath Module

# data[].attributes.body
Implementation of visual management and bin support to standardize organization, reduce search time, and eliminate waste in the Temperature Bath Module.

# data[].attributes.attachment_link.title
Visual Management and 6S Bin Support for Temperature Bath Module

# data[].attributes.body
Store more wheels but find the right wheel quickly

# data[].attributes.body
visual management to avoid the fixture choose mistake

# data[].attributes.body
In  874, a rivet breaking test was performed, during the test, an unsafe condition was detected and reported to the Safety and Engineering department, with the objetive of eliminating the condition.

After revision, the Maintenance People  install a security guard eliminating unsafe condition.

# data[].attributes.headline
Reduction of energy consumption in the centralized Motan system

# data[].attributes.subject
Reduction of energy consumption in the centralized Motan system

# data[].attributes.body
Reduction of 16.4°C (30%) in heat emission in the hot air duct distributed to the 12 drying hoppers, this could reduce energy consumption by 25%.

# data[].attributes.headline
Machine inefficiency during model changeovers, currently averaging 63 minutes per part number (P/N)

# data[].attributes.subject
Machine inefficiency during model changeovers, currently averaging 63 minutes per part number (P/N)

# data[].attributes.body
-Change Over - Alignment time was reduced by 15 minutes compared to the current condition.

-Non-optimal machine conditions were corrected, improving overall equipment

efficiency (Button, conector, Andon System)

-The delay time was adjusted to allow operator access to the machine with Secutiry

# data[].attributes.attachment_link.title
Kaizen Card Mar26 MM0044 Improve machine efficiency

# data[].attributes.body
Robot station installed on the vertical machine MM-0022, operating automatically, the robot places the rods in the mold and removes the parts after over molding, finally placing them in a container for storage and disposition to the next process

# data[].attributes.body
Eliminating waste about: Transferring & movements., increasing output of the line.

# data[].attributes.attachment_link.title
Kaizen Card - 781 Performance         4 27 2026

# data[].attributes.headline
Eliminate excess flash rework in 880-02-001

# data[].attributes.subject
Eliminate excess flash rework in 880-02-001

# data[].attributes.body
Reducing Labor.

# data[].attributes.attachment_link.title
Kaizen Card Mar26 Eliminate excess flash rework in 880-02-001

# data[].attributes.body
After of the change, we reduce the CT from 8.96 to 8.87 seconds. Then according to Uptime % & QA%. Improved the capacity of 365 to 377 pieces by hour. Then increased 128 pieces by day.

32 046 pieces at 50 weeks.

The Annually saving Projection for 2026 is $40 057.35 USD

# data[].attributes.attachment_link.title
Kaizen Card Jan26 Improve Uptime 5% at 705 Line

# data[].attributes.body
After of the change, we reduce the CT from 8.9 to 7.9 seconds at the Laser Station. The new Bottleneck is the Cover Assembly Station with 8.45 Seconds. Then according to Uptime & QA. We Improved the capacity of 377 to 397 pieces by hour. Then increased 337 pieces by day at two shifts. 84 292 pieces at 48 weeks.

The Annually saving Projection for 2026 is $134, 024.00 USD.

# data[].attributes.attachment_link.title
Kaizen card Jan26 Improve Uptime 5% at 706 Line

# data[].attributes.body
Reduce Labor in 706: Load Connector & Cover Operation.

# data[].attributes.attachment_link.title
Kaizen Card March26 Automation 706 Reduce labor on FA IbTest

# data[].attributes.attachment_caption
Kaizen Card Jan26  Modify the 781-40-021 operation method  -   Molding Area - MM0006

# data[].attributes.headline
Modify the 781-40-021  operation method to change  from 2 to 1 operator

# data[].attributes.subject
Modify the 781-40-021  operation method to change  from 2 to 1 operator

# data[].attributes.body
"Together, we improve—because in continuous improvement, teamwork makes the difference, and the molding team proves it."

# data[].attributes.attachment_link.title
Kaizen Card Jan26  Modify the 781-40-021 operation method (1)

# data[].attributes.body
We used similar hangers on wheels at my previous job in the production of cable assemblies. It could be use in keeping or moving cables or any other parts also.

# data[].attributes.attachment_link.title
Selection of temperature sensors after the resistance test

# data[].attributes.body
The pneumatic crimping tool is used for several projects; all we had to do was adapt it for this one.

# data[].attributes.attachment_link.title
Modification of the process for pressing two metal components together

# data[].attributes.body
Simple solution for:

Better ergonomics

Increased yield

Improve quality

# data[].attributes.headline
SMT Wave soldering conveyor alarm improvement

# data[].attributes.subject
SMT Wave soldering conveyor alarm improvement

# data[].attributes.body
-Wave soldering conveyor chain alarm around 10 days which caused efficiency and quality loss

-Root cause: Hanging design for conveyor chain which position will change caused chain loose step by step

-Action: Design and add supporting block to fix motor frame position which make the conveyor running stable, improved efficiency and quality

# data[].attributes.attachment_link.title
SMT WS conveyor chain alarm improvment(5.14)

# data[].attributes.headline
Kaohsiung: 206-12X and 206-21X efficiency improvement

# data[].attributes.subject
Kaohsiung: 206-12X and 206-21X efficiency improvement

# data[].attributes.body
During the assembly process, push buttons (206-12X and 206-21X) were fed via a vibratory feeder as one of the components. A design gap at the turning section caused parts to drop during transfer, reducing feeding stability and line productivity.

By implementing a simple, low-cost design modification, the ME team installed a retaining wall to improve feeding stability, resulting in a 20–26% increase in productivity.

# data[].attributes.attachment_link.title
206-12X and 206-21X efficiency improvements

# data[].attributes.body
282 series element had been suffered from high reject rate (about 20%) due to linearity output out of spec with 2%.

We conducted the design change on printing pattern to decrease the variation of the linearity output. The yield rate was improved from 80% to 98% above.

# data[].attributes.attachment_link.title
CTS Global OS Ideas CI Awards  Candidate Idea  Apr'26 - 282 lineaity improvement

# data[].attributes.headline
Automation of Front and Back Strip Process for Wire Cutting

# data[].attributes.subject
Automation of Front and Back Strip Process for Wire Cutting

# data[].attributes.body
The enhancement of the wire stripping machine capability resolved compatibility issues for models J068, J067, and J027, eliminating the need for manual insulation removal and additional handling processes. By removing non-value-added activities such as manual measuring, marking, and stripping, the process achieved faster operation, reduced operator workload, and improved production consistency. This resulted in a cycle time reduction of 56.6 seconds per piece, an estimated annual savings of $203.00, and a 79.72% improvement in process efficiency.

# data[].attributes.headline
Installation of Limit Switch to Prevent Jig Falling and Part Rejects

# data[].attributes.subject
Installation of Limit Switch to Prevent Jig Falling and Part Rejects

# data[].attributes.body
The installation of a sensor notification system improved the belt furnace conveyor process by alerting operators when bead holders were ready for pickup, preventing conveyor clogging and material flow interruption. This action reduced incidents of bead holder jamming, rejected units, and missing parts, resulting in improved process stability and minimized production downtime with generated an estimated annual cost savings of $2,880.00 while maintaining overall beads production stable.

# data[].attributes.headline
Silicon Oil and IPA Recovery & Reuse Improvement

# data[].attributes.subject
Silicon Oil and IPA Recovery & Reuse Improvement

# data[].attributes.body
The improvement of a strainer on the test bath container reduced Silicone and Isopar fluid wastage by allowing excess oil from tested parts to be collected and reused. This improvement enhanced material utilization minimized consumable losses during grinding and testing operations and reduced unnecessary fluid disposal.

With this implementation we gather an estimated annual material cost savings of $1,597.05 while maintaining an efficient and sustainable oil recovery process.

# data[].attributes.headline
Provision of Pressure gauge for blast burner

# data[].attributes.subject
Provision of Pressure gauge for blast burner

# data[].attributes.body
Installing a pressure gauge on the blast burner improved process stability by reducing burner setting adjustment time from 100 seconds to 20 seconds, saving 80 seconds per adjustment. The improvement minimizes machine downtime, enables faster troubleshooting, and provides more consistent burner performance through accurate pressure monitoring.

As a result, the project achieved an estimated annual savings of $2,640 and improved overall process efficiency by 9.24%.

# data[].attributes.body
In the 6S workshop led by Libor M. An opportunity for improvement was identified in the organization and management of the powder (raw material) storage rack. The initiative aligned with lean principles and contributed to enhancing overall process efficiency by reducing non-value-added activities, strengthening visual control, mitigation of ergonomic risks and improving operational stability within the area.

# data[].attributes.body
Estimated saving: approximately 80 hours per month. - Estimated labor cost saving: approximately 800 USD per month. Reduced bottleneck risk. Improved machine utilization.

# data[].attributes.headline
Kaizen - Green Density Measurement System Accuracy Upgrade

# data[].attributes.subject
Kaizen - Green Density Measurement System Accuracy Upgrade

# data[].attributes.body
Improved green density control accuracy ensures uniform shrinkage and consistent PZT properties across production batches

# data[].attributes.attachment_link.title
Kaizen - Green Density Measurement System Accuracy Upgrade

# data[].attributes.headline
Cleaning supplies panels in Nupaky foundry

# data[].attributes.subject
Cleaning supplies panels in Nupaky foundry

# data[].attributes.body
Making the cleaning supplies more accessible.

# data[].attributes.headline
Ergonomy improvement of Netzch mill mixer

# data[].attributes.subject
Ergonomy improvement of Netzch mill mixer

# data[].attributes.body
Creating space for comfortable manipulation.

# data[].attributes.body
Lean-driven improvement by eliminating process variability and establishing a physical standard through a 3D-printed guide. The implementation reduced waste, improved process stability, and enhanced quality and operational efficiency.

# data[].attributes.headline
Visual Management Transformation: From Information Overload to a Standardized PSQDC System

# data[].attributes.subject
Visual Management Transformation: From Information Overload to a Standardized PSQDC System

# data[].attributes.body
Visual management improvement through 6S principles and PSQDC standardization, eliminating information overload and establishing a clear, clean, and actionable system. The implementation reduced waste and was scaled across the site, strengthening overall Lean organizational maturity.

# data[].attributes.body
Use this format to upload Kaizen Activity.

Preference use English language.

# data[].attributes.headline
OSTRAVA - Series 360 - improving laser marking on current sensors

# data[].attributes.subject
OSTRAVA - Series 360 - improving laser marking on current sensors

# data[].attributes.body
The project focused on improving laser marking quality on current sensors in the Series 360 line.

# data[].attributes.headline
OSTRAVA - CTS Global OS Ideas: CI Awards – Tool management

# data[].attributes.subject
OSTRAVA - CTS Global OS Ideas: CI Awards – Tool management

# data[].attributes.body
Implementation of a new sliding shelf system improved material accessibility directly at the assembly line. The solution reduced unnecessary operator movement, handling of heavy boxes, and replenishment time, resulting in better ergonomics, improved safety, waste elimination, and higher production efficiency at CTS Czech Republic.

# data[].attributes.attachment_link.title
ANNA RYBICKA_CTS OST_Best idea - Q1 2026_

# data[].attributes.body
All the things needed in a meeting room are now gathered together with allocated space.

Solution drawn and printed in 3D.

Keep it simple :-)

# data[].attributes.body
Through 551 housing ZHO in-house from existing external supplier:

-Better quality, inventory control

-Better supply and delivery management

-Estimated annual saving $183K

# data[].attributes.attachment_link.title
551-02-004 housing molding in-house project

# data[].attributes.headline
700 full travel output failure improvement

# data[].attributes.subject
700 full travel output failure improvement

# data[].attributes.body
Through optimized SSPSS and drawing parameter setting, the failure was eliminated.

# data[].attributes.headline
551 haptic frequency failure improvement 

# data[].attributes.subject
551 haptic frequency failure improvement 

# data[].attributes.body
Through optimize the process, 551 frequency failure rate improved from 5% to <1%.

# data[].attributes.attachment_link.title
551 frequency testing failure improvment

# data[].attributes.headline
Title: Merz imagers: Masking before coating

# data[].attributes.subject
Title: Merz imagers: Masking before coating

# data[].attributes.body
Optimization of the working environment - less one-sided repetitive work.

Increased efficiency

# data[].attributes.headline
Installation of a fume hood at workstation used for mixing oxide materials for casting ceramic tapes

# data[].attributes.subject
Installation of a fume hood at workstation used for mixing oxide materials for casting ceramic tapes

# data[].attributes.body
Improving safety and reducing risks for operators in another area of our PLLB plant.

# data[].attributes.attachment_link.title
Installation of a fume hood at workstation used for mixing oxide materials for casting ceramic tapes

# data[].attributes.headline
Kaohsiung: Reducing high noise levels from assembly equipment through improvement

# data[].attributes.subject
Kaohsiung: Reducing high noise levels from assembly equipment through improvement

# data[].attributes.body
The 270 assembly equipment produced excessive noise during air blow-off operations. By increasing the outlet pipe diameter, the noise level was successfully reduced from over 85 dB to below 50 dB, earning positive feedback from operators.

# data[].attributes.headline
Kaohsiung: Enhance efficiency by minimizing manual operations

# data[].attributes.subject
Kaohsiung: Enhance efficiency by minimizing manual operations

# data[].attributes.body
Improve time‑based sampling inspection efficiency by reducing picking activities through small improvements

# data[].attributes.attachment_link.title
CTS Global OS Ideas CI Awards  Candidate Idea – 218

# data[].attributes.headline
Moving parts from dust-free area to another dust-free area

# data[].attributes.subject
Moving parts from dust-free area to another dust-free area

# data[].attributes.body
Dedicated solution for a critical process.

From pre-gluing crystals for pacemakers, to testing and packaging, parts are not exposed to dust and human hands

# data[].attributes.attachment_link.title
Moving parts from dust-free area to another dust-free area

# data[].attributes.headline
Moving parts from dust-free area to another dust-free area

# data[].attributes.subject
Moving parts from dust-free area to another dust-free area

# data[].attributes.body
Dedicated solution for a critical process.

From pre-gluing crystals for pacemakers, to testing and packaging, items are not exposed to dust and human hands

# data[].attributes.attachment_link.title
Moving parts from dust-free area to another dust-free area

# data[].attributes.headline
Construction a new cutting machine for special types of tubes

# data[].attributes.subject
Construction a new cutting machine for special types of tubes

# data[].attributes.body
We have a great team in the maintenance department, this is just one of many projects submitted by the production department to our maintenance team to implement. Thank you to team!

# data[].attributes.attachment_link.title
Construction a new cutting machine for special types of tubes

# data[].attributes.body
Safety always comes first. Marcin did a great job, he spent many days working on this project.

# data[].attributes.body
Many thanks to all people who are changing the mindset to 6S. Space in a plant is just as important as free RAM in a computer.

# data[].attributes.headline
5S initiative: Tools standardization - mixing

# data[].attributes.subject
5S initiative: Tools standardization - mixing

# data[].attributes.body
Standardization of the workplace.

# data[].attributes.attachment_link.title
5S initiative - Tools standardization - mixing

# data[].attributes.body
Safety‑focused Kaizen that implemented an engineering control to secure worktables, eliminate unintended movement, and reduce risks associated with oil leaks, fires, and slips, while improving overall workplace stability and 5S conditions.