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Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,CONFIDENTIAL,CONFIDENTIAL,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,PC Final SFR failure unit FA,Aug.01.,1/28,Background:,Piranha Color BTB suddenly happen high final SFR yield loss 0.57%on production line on,July.31.,2/28,Final SFR unit FA:,Randomly take 10pcs SFR defect units to analysis and the result as table:,FA Methodology flow:,Retest at golden,Tester,Search for original Focus/Final test data,Compile SFR data,Visual Inspection,1 Visual Inspection&Retest test at golden test result as table:,Visual Inspection result as below:,Retest result as below:,Status,lens Contamination,pass,pass,fail,QTY,0,10,3,7,TTL,10,10,Golden tester retest data as below:,SN,Status,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,VDC306H7092,FAIL,0.599,0.455,0.659,0.623,0.454,VDC306H7163,FAIL,0.595,0.422,0.69,0.629,0.548,VDC306J1027,FAIL,0.696,0.667,0.617,0.653,0.643,VDC306J5112,PASS,0.659,0.609,0.683,0.668,0.597,VDC306J5128,PASS,0.632,0.644,0.638,0.651,0.648,VDC306J5179,PASS,0.667,0.671,0.647,0.65,0.656,VDC306K1176,FAIL,0.646,0.529,0.698,0.647,0.598,VDC306K5093,FAIL,0.665,0.661,0.628,0.642,0.602,VDC306K5117,FAIL,0.531,0.661,0.559,0.486,0.663,VDC306K5118,FAIL,0.65,0.663,0.625,0.653,0.659,Remark:final limit 0.53(UL UR LL LR)1 0.63Center0.06)between focus and final test except,1pcs unit(VDC306J5112)due to contact no well during final test which lead to SFR image abnormal cause SFR failure.,Original focus data:,Orignal Final test data,Delta(Focus data-Final data):,SN,Status,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,Status,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,VDC306H7092,PASS,0.616,0.569,0.695,0.65,0.558,FAIL,0.597,0.465,0.671,0.631,0.448,0.019,0.104,0.024,0.019,0.11,VDC306H7163,PASS,0.648,0.58,0.713,0.644,0.622,FAIL,0.594,0.434,0.699,0.64,0.521,0.054,0.146,0.014,0.004,0.101,VDC306J1027,PASS,0.69,0.652,0.677,0.66,0.643,FAIL,0.685,0.653,0.573,0.627,0.61,0.005,-0.001,0.104,0.033,0.033,VDC306J5112,PASS,0.666,0.622,0.696,0.684,0.611,FAIL,2.089,0.343,0.485,0.639,0.594,-1.423,0.279,0.211,0.045,0.017,VDC306J5128,PASS,0.665,0.654,0.673,0.655,0.613,FAIL,0.606,0.645,0.614,0.647,0.663,0.059,0.009,0.059,0.008,-0.05,VDC306J5179,PASS,0.687,0.675,0.681,0.666,0.663,FAIL,0.679,0.661,0.61,0.645,0.657,0.008,0.014,0.071,0.021,0.006,VDC306K1176,PASS,0.653,0.58,0.701,0.65,0.623,FAIL,0.644,0.512,0.697,0.653,0.605,0.009,0.068,0.004,-0.003,0.018,VDC306K5093,PASS,0.673,0.687,0.655,0.654,0.622,FAIL,0.665,0.669,0.625,0.641,0.611,0.008,0.018,0.03,0.013,0.011,VDC306K5117,PASS,0.642,0.63,0.691,0.649,0.603,FAIL,0.515,0.656,0.548,0.457,0.666,0.127,-0.026,0.143,0.192,-0.063,VDC306K5118,PASS,0.656,0.675,0.707,0.632,0.658,FAIL,0.637,0.672,0.596,0.644,0.666,0.019,0.003,0.111,-0.012,-0.008,Original Final test SFR image,Retest SFR image,4/28,Final SFR unit FA summary:,80%(8/10)final SFR defect unit are from SFR marginal Pass in focus test;,60%(6/10)SFR failure are marginal failed in final test include 2pcs retesting marginal pass;,70%Final SFR defect unit have big SFR drop(delta0.06)between focus and final test.,5/28,Fish bone diagram,Final SFR failure,MATERIAL,MAN,Machine,Poor handling which cause physical deformation(localized to certain tester since operator assignment by tester),METHOD,Localized to certain testers(Focus and final),Use difference lens supplier which has performance difference,Check by tester defect distribution,Check back production history latest 1week,Check UV intensity for all testers,Check Torque monitoring data,Check tester by tester variance compare to golden tester,Check focus SFR performance,Check Lens MTF performance,6/28,What action have been done:,1Check 10pcs defect unit from focus tester and Final test breakdown as table:,The result show tester distribution is randomly.,Pls.note the production line only 5set focus testers and 3sets final testers on start of morning,shift.,Station,Qty,Station,Qty,PC-FOCUS1,1,PC-FINAL1,5,PC-FOCUS3,3,PC-FINAL3,3,PC-FOCUS5,2,PC-FINAL4,2,PC-FOCUS7,3,PC-FOCUS8,1,7/28,What action have been done#2:,2Take 3pcs golden units to do quickly the correlation of all tester include(Focus/Final tester,)compile data,the result as below:,The result show all testers are under controlled(SFR delta Check UV intensity of all semi-auto glue machine,Result as follow:,The result showed UV machine all are under controlled.,Tester ID,3500mj/cm,CH1,CH2,PC-FOcus01,4542.79,3722,PC-FOcus02,3923.02,3752,PC-FOcus03,3931.78,3673,PC-FOcus04,4304.08,3706,PC-FOcus05,4057.34,3637,PC-FOcus06,3809.87,3655,PC-FOcus07,4026.68,4583,PC-FOcus08,3776.29,3714,9/28,What action have been done:,4Check Lens torque monitoring data.,Data showed that the lens torque data are under controlled and above the spec limit of min.20N-,MM.,10/28,What action have been done:,5Look for latest 1week SFR test history,SFR yield loss as table:,The result show SFR yield of NM Bb with texture tooling is bad compare to KT and MN AA.,Lens tool,KT,NM(7/28 8/1),Diffence,WW29,DAA without texture,FBB with texture,B vs A,B vs KT,Focus Test input Qty,38147,3501,4029,Focus SFR defect rate(FPY),0.68%,1.05%,2.55%,1.50%,1.87%,Final SFR,0.03%,0.09%,0.83%,0.74%,0.80%,11/28,What action have been done:,6Randomly take 4000pcs unit data from focus testing from KT and NM lens separately,the SFR,Performance comparison result as table:,Finding:,The SFR performance from KT is clear better than NM on SFR average and SFR CPK.,Pls.note:KT SFR data is from July.25,NM SFR data is from July.31.,SFR average comparison,SFR Stdev comparison,SFR CPK comparison,12/28,The SFR data from KT is better than NMs.,4000pcs unit data from focus testing from KT and NM lens separately,the SFR comparison result as table:,13/28,7Randomly take MTF test data from IQC by supplier,(KT:250pcs NM tool A:196pcs NM tool:B)the MTF,performance comparison result as below:,Finding:,NM A and B tool performance no clear different,on MTF Average,Stdev and CPK.,KT lens performance is better than NM on MTF,average CPK Corner.,The MTF Corner Stdev of KT is better is NM,the,MTF Center of NM is slight better than KT.,What action have been done:,MTF average comparison,MTF Stdev comparison,MTF CPK comparison,14/28,250pcs KT lens and tooling”AA”196pcs&tooling”BB”160pcs lens MTF,data comparison by boxplot as below:,The SFR comparison result is showing:,KT lens MTF data is better than Newmax tooling“AA”lens and tooling“BB”lens.,KT lens,NM-AA lens,NM-BB lens,KT lens,NM-AA lens,NM-BB lens,15/28,Study#1-Final SFR comparison by stage time:,Take 8 of 10pcs SFR defect unit to do stage time 12H/24H and retest them at original final Tester,and Then compare SFR test data(include original Focus/Final and stage 12H/24H).,The result show 5 of 8pcs Final SFR failure retest pass after stage 12H include 1pcs marginal SFR pass.,The result show 6 of 8pcs Final SFR failure retest pass after stage 24H include 2pcs marginal SFR pass.,8pcs final SFR data comparison by stage result Pls.refer to slide#7 10.,Retest result at original final tester after stage 24H:,SN,Status,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,VDC306H7092 stage 24H,FAIL,0.57,0.441,0.655,0.602,0.411,VDC306H7163 stage 24H,FAIL,0.597,0.409,0.695,0.645,0.508,VDC306J1027 stage 24H,PASS,0.681,0.648,0.684,0.667,0.641,VDC306J5128 stage 24H,PASS,0.633,0.658,0.655,0.658,0.648,VDC306K1176 stage 24H,PASS,0.639,0.538,0.7,0.648,0.618,VDC306K5093 stage 24H,PASS,0.659,0.672,0.644,0.644,0.614,VDC306K5117 stage 24H,PASS,0.622,0.614,0.669,0.605,0.657,VDC306K5118 stage 24H,PASS,0.67,0.662,0.685,0.688,0.645,Retest result at orignal final tester after stage 12H:,SN,Status,SFR_UL,SFR_UR,SFR_Center,SFR_LL,SFR_LR,VDC306H7092 stage 12H,FAIL,0.566,0.423,0.647,0.599,0.407,VDC306H7163 stage 12H,FAIL,0.592,0.393,0.691,0.648,0.491,VDC306J1027 stage 12H,PASS,0.682,0.646,0.685,0.668,0.64,VDC306J5128 stage 12H,PASS,0.629,0.659,0.664,0.659,0.651,VDC306K1176 stage 12H,FAIL,0.638,0.527,0.694,0.654,0.613,VDC306K5093 stage 12H,PASS,0.651,0.674,0.634,0.639,0.615,VDC306K5117 stage 12H,PASS,0.614,0.609,0.669,0.601,0.645,VDC306K5118 stage 12H,PASS,0.67,0.664,0.684,0.687,0.654,16/28,2pcs units SFR data no change after stage 12H and 24 H compare to original final SFR data.,17/28,2pcs units SFR value have clear rise again after stage 12H compare to original final SFR data,especial is on SFR Center,after stage 12H,Units SFR value is stable.,18/28,2pcs units SFR data no clear change after stage 12H and 24H compare to original final SFR data.,19/28,2pcs units SFR value have clear rise again after stage 12H compare to original final SFR data,especial is on SFR Center,after stage 12H,Units SFR value is stable.,20/28,Final SFR comparison by stage time summary:,Based on 8pcs SFR comparison by stage time,the result finding:,4 of 8pcs SFR value have certain recover after stage 12H,especial is on SFR Center.,21/28,Study#2-,Refocus 3SFR failure unit:,3SFR defect units SFR data after refocus as table:,Data show SFR data can recover to focus test data after refocus.,Refocus lens direction as:,SN,Refocus Status,Refocus,direction,VDC306H7163,PASS,Lens downward turn,10,VDC306K1176,PASS,Lens downward turn,8,VDC306H7092,PASS,Lens downward turn,10,SN,Test process,Status,SFR_UL,SFR_UR,SFR_C,SFR_LL,SFR_LR,VDC306H7163,Original Focus data,PASS,0.648,0.58,0.713,0.644,0.622,Before refocus,FAIL,0.597,0.409,0.695,0.645,0.508,After refocus,PASS,0.67,0.655,0.716,0.654,0.668,VDC306K1176,Original Focus data,PASS,0.653,0.58,0.701,0.65,0.623,Before refocus,FAIL,0.639,0.538,0.7,0.648,0.618,After refocus,PASS,0.638,0.579,0.719,0.655,0.609,VDC306H7092,Original Focus data,PASS,0.616,0.569,0.695,0.65,0.558,Before refocus,FAIL,0.57,0.441,0.655,0.602,0.411,After refocus,PASS,0.622,0.623,0.709,0.655,0.589,22/28,23/28,Study#3-,DOE for reducing final SFR failure rate,To reduce final SFR defect rate,one DOE have been done:,Methodology:,Focus test,Glue,Place,electrostatics kin,on lens surface,UV Curing,Final Test,Place,electrostatics kin,on lens surface as below fig:,24/28,Material requirement:,Take 1PT units(130pcs)from NM Tool B with texture.,DOE result:,The result show 100%unit is pass in final test.,SFR data comparison between focus/Final test and the result summary as table:,1pcs units delta 0.06 possible factor:,Possible place the electrostatics kin onto the surface of lens move lens.,Possible move lens by tip while glue.,Possible Lens element moving.,1DOE test result:,Unit:PCS,Focus,Input Qty,130,pass,120,SFR Fail,8,Particles Fail,2,Final,Input Qty,120,Pass,120,Fail,0,Input Qty,Delta0.06 Qty,Delta0.1,Remark,Qty,Rate,Qty,Rate,120,1,0.83%,0,0,Delta is-0.068,Remark:Delta=Focus data-Final data,25/28,DOE summary:,According to DOE 1pts test result,Found add the electrostatics kin on lens surface while lens UV,Curing have clear improvement to Final SFR yield loss,to confirm its effecting,we will plan to do,More sample size for it.,26/28,Next action:,Send sample unit from Newmax lens tool A/new&old B/old C and KT lens to FA for cross section to check the thread.Owner:SG Dong/Tracy Qin Due date:Aug.7.,Take 10pcs Focus SFR failure unit to do SFR/MTF Thru focus.Owner:SG Dong Due date:Aug.7.,Use 10pcs good units with glue and 10pcs good units without glue from new tool B to study SFR drift by stage experiment 30minutes/12H/24H-Owner:SG Dong Due date:Aug.8,Confirm the lens material of KT and NM BB-Owner SG Dong/Tracy Qin Due date:Aug.7.,DOE-,add the electrostatics kin on lens surface while lens UV,:To do more sample to confirm it effect using tool new B material-Owner SG Dong Due date:Aug.8.,27/28,Thank you,28/28,
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