DFM教材1.ppt

按一下以編輯母片標題樣式,按一下以編輯母片,第二層,第三層,第四層,第五層,*,訓練課程,Design For Manufacturing,Design For Manufacturing,-,NOV,2001 By Yvonne,.Nie,簡介,DFM,-,是,標準化,及,整合,廠際間的流程，透過,DFM,達到與設計單位,同步,的,工程,，並由,PE Team,成為連接研發和製造的橋樑,為使量產順利與確保機種移轉其品質及作業之一致性.,概觀,START,QTY LIMIT,DEVELOPING SCHEDULE,SAMPLE,REVIEW,KICK OFF MEETING,S/M,P/R,P/R RESULT,CONDITIONAL ACCEPT,ACCEPT,NEW DESIGN,SERIES MODEL,QTY LIMIT,OK,NG,NG,DESIGN,MODIFY,DISCUSSION,&ENG,IMPROVEMENT,REJECT,DISCUSSION,MEETING,MODIFY MODEL,TRANSFER,(P/R-M/P),ACCEPT,PRE-M/P,M/P,CONDITIONAL ACCEPT,M/P,ALLOWANCE,PRE-M/P,REJECT,DESIGN,REVIEW,REJECT,AFTER GREEN LIGHT,DFM Flow Chart(ADP&DESKTOP),P/R MEETING,OK,NG,Developing Schedule,Developing Schedule Flow chart,Customer/Delta Demand,(1),R/D engineer Preview,(2),Preliminary Developing Schedule,(4),(1),Customer/Delta Demand,客戶需求:客戶提供初步規格.,內部需求:應市場預測或內部規劃,(2),R/D Engineer Preview,設計工程師針對初步規格,研討開發重要事項,及開發時程,(3),Preliminary Developing Schedule,PM,或,Sales,依客戶需求(或台達內部規劃),及工,程師,Preview,結果,草擬開發計劃,時機:接收客戶需求,取得客戶之初步規格,主導:,Sales,或,PM,目的:針對新機種,使設計人員有初步了解,PM,能初步規劃,Kick Off Meeting,Inform Kick Off Meeting(1),Project Schedule Confirm,(3),Kick Off Meeting,(2),Design Review,Sample Review,New Design,Series Model,No,Yes,No,Yes,Team Member:DEIC:,業務、電子、機構、,QE、Safety、,統購、生管、,PE、,規格組、.,Layout,組,DCGP:,業務、電子、機構、,PE、,資料中心、統購、生管,首先由,Sales,說明此專案之需求,來源及發展計劃,客戶需求,a.,客戶承認時間及評鑑,b.QE、Safety,評估數量及時間,c.S/M、P/R Meeting、P/R、M/P Delivery,d.,工程,spec issue,時間(,PCB,生產,SPEC),e.,交叉料,Design review,實施計劃,f.,模具(,CASE,P/C),開發討論,g.Special B/I&Test Connector,h.,業務發行“,Kick Off Meeting,會議記錄”,Kick off,會 議 內 容,Kick Off Meeting Flow chart,目的:,使新機種開發至量產之專案有效管理及運作,時機:,新機種專案開始,主導:,SALES,Design Review,目的:,與設計同步,提供建議,減少,S/MP/R,問題,使產品順利量產,主導:,工程及,DEIC PE,定義:,工程設計初期,將量產制程標準與品質防呆理念,配合,Design,Guide line,之原則,提前導入,以利量產,工程部依“,Design Review Report”,之建議修改設計,進行樣品制作,Paperwork Design&Design Process,(1),Engineering Prototype,(2),Design Review,(3),Design Review Record&Suggestion,(4),ENG Design Modify,(1),工程部于手稿階段設計最初架構,並與,PE,共同討論,PE,提供建議做為設計之參考,工程設計樣品,PE,依工程初步樣品或相關資料進行評估,或與工程共同會測,評估及會測項目含:,Layout、,機構、作業性、設備及工具等,PE,評估後提供“,Design Review Report”,與工程設計人員共同討論,作為設計改善之參考,改版後之追蹤,Sample Review,目的:,簡化相似機種之,Lead time,及,DFM Process,主導:,PE,范圍:,凡符合系列機種判斷原則之機種,Sample Review Flow chart,ENG Sample,(1),ENG Spec,(1),Sample Review,(2),Transfer (P/RM/P),(5),Discussion ENG Improvement,(3),P/R Process,(4),NG,NG,OK,OK,1.,PE,判斷必須依 5,item:,a.LABEL,b.CABLE,長度,c.CASE,材質不變顏色修改,d.,包裝材料,e,.FAN,2.,依原始機種開發,且原始機種已通過,Green light issue。,3.,不,影響,Workmanship,及電氣特性結構,S/M Making,Requirement Issue(1),Sales Engineering RE-S/M Request,Inform S/M Meeting (2),Engineering,Manufacturing,Materials Preparation (3),S/M Preparation&Tracking (5),Sampling Making (6),S/M Review Meeting,(7),S/M Result Evaluation (8),Design,Modify,(9),P/R Process (11),Discussion&ENG Improvement,Transfer,Re-S/M Confirmation (10),S/M Meeting,(4),NG,OK,NG,OK,NG,OK,START,目的:,為滿足客戶及需求,爭取訂單,時機:,工程設計階段或需送樣于客戶,主導:,由,業務,召開會議,DCGP PE,主導會議之進行,Discussion&ENG Improvement,S/M,Sample Review,Discussion&ENG Improvement (1),Design Modify (2),P/R,Transfer (3),OK,NG,New Model,Series Model,Flow chart,當機種,S/M,結果為“,Agree”,或系列機種經,Sample Review,後判定為,NG,者,若客戶有緊急需求時,則,Sales,可要求召開會議進行討論,內容如下,A.S/M,之重大問題及解決對策,B.,後續,Schedule,之安排,C.,不受影響之材料,採購先行買料,D.,若須轉至量產,則須討論,a.,短期對策,b.,新舊版本切換時間,c.,舊版本成品及半成品之處理方式,d.,支援方式,會簽“量產特採單”,OK,後可移轉至,M/P,目的:,為滿足客戶交期需求,爭取訂單,主導:,SALES,P/R Meeting,P/R Meeting Flow chart,Inform P/R Meeting(3),P/R Meeting(4),PM Judgment (6),Transfer(P/RMP),PRE M/P,M/P,P/R,P/R Result,Accept,C/A,Reject,Reject Discussion Meeting,在,Kick off meeting,中即規劃,P/R Meeting,討論工程規格,相關部門移轉日期與事項,工廠上線安排等,P/R Meeting,討論內容如下,;,A.PCB Version,ENG SPEC,FN,B.ToolingPCB,CASE,H/S),C.QE,Safety,Customer Approval,D.P/R,M/P Schedule,E.AI,SMD,PF Schedule,當,討論之上線點無法達成客戶需求時,a.,業務征求客戶同意工廠上線計劃,b.,客戶不同意則須重新討論計畫,生管,召開,P/R Meeting,須以雙方會議之方式,於,P/R,前兩周,召開,會議中討論,並確認各項轉移之正確性,並依,Schedule,安排各相關部門之作業時間,會後由生管發行會議記錄至相關單位,Transfer Meeting(SER&NET),Transfer Meeting Flow chart,Inform Transfer Meeting,Transfer Meeting,BOM SPEC Version Confirm,Tooling Part&On Line Date Confirm,Production,Resources,Confirm,PM Judgment,Pre-M/P,P/R,Preparation Tracking,DEIC PE,召開移轉會議,並且須以雙方會議之方式,于會中計論及告知問題,並確認各項轉移之正確性,會後並由,PE,發行會議記錄至相關單位及生產工廠,PM,移轉會議中須確認以下事項:,a:,電子工程師告知該機種生產版本,b:,電子工程師告知,PCB,版本發行的,FNc:,機構于會中核對材料規格之最新版本,d:P/R,M/P,時間,e:,P/R REPORT,TEST&AI&SMD PROGRAM,f:QE,Safety,customer approval,g.,SAMPLE&,支援事由,Pilot Run,P/R Flow chart,A.,由,PE,依據,M/P,問題不斷回饋而修訂之,Design Guide,Line&Index,在,P/R,線試做生產,反映,P/R,中所發生之問題點,B.,依工程,Spec,進行試做,凡規格不清遺漏或錯誤之處須經由原設計工程師同意並發行“新機種試做變更通知書”方可變更,C.QC,人員須提出,P/R,期間已發生或未來可能發生之品質問題,並提供電氣問題及,CPK,資料,D.AISMD,加工站人員須提出,P/R,間已發生或未來可能發生之問題,E.TE,人員須提出,P/R,期間已發生或未來可能發生之問題,F.IE,人員針筒,P/R,收集並匯總電氣機構,Layout,規格測試及交叉料分析等問題,列入,P/R,分析報告,供相關單位參考改善,G.,若,P/R,因缺料造成上線點延後或生產中斷,生管須知會業務及,PE,重新檢討,Schedule,內容包括:上線出貨時間;量產上線出貨時間,P/R Requirement(1),P/R Reject Discussion Meeting,(6),P/R PreparationTracking (2),P/R Making(3),P/R Review Meeting(4),P/R Result Evaluation(5),Green Light Issue,Transfer(P/RM/P),Re-PR Confirmation (8),Pending Issue Tracking,(7),Design Modify,YES,OK,NG,NO,目的:,為確保產品之成熟度以達可量產要求,並找出適合量產之最佳生產條件,Reject Meeting,Reject Meeting Flow chart,會議中須討論:,A.P/R,之重大問題與解決對策,B.,後續,Schedule,之安排,C.,若客戶量產需求很急,必須移轉,則須討論:,a.,短期對策,b.,新舊版本之切換時間-,c.,舊版本成品或半成品之處理方式,D.,若客戶需求急而來不及,RE-P/R,SALES,須會簽“,量產特採單,”至,M/P,Inform Reject Discussion Meeting,Reject Discussion Meeting,Transfer (P/RM/P),RE-PR,目的:,即時反應,P/R,結果,以利計劃重新安排,範圍:,P/R Result,為,Reject,Transfer(P/R-M/P),Transfer Flow chart,PE,于會中討論及告知並確認內容:,A.P/R Report,及,Follow up,狀況,B.,制程(含測試,B/I,及治具使用)注意事項,C.,現行產品版本及最,Final,之,FN,D.QESafetyCustomer Approval,完成狀況,E.AI By Pass,材料說明,F.Forecast,及量產時間安排,G.,提供客戶料號(,ADP),PE,依會議內容,發行“,P/RM/P Transfer Meeting Minutes”,至相關單位,目的:,確保機種移轉量產,其品質及作業之一致性,範圍:,凡新機種由,PR,直接,Handle,者均屬之,Before Transfer Preparation (1),Inform Transfer Meeting Notice (2),Transfer Tracking (3),Preparation Tracking (4),PREMP(5),Pre-M/P,Flow chart,First M/P Allowance:,A.,須經,SafetyQE,及,Customer Approval OK,且經,PE Green Light,B.,若以上條件有一項不滿足,且客戶量產需求急,則,Sales,須會簽“量產特采單”,目的:,量產前試產,找出適合生產之最佳條件,範圍:,首批量產,主導:,PE Support,PE,于首批量產,Support,上線過程:,a.Follow P/R Report&,制程注意事項,b.Follow Test Program&Fixture,狀況,c.,確認制程是否合理,d.,確認,FN,變更及,AI By Pass,零件實施狀況,First M/P Allowance (1),M/P Making (2),Inform First M/P Meeting (3),First M/P Meeting (4),Design Modify&Process Improvement (5),Result Tracking(6),M/P,NG,The end!,