HU-QA-PLAN-.pptx

Nicholas Chien,201Nicholas Chien,2011/1/Jun/15Jun/15Hinge-Up QA Plan CustomerCustomer Quality Quality ExpectationExpectationSystem Quality System Quality AssuranceAssuranceSupplier Quality Supplier Quality ManagementManagementProcess Quality Process Quality Management Management We Commit We Commit We Learn We Learn We Share We Share We Support We Support Customer Oriented!Commitment to Excellence!SQMYT TanOQCJack16QEEn3IPQCLing4QA DIV.Nicholas ChienMQALuke LongRMAAnny10CSTom2QSAnny5SHH Quality TeamCSDEast HeIQCJenny24MEStone4OELee1EEGina3Quality Plan ContentsQuality Plan SummaryOverview of the Quality Plan established for the projectC-Flow Overview of the document output of each stageSampling PlanOverview of sampling plans used in each audit and phase of the projectClose Team WorkOverview of the Team TaskComponent Quality ControlList of criteria for approval for shipment release and MPMFG flow Management MFG Quality Control process,checklist of tests and associated equipment,specs,CTQ.OQC ManagementOutgoing Quality Control process,checklist of tests and associated equipment,specs,sampling plans Continuous Improvement Defined the Team,Tool&of CIT programTraining PlanTo enhance Inspector detectable capability.Line QualificationProduction Line qualifications requirements and processProcess Coverage ReviewProcess Review of OQC,Production Line&IQC by Failure Mode Reliability Test PlanReliability Test,checklist of tests and associated equipment,specs,sampling plans NPI Correlation PlanCorrelate OQC inspection method&equipment to customersFailure Mode Capture PlanReview Customer Return units to correlate failure symptom to root cause for improvement actionsQuality PlanCathostDocumentC0C1C2C3C4C5C6SALPMProduct PlanvSalesCustomer forecast updatevvPURPURTooling Management Plan?vPURPMCMaterial and finished goods check listvPURPurchase Agreement:Regulation of C/D/Q/S&PenaltyvPMPMDevelopment milestonevPMProject team member listvupdatePMDevelopment units planvvvvPMLong lead time parts control listvPMProject schedule updatevvvPMEMI Safety App form/ReportvReportPMProduction schedule updatevvvPMPCBA Trial-Run ReportvvvPMSafe Launch Document ChklistvvPMPhase Out planvvC-FlowCathostDocumentC0C1C2C3C4C5C6RDRDTechnical Feasibility ReportvRDPreliminary Product SpecificationsvRDProduct Specifications.vFinalRDProduction Feasibility ReportvRDFMEADFMEAPFMEARDBOMPre-BOMupdateFinalRDEngineering SpecvupdateFinalRDDrawing releasedraftupdatefinalRDCTQ control ChartvvvRDCTQ CPK Review ReportvvvRDComponent approval sheetvRDEMI&Safety Report&ApprovalvvRDICT Coverage Report vvRDGerber file releasevfinalRD/EESMT Summary ReportvC-FlowCathostDocumentC0C1C2C3C4C5 C6MFGME/TEWorking InstructionDraftFinalME PMPDraftFinalIEStandard Cycle TimevFinalPEPFMEA EERepair GuidevPETrouble Shooting GuidevPETrial run reportvvvPEFailure list&Corrective action reportvvvPEFormal BOM release vPEEngineering Run Production reportvvvPEMajor Bug list&Corrective action report vPEM-Run(Yield rate/Failure analysis)Production Report vPEPPA(Post Production Audit)2 pcs2 pcsC-FlowCatHostDocumentC0C1C2C3C4C5C6QADQEReliability test planvORTDQEReliability test reportvvORTQEOn going reliability test plan vPQEProcess Coverage ReviewvQEQC flow chartvQSRoHS survey check listvvSQEIOC inspection criteriavPQEOQC inspection criteriavPQETrial-Run Quality Summary ReportvvPQEProduct Process Capability Analysis Report(CPK)vvSQEKey Component Process Capability Analysis Report(CPK)vvCSNPI Correlation ReportvDQECIT(Customer Integral Test)vCSDRSPL(Recommend spare parts list)vC-FlowQuality Gate of Each StageEVTDVTPVTMPSafety Launch Quantity1 520 50MTBF included30 200No LimitFirst Yield Rate/Pre-test 85%Final Test 90%FQC 95%95%Single Defect Rate/1.33Process Major Bug/000Process On-going Minor Bug/Determine IndividuallyDetermine IndividuallyProcess Open Minor Bug/000DMT Test Open Minor Bug/000Quality GateAudit/Test/Review of StagesStageAudit/Test/ReviewPurpose PlanHostEVTEVT PPA Trigger EVT RunNARDDVTDVT PPATrigger DVT Run2 units RDDVT RTDesign Maturity DVT RT Test PlanDQEPVTPVT PPATrigger PVT Run2 unitsPEMFG Line Qualification ReviewProcess MaturityLine Qualification PlanIPQCMFG Process Coverage ReviewProcess DebugProcess Coverage Review IPQCPVT RTDesign Maturity PVT RT Test PlanDQECustomer Integral TestDesign conformingCustomer DQEMPMP PPAEnsure ProcessFAIFQCOn-going Reliability TestDetect Process LeakageORT PlanQEECReliability TestPrevent Side EffectEvaluation individuallyQEAudit/Test/ReviewQA Sampling PlanEVTDVTPVTLine QualifyPVTMPIQC100%1.Key Parts Function-100%2.Key Parts Cosmetic -100%3.Others:follow MP Rule4.Dimension:60 100 pcs5.CTQ Parameter:60 100 pcsNA1.First 1K follow DVT Rule2.After 1K follow MP Rule3.Dimension:30 100 pcs4.CTQ Para:30 100 pcsMIL-STD-105E1.Function L2,AQL 0.42.Cosmetic L2,AQL 0.653.Dimension-30 pcs/week4.CTQ Para-30 pcs/weekFQC100%1.Function-100%2.Cosmetic-100%3.Dimension-100%4.CTQ Para 100%1.Function-100%2.Cosmetic-100%3.Dimension-100%4.CTQ Para 100%1.Function-100%2.Cosmetic-100%3.Dimension-100%4.CTQ Para 100%1.Function-100%2.Cosmetic-100%3.Dimension-30 pcs/day4.CTQ Para 30 pcs/dayOQC100%1.Function-100%2.Cosmetic-100%3.Dimension-100%4.CTQ Para:-100%1.Function-100%2.Cosmetic-100%3.Dimension-100%4.CTQ Para:-100%1.First 1K follow DVT Rule2.After 1K follow MP Rule3.Dimension:30 100 pcs4.CTQ Para:30 100 pcsMIL-STD-19161.Function-Level 32.Cosmetic-Level 33.Dimension-30 pcs/week4.CTQ Para-30 pcs/weekRTNADVT RT Test PlanNAPVT RT Test PlanORT PlanReal Transportation Test:1 PalletQA Sampling PlanIncoming Material Incoming Material Inspection Inspection Process Process Quality AuditQuality AuditCustomerCustomerSupplier Quality Supplier Quality ManagementManagementOut-going Out-going Quality ControlQuality ControlProcess Failure Process Failure ImprovementImprovementOut-going Out-going Reliability TestReliability TestClose Team WorkSQESQEPE/MEPE/MERMARMARDRDFIELD FIELD REJECTREJECTLINE LINE REJECTREJECTIQCIQCCSECSEOQCOQC-PQEPQEIPQCIPQC-QEQECustomer Engineering TeamCustomer Engineering TeamCustomer Quality Customer Quality ServiceServiceCSECSEKey Parts Quality ManagementDocument ReadinessParts Vendor SpecFunctional ItemsElectric ItemsOptical ItemsCosmetic itemsCTQ sheetGPMS Approval Sheet Stage EVTEVT DVTDVTDVTDVTDVTDVT PVT Host RD/PUR RD RDRDRDRDRDPUR CE LCD COVER ASSY 日騰日騰 vvNANAvxvx MagnetvvvNASticker LCD BEZEL ASSY大智大智 vvNANAvxx x Open Cell IVO vvvvvxvxBKL PartsSHB vvvvvxvxCamera ModuleLITE-ON海華海華vvvvvxvx 2IN1 LVDS CABLE博碩博碩維翰維翰vvvNAvvx ANTENNA國巨國巨vvvNAvxvxHINGE新日興新日興vvNANAvxvxKey Parts Quality ManagementKey Parts Quality ManagementProcess ReadinessParts PMP/QC FlowCTQ DefinitionSOP/SIPEng Stage Sampling PlanMP Stage Sampling PlanQuality GoalStage PVT DVT PVT DVT/PVTMPMPHost SQE RDSQE SQESQESQELCD COVER ASSY vvv100%Dimension:5pcs/lotCosmetic:AQL 0.65Dim:30 pcs/week5000 DPPMMagnetLCD BEZEL ASSYvvv100%Dimension:5 pcs/lotCosmetic:AQL 0.65Dim:30 pcs/week5000 DPPMOpen Cell xvv100%Dimension:5 pcs/lotCosmetic:AQL 0.6510000 DPPMBKL PartsvvvAQL 0.65Dimension:5 pcs/lotCosmetic:AQL 0.653000 DPPMCamera ModulexvvAQL 0.65Dimension:5 pcs/lotCosmetic/Electric:AQL 0.651000 DPPM 2IN1 LVDS CABLEvvvAQL 0.65Dimension:5 pcs/lotCosmetic/Electric:AQL 0.651000 DPPM ANTENNAvvvAQL 0.65Dimension:5 pcs/lotCosmetic/Electric:AQL 0.651000 DPPMHINGEvvvAQL 0.65 AQL 0.651000 DPPMKey Parts Quality ManagementKey Parts Quality ManagementMP ReadinessParts Prod Equip StatusInsp Jig StatusCapacity EvaluationTool ResumeAll Dim FAI All Dim Measure OQC ReportRT Report Risk AssessStage DVTDVTPVTPVTDVT DVT From PVTPVT PVT Host SQESQEPURTETETEIQCCE RD/SQE/PURLCD COVER ASSY vvxvv v vx x MagnetLCD BEZEL ASSYvvxxv v vx x Open Cell vvvNAxxxx vBKL PartsvvvVv v vx vCamera ModulevvvNAxxvx v 2IN1 LVDS CABLEvvvNAv v vx v ANTENNAvvvNAv v vx vHINGEvvvNAv v vx vKey Parts Quality ManagementIQC Inspection EquipmentEquipmentSpecLimitQtyClipper0-300-450-600-1000100019Spectrum Analysis EquipSR-3A-1Pin Gauge1.550-6.275mm6.275mm4Filler Gauge0.05-1.00mm1.00mm2CMM600*450-2Magnifier10 X-2Manual Torque Meter-1Screw Thread Gauge-11Signal Generator-1Acoustic Gauge-1 setLuster Meter-1 setChromatic Aberration Meter-1 setPattern Generator-1XRF-Q3 PlanIncoming Quality ControlQualified VendorMaterial DeliveryW/HSMPL INSPOKNGMRB MEETING SCRAPRTVWAIVEREWORKIPC RECHECK VENDOR SCRAPED W/HSEPARATW/HIQC SMPL PLAN:PVT Stage:1.First 1K:100%2.After 1K follow MP Rule3.Dimension:30 100 pcs4.CTQ Para:30 100 pcsMP Stage:1.Function:105E/L2,AQL 0.42.Cosmetic:105/EL2,AQL 0.653.Dimension:30 pcs/week or lot4.CTQ Para:30 pcs/week or lotVENDORIMPROVELB/LGP/FILM ASSYEDIDFLASHCELLASSYA-PART ASSYB-COVERASSYHINGEASSYAGINGCMOS&LVDSCABLE ASSYRepair FQC F/TFQC COS/TOKNGOKNGMFG Self-Management 1.Daily Floor meeting2.ESD check3.MFG Equipment check4.FAI of every shiftIPQC Audit1.WI/MN Version&Expire2.OP Discipline Audit3.Equipment Audit4.Parts P/N,F/W Version Audit Production FlowOQCSFCSMFG Line Yielding DataTracking:Key Parts to SYSSYS to Key PartsTracking:Common Parts Lot CTRLSFCS Tracking SystemInput MO&S/NInput Part NoInput ASSY DataAging Site ScanFQC Site ScanOQC Site ScanPacking StationScanShipping ScanS/N,ModelQuantity,CardW/H Entrance ScanOQC FlowOQC FUNC INSPECTIONPASSOQC COSM INSPECTIONPACKINGREPAIRREFLOW OBA AuditPASSA.XVT,OQC check by 100%B.MP check by 100%,as continuous 10 lots with no reject then OQC check by MIL-STD-1916 Sampling plan:1.Functional:Level 3 2.Cosmetic:Level 3 3.Dimension:30 pcs/wk 4.CTQ Para:30 pcs/wkC.Once 2 lots rejected,OQC back to 100%check.OKNGOKNGOKNGFQCW/HCLOSELine Escape ManagementMEETINGFACUT-IN PRODUCTIONPROD/SHIPON HOLD 3 LOTSTRACKCAOKNGOKNGOKNGLINE ESCAPELine Escape:1.Single defect rate 3%.2.Single defect continuous 3 pcs reject.3.Safety issue occurred!4.Isolation should be taken before Line Escape confirmed!MQA Inspection EquipmentSiteEquipmentSpecLimitQtyIPQCClipper0 3003001IPQCClipper0 4504501IPQCClipper0 6006001IPQCClipper0-100010001IPQCBM-7-2IPQCStatic Tester-1IPQCCCD-4IPQCBM-5AS-1IPQCLumen Meter-1IPQCSurface Resistance Tester-1IPQCParticle Meter-1IPQCPattern Generator-1IPQCAnemometer-1OQCPattern Generator-1OQCMagnifier 50 X2OQCFiller Gauge0.05 1.00 m/m-2FYR TREND FYR DATAContinuous ImprovementCORRECTIVE ACTIONROOT CAUSETRAKINGCIT MEETINGMFG/PQEMFG/PQEME/PE/RDME/PE/RDPQE/SQEPQE/SQEMFG/ME/PEMFG/ME/PEPQE/SQEPQE/SQEMFG/ME/PEMFG/ME/PEPQE/MPMPQE/MPMitemTraining Subject LocationTimeHost1SIP introduceFloor1 hrMQA/Luke2Handling of Scale,Gauge&MeterFloor1 hrOQC/Jack3Failure Mode IntroduceFloor1 hrIPQC/Ling4On-site OperatingFloor2 hrForeman5On-site PracticeFloor24 hrsForemanTraining PlanTraining Plan:To enhance Inspector detectable capability.A.Contents:B.Training Program:SIPSIPHandlingHandlingFailure ModeFailure ModeOperatingOperatingPracticePracticeflunkflunkLine Qualification ProcessCategoryLine-Qualification ItemsDescriptionsHostOperatorOperator trainingTraining material&RecordForemanIPQCCheck at assembled or sub-assembled units10 units of each OperatorsForemanIPQCFixture&EquipmentThe daily maintain/daily check record Certificate validation&operation audit ForemanIPQCThe Fixtures abnormal tracking recordTracking RecordMEIPQCEquipment standard operation instructionChecklist and/or calibration Status RecordMEIPQCMethodWI verificationUpdate versions per buildPEIPQCThe WI execution statusUpdate versions per buildFormanIPQCFixture FAI Record checkCalibration validation,proper function checkFormanIPQCEnvironmentProduction line ESD,dust&Illumination check record1.Validation by ESD equipment measurement.2.Operating zone luminance:900 1100 Lux.3.BKL assemble zone dust grade:10K DegIPQCQAFirst line qualificationThe rest Line qualificationRebuild Line Qualification1.First line qualification=180 units/line/shift2.The rest Line Qualification=90 units without failure.3.Rebuild Line Qualification=90 units againOQCTherapy Audit3 NG units/Line/shift to check if kick outForemenIPQCLine Qualification ProcessTEST ITEMEVTDVTPVTMPORTECHostHostDQEDQEDQEQEQE1Temperature test(Operating)vvvTBD2Temperature test(Non-Operating)vvTBD3Humidity test(Operating)vvvTBD4Humidity test(Non-Operating)vvTBD5Temperature/Humidity test(Operating)vvvTBD6High temp leaving(Operating)vvTBD7Thermal shock(Non-Operating)vvvTBD8Shock(Non-Operation)vTBD9Vibration(Non-Operation)vTBD10ESDvTBD11Package VibrationvTBD12Package Drop vTBD13Real Transportation test(1pallet)vReliability Test Key PartsTest ItemLife Time Level1LGPAbrasion testNACompression testNAHardness testingNALGP matrix dot adhesionNA2FILMAbrasion testNA3Light BarStudyingPendingFPC Bending test20 cycle4A CoverHardness testingNA5B CoverLogo Adhesion testingTape(3M/610)sticker 3 times 6CellStudyingPending7CMOSStudyingPending8MicrophoneStudyingPending9AntennaStudyingPending10Cable(2 in 1)Bending test 3000 cycleConnector life cycling testPending11Cable(LVDS)Bending test 3000 cycleConnector life cycling testpending12HingeSwing test20K cycleComponent Reliability Test QE EquipmentEquipmentRangeSizeQtyConstant Temp/Humid CabinetTemp:-30 80 0CHumid:10 95%2600*2400*20004Thermal Impact CabinetTemp:-70 200 0C-720*920*4501Hearting OvenTemp:RT 200 0C-800*1050*8002CMM-1Microscope200 X-1BM-7-5SR-3-1CCA 133 NB system C/D Parts-Q3 PlanND Filter 5%-Q3 PlanND Filter 6%-Q3 PlanMulti Function Board-Q3 PlanC/D Parts Connect Cable-Q3 PlanLight Bar Meter-Q3 PlanLumen Integration Ball-Q3 PlanCustomer Quality ServiceCategoryContentsReportHostCorrelationCheck customer IQC/MFG site quality status of NPI 100 units with OQC inspection Record Correlation ReportCSECustomer Complain1.24 working hrs initial response time2.24 hrs working hrs of process issue close time3.7 working days of engineer issue FA&CA report 4.Tracking1.Failure Analysis Report 2.Corrective Action Report 3.Customer complain tracking logCSEEngineering Change1.Follow up Customer Engineering Change(ECN)2.Offer Supplier Engineering Charge Request (SECR)SECN/ECN tracking logCSEFailure Mode Capturing Investigation the root cause of first 100 function failure units and customer assigned failure with corrective action conduct inFARQELesson&Learn Design GuideRDRMARMA program operatingRMA RecordCSECSE Review1.Customer offer LRR&detail failure ledger 2.Monthly Review meeting or Bi-weeklyCSE ReportCSECustomer Quality ServiceTHANK YOU!