FMQAI-502(15)NewLineQualificationProcedure(新生產線資格驗收程序)

1、學習資料收集于網絡，僅供參考學習資料學習資料收集于網絡，僅供參考學習資料FLEXTRONICSWORK INSTRUCTION作業(yè)指導書DOC. No. /文件編號： FMQAI-502REV./版本號：15PRODUCT/ 產品：Microsoft ProjectsTITLE / 標題:New Line Qualification Procedure新生產線資格驗收程序PAGE/頁數1 OF 15REVISION HISTORY /版本記錄REVISION版本CHANGE DESCRIPTION修改內容ISSUER發(fā)布白RELEASE DATE發(fā)行日期01First release/ 首次發(fā)

2、行Jolley Wang06/28/0802Updated new line qualification target for console project 6.5.Add new line qualification target for Kinect 6.5.Jolley Wang8/10/0903Update console new Safe Launch process as per MS requirement.Martin Chen2010/11/1204Update PCBA Manufacturing Process Qualification audit Checklist

3、, add Kinect content. Cancel Zune content. Update Appendix 1 Add Kincet PCBA buy off checklist.James Fu2011/8/1305Update Appendix 3 Kinect BB buy off checklist.Update Appendix 3 Form.Update Appendix 4: Safe Launch yield ReportCandy Tang Taylor Dai Tony lee2012/01/1806Cancel 5.1, 6.6.2 and Appendix 3

4、、4、5 Agra content for AgraEOL; Add 6.1 Safe Launch Trigger and Timing; Combine 6.10 into 6.5; Combine 6.8 and 6.9 into 6.6 Update 6.6.2 and 6.6.3; Cancel Monaco content for it EOLCandy Tang Taylor Dai2012/04/2307Update PCBA manufacturing process qualification audit check list: FMQAI-502-F1, add Box

5、Build manufacturing process qualification audit check list FMQAI-502-F12James Fu Cissy Ma2012/05/2408Add 3.6 EHS dept.Add 5.6 EHS New EHS checklist.Add EHS safety compliance into 6.5Add EHS check listAmol Lin2012/09/1909Add the requirement 100% checking X-ray for whole PCBA into phase I-10pcs FAICis

6、sy Ma2013-5-2710Update item 6.5: added CP into documentation buyoff.Adman Wu2013-8-111Update the Console line buyoff check list FMQAI-502-F12Add the Durango BB Line layout check for cosmetic impact in 6.3 and update Kinect line qualification check list FMQAI-502-F8.Update the Durango Target in / 更新

7、Buyoff 點檢表 / 6.3增加檢查線體設置是否影響外觀/更新Durango的目標和更新Kinect Buyoff 點檢表Tony Lee Elina Zuo2014-4-2112Update the version of XBOX One PCBA Manufacturing Process Qualification audit Checklist from FMQAI-502-F1.03 toFMQAI-502-F1.04更新XBOX One PCBA 線驗收清單Updated item 6.1 to add New Line for Special Builds更新條款6.1增加新

8、生產線的特殊生產Update KPI Target for XBOX One and add ESD engineer for ESD responsibilityCissy Ma Tony Lee Xulork Fan2014-6-20學習資料收集于網絡，僅供參考學習資料學習資料收集于網絡，僅供參考學習資料REVISION版本CHANGE DESCRIPTION修改內容ISSUER 發(fā)布白RELEASE DATE發(fā)行日期131415Update the version of Maya PCBA Manufacturing Process Qualification audit Checkli

9、st from FMQAI-502-F7.01 to FMQAI- 502-F7.02 and add Lithium PCBA 、Petra PCBA Manufacturing Process Qualification audit Checklist FMQAI-502-F14.01and FMQAI-502-F15.01更新 Maya PCBA 線驗收清單，增力口 Lithium PCBA 、 Petra PCBA 線驗收清單 FMQAI-502-F14.01 and FMQAI-502-F15.01Due to GC and Boron EOL,update the For Lith

10、ium/Homer/Marge/Caddy target因為GC及Boron機種停產，更新 Lithium/Homer/Marge/Caddy 目標。Update the BB Line Buyoff Checklist (From FMQAI-502- F12.02 to FMQAI-502-F12.03) for replacing PMP by Control Plan更新Console BB 線驗收清單，Add Baker project safe launch yield target andBaker line qualification audit check lists FMQ

11、AI-502-16.01& FMQAI-502-17.01 & FMQAI-502-18.01Combine BB and PCBA line qualification audit check list from different projects. Delete FMQAI-502-F1 、-F7、-F8、 -F9、-F11、-F12、-F14、-F15、-F16、- F17、- F18and Add FMQAI-502- F19.01and FMQAI-502- F20.01刪除 FMQAI-502-F1、-F7、-F8、-F9、-F11、-F12、- F14、-F15、-F16、-

12、F17、- F18 和增加 FMQAI-502- F19.01and FMQAI-502- F20.01Quanping QiuXulork FanElina ZuoVince Gao2014-11-082015-04-152015-05-26REMARK備注APPROVALDEPARTMENTNAMETITLE部門名字職位QA SF Toh ManagerTE HW Boey Sr. ManagerPE Ge0rge Liu DirectorMBU GuoFengLi ManagerMBU Eric Qiao ManagerMBU Tony Li ManagerPurpose 目的To es

13、tablish the qualification procedure for new production lines and ensure the machines have been evaluated, operators, related documents and related materials have been prepared before mass production. 為新生產線建立一套資格驗收程序以確保機器在產品批量生產前得到評估人員，相關文件及物料等在批量生 產前準備就緒。Scope 范圍The procedure applies to the new line

14、s set up and line move, lay out change for all Microsoft projects in Flextronics Manufacturing (Zhuhai) Co, Ltd.此程序適用于偉創(chuàng)力制造(珠海)有限公司所有微軟項目新建生產線,線體移動 ,布局的改變。Responsibility 職責IE Dept.IE is responsible for designing and setting up new line and follow up the status. IE 負責統(tǒng)籌和建立新的生產 線并跟進生產線的狀態(tài)。EE/PE/TE Dep

15、t.:EE/PE/TE is responsible for evaluating the capacity the machines/testers etc. (e.g. GR&R, Cpk.).EE/PE/TE 部負責對機器，測試儀設備能力等進行評估(如 GR&R, Cpk) 。MBU Dept.:MBU is responsible for preparing the hardcopies of necessary documents, personal training, materials and others necessary on the production lines.MB

16、U 負責準備生產線上所需用的文件, 人員培訓 , 物料等等。CQE Engineers/Auditors:CQE Engineers/Auditors is responsible for performing the qualification audit for new production lines and requesting corrective action for the non-conformance, verifying the result of provided corrective actions. CQE 工程師/稽查員負責對新生產線進行稽查，并針對稽查中所發(fā)現的不

17、符合項，要求相關的負責人提供相應的改善行動，并對改善行動的結果進行驗證。All Departmental Managers/Supervisors:Departmental Managers/Supervisors are responsible for providing necessary supports for the qualification audit and ensure the departmental operations comply with the requirement. The effective corrective actions need to be pro

18、vided for any deviation, which is found during the audit.所有部門經理/ 主管 /工程師：負責對資格限定稽查提供必要的支持，并確保本部門的運作符合相關的控制要求，并針對稽查過程中發(fā)現的任何不符合項采取糾正改善措施。EHS Dept.:EHS is responsible for safety evaluating the compliance of line/machines /tool etc.EHS 負責對產線、機器和工具等進行安全符合性評估。ESD Engineers:ESD Engineers is responsible for

19、 ESD evaluation the compliance of line/machines/tool etc.ESD 工程師負責對產線、機器和工具等進行ESD 符合性評估。Definitions 定義PCBA: Printed Circuit Board Assembly.PCBA: 印刷線路板裝配BB: Box-Build Assembly.BB: 外殼組裝ESD: Electro-Static Discharge.ESD: 靜電釋放新產線安全評估表 FMAQAI-502-F13Procedure 程序Safe Launch Trigger CriteriaSafe Launch 的觸發(fā)

20、條件When met any of the following criteria, need trigger and follow Safe Launch process當達到以下任何條件，需要觸發(fā) Safe Launch過程Setup new lines additional to the existing MP line for ramp support 在MP階段增加新線25% new operators introduce to an existing MP line超過25%的新員工加入現有量產的生產線。Resumed a MP Line which idle for more th

21、an 3 months在MP階段，重新使用閑置超過三個月的產線Moved a MP line from one place to another place搬動MP產線New Line for Special Builds新生產線的特殊生產Notes: this applies for a product which already in MP stage only; qualify a new material, new product follow the standardized PV process which not cover in this process.注意：Safe Lau

22、nch只針對MP階段的產品；驗證新的物料，新的產品安裝PV過程標準執(zhí)行，不適用于Safe Launch過程。IE Engineers prepare Sequence of Events (SOE) , layout for the new project, calculate the requiredquantity of operators and prepare schedule for ESD system buy off, and notice the related departmentsto set up the new line. IE工程師準備事件順序表( SOE ),新生產

23、線工位布置圖，計算需求人數并準備ESD驗收進度表，同時通知相關部門。PE,TE,FE, and EE technicians will perform the ESD system buy off for the new production line after it was set up, QA auditors will verify th e ESD system when received the PE s checking results and send the reports to the team members. PE, TE, FE 和EE技術員在新生產線建成后對ESD系

24、統(tǒng)進行驗收，QA稽查員收到驗收結果之后對新生產線進行ESD驗證并將結果通知項目組成員。Program should notice Quality Engineer and team members to perform the new production line qualification audit when the documents, Equipment, tooling and fixtures, KANBAN, ESD etc. have been prepared.當文件，機器，夾具，看板 ，ESD等準備就緒后，商務負責通知品質工程師及項目組成員對此 生產線進行驗收。Quali

25、ty Engineer prepares the process qualification audit checklist for the new production lines base on the checklists (Appendix 1) and performs the audit with the team members. Complete the audit, summarize the non-conformances in the Qualification Audit Findings and Actions Report of FMQAI- 502-F3.02

26、and send it to the related departmental responsible persons. (Remark: Score base on rating scale Tabel-1) 。The process follow chart of every project is not the same, check list can adjust.品質部工程師根據稽查表建立適用新生產流程的稽查清單(附件1),并和項目成員一起對新生產線進行資格驗收。完成驗收，將不合格項匯總在FMQAI-502-F3.02 ,通知相關部門。(備注：評分依據等級量表-1.)針對各個項目的流

27、程不同，檢查表可以做適當的調整。Table-1/ 表-1Milestone Readiness %Rating ColorRating Explanation100%GRNQualification of Element is completed/符合所有要求50%YELFew part of the Qualification Element is not completed/部分要求未充蔭足0%REDQualification Element is not started/所有要求未執(zhí)行.Pre-build line audit and buy off on areas listed be

28、low產線buy off檢查需包括以下內容：Documentation buyoff (PMP/CP, WI, Quality Alert Notice)文件 buyoff ( PMP/CP, WI, 品質警報線)Operator Training and Certification操作員培訓記錄和上崗證明Machine, Testers, Fixture and Tools calibration and maintenance schedules設備、測試機、夾具和工具的校準以及維護記錄在有效期內Product specific Critical processes, process se

29、quence, tools and fixture compliance.關鍵工序、工藝流程、工夾具符合 TQCI 和 WI 要求ESD and MSD control (if applicable)ESD 和 MSD 控制SFCS and TCS validation(if applicable)SFCS 和 TCS 控制Module capability demonstration for machine and tooling (CPK ， GR&R, etc)設備和工具的驗證( CPK ， GR&R )Strain Measurement data for each new line

30、of Console and Kinect Project.在 Console 和 Kinect 項目必須進行應力測量EHS safety complianceEHS 安全符合性Check the line layout impact the product during product transfer. 檢查產品在傳動的過程中線體設置會影響產品產品外觀。If the total score of the new production is less than 90%, the production line must be stopped to improve. The relative

31、Departmental Managers/Supervisors/ Engineers provide the effective corrective actions for the non- conformance, Quality Supervisor/ Engineer verify the result of provided corrective actions. If the result is accepted, next step can be run. Otherwise, responsible department should continue to provide

32、 the effective action till the result is accepted. All of the items should be closed in 24h.如果稽查得分低于90%, 此條生產線必須停止生產進行改進，相關部門經理/主管 / 工程師對稽查過程中發(fā)現的任何不符合項提供有效的改善措施，品質主管/工程師對改善結果進行驗證，如果改善結果可以接受下一階段的安排方可進行，否則，責任部門應繼續(xù)提供有效措施直到改善結果被接受為止。所有的不合格項目必須在 24 小時之內完成。If the result is accepted, QA should summarize al

33、l line buy off reports, and then submit this to MicrosoftFM team within 12 hours to do a final approved for new line buy off. Once FM team approve, QA can agree MBU go ahead phase by phase on condition that hit determined acceptable goals for each phase, send the phase data to customer within 12 hou

34、rs, only can move to next phase when current phase data be reviewed by customer and meeting the defined goals. QA respond for collecting data and TE should do deep dive FA for every failed unit. Corrective action is also need till all of open item was closed. If the result is still good, go to 3 rd

35、phase, two weeks trial run. Once completed this control run.QA should collect all function station s yield and OBA performance. TE should perform failureanalysis on defective units and find root cause. Corrective action is also needed， QE should follow upon all Open Item till closed.如果稽查的結果可以接受， QA

36、應該收集所有的生產線 buy off 的報告，在 12 小時之內提交給微軟FM做一個最后的批準，一旦FM 批準， QA 可以同意生產部安排各階段的生產， 每個階段必須滿足設定的目標并在 12 小時內發(fā)送給客戶審批，經客戶審批后才能進行下一階段的生產。每個階段一完成， QA 應該收集所有功能測試站的良率和 OBA 的 DPPM,TE 負責分析所有的不良，針對每一片不良，需要有 改善措施.直到所有的問題被關閉, QE 工程師負責所有的問題被關閉。Notes: No. of phase and Qty. for each Phase may change based on product compl

37、exity and UPH, Tier1 factory need come up the proposal for FM approval.注意：每個階段的數量可以根據產線UPH 進行調整，并得到客戶認可。After Microsoft FM team reviewed the phase report and approved, all of the finished goods which inphase 1,2 and 3 can be shipped. Production line can proceed to mass production and continue to mon

38、itor the yield for 2 weeks.客戶批準階段報告后，1,2,3階段的產品可以正常出貨。產線可以開始批量生產，持續(xù)跟蹤2周5.9.1 General Target Setting GuidelinesPhase 2 FPY target follow existing MP line - 2 SigmaPhase 2 FPY 目標參照現有的 MP線數據減去 2倍SigmaPhase 3 FPY target follow existing MP line 1 SigmaPhase 3 FPY 目標參照現有的 MP線數據減去1倍SigmaPhase 4 FPY target

39、follow existing MP linePhase 4 FPY 目標參照現有的 MP線數據 For ConsoleProjectStationPhase -1Phase -2Phase -3Phase -410 (FAI)100 (Hourly out put)1000 (shifty out put)2 Weeks out putTargetTargetTargetTargetConsoleICT100%98.33%98.55%Collect recent three months average yield data as base lineXT100%92.12%93.45%ACT

40、100%98.38%98.65%OBA100%100%100%NormalOBA Sample Size100%100%10%Normal Sample SizeRemark: The 1 phase as qualification phases and need 100% check X-ray for whole PCBA, the 2 , 3 phases as the Safe Launch phases; all phases successes can treat as Safe Launch finished; If the 2n and3r Safe Launch phase

41、 failed, the new line must re-qualify the previous three phases. In phase 1, we should insure all X-stress test carts were covered.When we qualify X-stress test station , if there s any deviation received for Safe Launch from customer, follow the deviation.備注：第1階段屬于新線資格檢查階段并且需100%對PCBA全部位置照X-Ray，第2,

42、 3階段屬于SafeLaunch階段，所有的階段成功完成才能被認定Safe Launch完成，如果第2, 3階段不能夠符合要求，這條新線必須重新進行資格檢查。在新線試跑第1階段的時候，驗證老化測試架時，必須涵蓋所有的測試架。如果客戶發(fā)出DEV#要求暫時執(zhí)行新的Safe Launch,將按DEV#執(zhí)行。 For KinectSMT & BB lines UPH are differently, and will be qualified separately, and OBA testing not applicable forSMT lines. SMT 和BB過程UPH不同，需要分開驗證，O

43、BA測試不適用 SMT過程。PCBA Safe Launch criteria/goals for each phase ( For Maya and Petra )PCBA Safe Launch個階段目標(For Maya and Petra )ProjectStationPhase -1Phase -2Phase -3Phase -436 (FAI)380(Hourly input)3000 (Shifty input)2 Weeks inputTargetTargetTargetTarget學習資料收集于網絡，僅供參考學習資料學習資料收集于網絡，僅供參考學習資料Maya/PetraIC

44、T100.00%99.47%99.70%Collect recent three months average yield data as base lineFCT100.00%98.95%99.10%PCBA ETE100.00%98.43%98.80%Note: Above target will be fine tuned, if needed, after reviewed with MS team regularly.注意：以上目標可以被適當調整，并得到客戶同意BB Safe Launch criteria/goals for each phase (for INCA and Par

45、adise )BB Safe Launch 個階段目標(foENCA and Paradise )ProjectStationPhase -1Phase -2Phase -3Phase -415 (FAI, 5pcs/assembly line)450(Hourly input)2000 (4 Hour Input)Two weeks monitorTargetTargetTargetTargetINCAInitialization100%99%99.12%Collect recent three months average yield data as base lineCalibratio

46、n100%99%99.50%M&A100%99%97.07%X-tress100%98%98.05%Performance100%99%99.24%MCT100%99%99.45%BB ETE100%93.20%92.64%OBA100%100%100%Normal Sample SizeOBA Sample Size100%50%10%Normal Sample SizeProjectStationPhase -1Phase -2Phase -3Phase -415 (FAI, 5pcs/assembly line)450(Hourly input)2000 (4 Hour Input)Tw

47、o weeks monitorTargetTargetTargetTargetParadiseConnectivity check100%98.68%98.79%Collect recent three months average yield data as base lineIlluminationSystem100%98.82%98.92%Run in100%99.73%99.77%Power check100%98.99%98.77%P0 Calbiration100%99.13%99.37%Geometrical registration100%99.65%99.71%Perform

48、ance100%97.47%98.63%Audio100%99.39%99.49%MCT100%99.59%99.71%Note: Above target will be fine tuned, if needed, after reviewed with MS team regularly. Before Phase 3, we should insure all X-stress test cart locations were covered when we qualify X-stress test station.3階段之前，驗證老化測試架時，必須涵蓋所注意：以上目標可以被適當調整

49、，并得到客戶同意。在新線試跑第 有的測試架上所有的位置 For Lithium/Homer/Marge/CaddyProjectStationPhase -1Phase -2Phase -3Phase -410 (FAI)100 (Hourly output)1000 (shifty output)2 Weeks out putTargetTargetTargetTargetLithiumSMT VI100%99%99.80%Collect recent three months average yield data as base line, OBA(Normal sample size)

50、Target is 100%,W/S VI100%99%99.80%Base Band100%99%99.50%FVMI100%99%99.80%OBA100%100%100%OBA Sample Size100%100%10%FPY-E-E100%99%99.50%MargeSMT VI100%99%99.80%W/S VI100%99%99.80%FVMI100%99%99.80%OBA100%100%100%OBA Sample Size100%100%10%FPY-E-E100%99.0%99.80%HomerSMT VI100%99%99.80%W/S VI100%99%99.30%

51、Baseband100%99%99.70%RF Test100%99%99.70%Final VI100%99%99.90%OBA100%100%100%OBA Sample Size100%100%10%FPY ETE100%98%99%Caddy (Lobo R)VI for HDDM100%99%99.40%Image Test100%99%99.30%VI for package100%99%99.90%OBA100%100%99.90%OBA Sample Size100%100%10%FPY ETE100%99%99.3% for Baker ProjectProjectProce

52、ssPhase -1Phase -2Phase -3Phase -4Station10 (FAI)100 (Hourly output)1000 (shifty output)2 Weeks out putTargetTargetTargetTargetBakerSMTSMT BB test99.30%99.30%99.30%Collect recent three months average yield data as base line, OBA(Normal sample size)Target is 100%,W/S VI99.60%99.60%99.60%BoxBuildMotor

53、98.50%98.50%99.00%Charged99.50%99.50%99.80%FF0198.50%98.50%98.90%WAT99.50%99.50%99.80%CaAD0198.30%98.30%98.50%FFT0299.50%99.50%99.70%GAS99.00%99.00%99.30%Audio99.00%99.00%99.50%UV&ALS98.50%98.50%99.20%SIT97.80%97.80%98.00%Charge0299.90%99.90%99.90%BT99.80%99.80%99.80%FVI (CaAD02)97.50%97.50%98.30%Lo

54、ckBit99.90%99.90%99.90%FPY-ETE86%86%90%5.10 Quality Engineer should submit Safe Launch yield report and TE FA report to Quality manager for final review, then QA manager send to customer for approve. Release the new production line once customer approved. Please refer to Appendix 4.1 Qualification y

55、ield Report.QE工程師需要提交Safe Launch的良率報告和 FA報告給品質部門經理做最終審核，然后由 QA經理發(fā)送給客戶批準。一旦客戶批準可釋放新的生產線。報告格式見附件4.6.0 Appendix 附頁Appendix 1 PCBA Line Qualification Checklist附頁1 PCBA線驗收清單PCBA Line Qualification Checklist FMQAI-502-F20.01PCBA Manufacturing Process Qualification ChecklistStation TypeAreaQualification E

56、lement / CriteriaPCBA Line XXAssemblyOffline serial number label printing#DIV/0!ProcessCorrect TQCI / WI is on the workplace and followed /工作臺上放正確的 TQCI 并嚴格遵守ProcessOperator/inspector is skillful and certified /操作員熟練并被鑒定過ProcessAdequate tooling and fixture is available/有足夠的工夾具QAESD measurement is do

57、ne and compliance/已測 ESD 且符合EHSEHS compliance audit is done and pass/已通過 EHS 評估ProcessWorkstation layout completed/工站布局完成ProcessFloor and Material Identification / Non-conforming Material Collection /地板、良品和不良品分開存放并有清楚的標識ProcessFlow chart readiness /流程圖準備好ProcessControl Plan readiness /控制計劃準備好QAPFMEA

58、 readiness /PFMEA 準備好ProcessAll parameters setting flow with CP/所有的參數設置符合CP要求MESSFCS and TCS is readiness /SFCS和 TCS 系統(tǒng)準備就緒ProcessNo potential risk for product cosmetic impact /確認無潛在風險影響產品的外觀ProcessEquipment PM was performed & recorded設備保養(yǎng)并 t 己錄ProcessEquipment was calibrated and identified設備校驗合格Kin

59、ect: BB Line Qualification Checklist組裝線驗收清單PCBA Line Qualification Checklist FMQAI-502-F19.01BB Manufacturing Process Qualification ChecklistStation TypeAreaQualification Element / CriteriaMilestoneReadiness %ResultRemark#DIV/0!ProcessCorrect TQCI / WI is on the workplace and followed /工作臺上放正確的 TQCI

60、 并嚴格遵守ProcessOperator/inspector is skillful and certified /操作員熟練并被鑒定過ProcessAdequate tooling and fixture is available/有足夠的工夾具QAESD measurement is done and compliance/已測 ESD 且符合EHSEHS compliance audit is done and pass/已通過 EHS 評估ProcessWorkstation layout completed/工站布局完成ProcessArea / Material Identifi