1 dot hill confidential 3y psu weekly kpi week 06 presented by:xx date: 20 nov. 2011
TRANSCRIPT
1Dot Hill Confidential
3Y PSU Weekly KPIweek 06
Presented by:XX
Date: 20 Nov. 2011
2Dot Hill Confidential 2
Measurement
Shortage & Build Plan (CTB)Process YieldRMAECR/ECO& Rev Change ListORT&HASA
PSU Weekly KPI
3Dot Hill Confidential 3
The Gray is shipped
The Green is planned to build and ship
The pink is assumed to build, quantity need further confirmation.
PSU Weekly KPIShortage & Build Plan (CTB)
Shortage and build plan
SMT
23/4/20July 24, 2007
Dot Hill Confidential 5
SMT yield Trend
Trend chart – AOI and FQA
Unavailable
Next production schedule March
23/4/20July 24, 2007
Dot Hill Confidential 6
SMT Process Top Failure FACA
FACA – AOI and FQA
Unavailable
Next production schedule March
23/4/20July 24, 2007
Dot Hill Confidential 7
Assembly – front end yield Trend Until before pre-test
23/4/20July 24, 2007
Dot Hill Confidential 8
Assembly front end -- Process Top Failure FACA
Wave solder DPPM trend chart
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
total solder points焊錫點 293540
defective count不良數 255
DPPM焊錫不良 869
component qty零件數
defective count 不良數
DPPM作業不良 #DIV/0! ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### #####
TOTAL 869 ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### #####
Target目標 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950 950
類別
焊錫不良solder defect
作業不良workmanship
869 869
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
200
400
600
800
1000
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
焊錫不良DPPM
作業不良DPPM
TOTAL
目標Target
YM-3591AAR
23/4/20July 24, 2007
Dot Hill Confidential 9
week周別 type類別不良數量qtydef
完成時間due
責任人
responsible
5W sol der defect 30i mmediatel y
胡鑫
5W sol der defect 26i mmediatel y
胡鑫
corrective改善措施action
rootcause analysis原因分析主要不良位置description及現象
no sol dersol der contract t i me notenough
adj ust sol der t i me
sol der bri dgesol der contract t i me notenough
adj ust sol der t i me
Wave solder FA Analysis
Assembly – back end yield Trend
Assembly Backend – Test yield trend chart
FPY Trend chat
97.90%
98.00%
98.10%
98.20%
98.30%
98.40%
98.50%
98.60%
98.70%
Target
Yield
Target 98.17% 98.17% 98.17% 98.17% 98.17% 98.17% 98.17% 98.17%
Yield 98.61%
05 06 07 08 09 10 11 12
31
63 2 1 1 1
68.89%
82.22%88.89%
93.33% 95.56% 97.78% 100.00%
0
5
10
15
20
25
30
35
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
Q'ty 31 6 3 2 1 1 1
Rate 68.89% 82.22% 88.89% 93.33% 95.56% 97.78% 100.00%
材料不良 空焊 元件損壞 錯件 貼反 漏件 誤判
Defect Pareto
Defect corrective action
Defect item Q'ty Root cause Corrective action Status
材料不良materialdefect
31主要為T901*4pcs來料線反導致開機測試無輸出Major is T901*4pcs. Wire reverse,fail to boot
針對此不良，反饋廠商100%測試改善，料號8LM0249703GP，廠商益宏Feedback to vendor, 100% screen lot8LM0249703GP, vendor HongYi
closed
空焊insufficentsolder
6主要為SMD零件U107，U106，R227，R286空焊，Major U107, U106, R227 ,R286
反饋產線，領班，員工和IPQC進行檢查SMD零件Yield is above set target.inform line leader/operator/IPQC tocheck to monitor solder printing
closed
元件損壞damage
3 零件損壞為於轉運中受損 damage duringtransfer
反饋產線，領班，員工和IPQC進行檢查，落實於流水線中用托盤進行轉運，避免碰傷零件inform lineleader/operator/IPQC to ensure usageof PCBA tray
closed
Final test raw data
OBA
23/4/20July 24, 2007
Dot Hill Confidential 13
23/4/20July 24, 2007
Dot Hill Confidential 14
DPPM Trend chart OBA
30300 0 0 0 0 0 0 0 0 0 0 0 0780 780 780 780 780 780 700 700 700 700 700 700 700 700 7000
12000
2400036000
480006000072000
8400096000
108000120000
03000
60009000
120001500018000
2100024000
2700030000
總抽驗數 總不良率(DPPM) GOAL DPPM
23/4/20July 24, 2007
Dot Hill Confidential 15
Assembly – Final test yield Trend
OBA failure tracking
日期date
機型model
批量qty
抽樣數s
不良數def
不良描述 descr
不良原因 Failure analysis
改善措施action
責任單位dept
2012/1/5
GP.YM-3591AAR
440 50 1
均流測試燈不滅Test current LED on
將 U405 IC 加錫後機台橙色燈恢復正常橙燈不滅是由於 IC U405 假焊導致，屬SMD 異常U405 cold solder
1. 已將不良反饋各測試站作員要求後續 100% 檢查燈不的不良現象，各測試站均需查此項避免不良再次流出 2. 此批返工檢查Feedback to front endWork order 100% screenSMD prevention action --
TBD
SMD
23/4/20July 24, 2007
Dot Hill Confidential 16
RMA
RMA trend DPPM and failure analysis –DC PSU
0200400600800
10001200140016001800
2011
.7~12
W 12
01
W 12
02
W 12
03
W 12
04
W 12
05
W 12
06
W 12
07
W 12
08
W 12
09
W 12
10
W 12
11
W 12
12To
tal
Manu month 2011.7~12 W 1201 W 1202 W 1203 W 1204 W 1205 W 1206 W 1207 W 1208 W 1209 W 1210 W 1211 W 1212 Total
Shipment 3206 300 0 0 0 0 3506
total Returned 5 0 0 0 0 0 5
MTHLY kPPM 1560 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! 1426
RMA defect analysis – DC PSU
No. RMA#ReceiveDate(接收日期)
Original 3Y SN(原始 3Y 標籤序號)
3YRev.(3Y版本)
DateCode(周期)
Q'ty
Customerreported((FieldSymptom)(顧客不良描述)
Key ComponentLocation(關鍵失效元件
位置)備註
1 R111102001 11/02/11 SA000E161132MY01FQ A 1132 1 Amber LED NDF2 R111102001 11/02/11 SA000E161132MY0177 A 1132 1 IIC fail re-test IIC3 R111102001 11/02/11 SA000E161132MY015L A 1132 1 CASE distortion chassis CASE4 R111102001 11/02/11 SA000E161132MY019V A 1132 1 Amber LED +5VIC 不良5 R111227001 12/23/11 SA000E161141MY02X7 A 1125 1 IIC fail re-test IIC
YM-3571AAR RMA Returned Record
2011.7~12
Remark : Randcmn defect no action required
RMA DC PSU raw data
RMA trend DPPM and failure analysis -- AC PSU
Week 2011.7~12 W 1201 W 1202 W 1203 W 1204 W 1205 W 1206 W 1207 W 1208 W 1209 W 1210 W 1211 W 1212 Total
Shipment 4900 800 0 0 0 0 5700
total Returned 143 0 6 0 8 7 164
MTHLY kPPM 29184 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! 28772
YM-3591AAR RMA Returned Data
0
5000
10000
15000
20000
25000
30000
35000
數列1
RMA defect analysis –AC PSUPROBLEM 2011.7~12 W 1201 W 1202 W 1203 W 1204 W 1205 W 1206 W 1207 W 1208 W 1209 W 1210 W 1211 W 1212 Total %
F101,Q120 22 0 2 0 2 4 30 18%NDF 22 0 0 0 1 1 24 15%R441 17 0 1 0 1 0 19 12%Q111 10 0 0 0 3 1 14 9%F401 7 0 0 0 0 0 7 4%Q104 5 0 0 0 0 0 5 3%R278 4 0 0 0 0 0 4 2%F101,Q121 3 0 0 0 0 0 3 2%U109 3 0 0 0 0 0 3 2%Re-test IIC 2 0 0 0 0 0 2 1%other 48 0 3 0 1 1 53 32%
共: 164
F101,Q120, 18%
NDF, 15%
R441, 12%
Q111, 9%F401, 4%Q104, 3%
R278, 2%F101,Q121, 2%
U109, 2%Re-test IIC, 1%
other, 32%
F101,Q120
NDF
R441
Q111
F401
Q104
R278
F101,Q121
U109
Re-test IIC
other
AC PSU RMA raw data
23/4/20July 24, 2007
Dot Hill Confidential 21
NO. PROBLEM fail Q'ty Root Cause Corrective Action Remark
1 F101,Q120 303YU Q120 ,RD .Q120有送不良的 回台灣做分析 正在處理中defect part under analysis by RD
2 NDF 24 N/A
1. -- visual ok檢查電源外觀 沒有發現問題2. -- .no short檢查錫面和零件面 沒有發現短路和相碰現象or part touch adjacent part
3.B/I 24H , .B/I24 hrs . PSU function後電源有正常輸出normal
4. (H/P,ATE ) PASS. Retest H/P, ATE按正常流程測試 等 都是passes
5. . Return back to customer退還給客戶
3 R441 19
R441 ,因 零件上點有白膠而點白膠治具易與零件相, .R441 epoxy application process碰造成零件受損
nozzle contact R441 and casue damage
, MOI .Update生產時此位置不能點白膠並在 上特別定義MOI to not allow epoxy
RMA Top Failure FACA
22
Dothill PN:81-00000052 Emerson Mfg PN:7001540-J000
Week Issue Description: Root Cause Corrective Actions Owner Due Date Status(RYG)
WW26 … … … ongoing
RMA Issue Action Tracking List
PSU Weekly KPI
23/4/20July 24, 2007
Dot Hill Confidential 23
Production DFM
Production DFM review
3Y production optimisation data collection review
序號sn
發文日期Date
文件編號EC ref no
發文者issue by 機種名稱
model 研發單位RD team
責任人responsible 問題描述description 臨時對策containment
plan 永久對策 Longterm action
預計完成日期 target
completiondate
實際完成日期
compeltiondate
異常級別class grade 結案狀況
1 2010/5/20 胡紹文 YM-2751AAR RD1 范文鵬
初測站測試SB12V電壓低6.6V，范圍為(6.8V-7.1V)，Initital test SB12V below6.6V , spec 6.8V-7.1V. In-process detection
N.A.請產線針對12V Shunt 吃錫量減少，使等效阻抗變大 ，間接讓OP的電壓提升。Reduce shuntlength increase Voltage.
2010/5/30 2010/28/30 一般minor Close
25
PSU Weekly KPIECO monitoring
Update on: Updated By:
Item: DH PN: Mfg PN: ECR/ECO No#: Content: Phase in Date: FAI SN: Updated Rev: Status:
Remark: For the newest update in this week, please use blue font, or else, mark the font in black.
EC & Rev Control Table2012/2/8 XX
Remark : No EC as of year 2012
262626
ORT – DH procedure still pend 3Y commitCurrent data is 3Y curretn test data for year 2012
Dot Hill Confidential
PSU Weekly KPI
23/4/20July 24, 2007
Dot Hill Confidential 27
3Y improvement projects trackerProduct partnumber :1.81-00000047-00-01 / CP-1401R22. 81-00000063 / YM-3591-AAR
Projects :1.Assembly front end a)AOI to replace manual inspection – target eval completion by end Febb) Eliminate lead trimming Phase ! – component lead list , done 10th JanPhase II – end Feb pend AOI evalc)ORT computer monitoring –end Aprild)Production DFM review –on-goinge)Vibration test – pend Taiwan RD for spec finalisation – TBD, pend Roger HuangPhase 1– sampling , need define sampling plan – 1st Mar
2828
THE ENDTHE END
Thanks!
Thanks!
Dot Hill Confidential
PSU Weekly KPI