品质改善报告ppt课件

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1、qContentsContents2CS1 Exit Criteria ReviewCS1 BackgroundKey Issue and Improvement Actions124Customer Service&Quality System Review32014/04:Ultra 10M AF qLite-on Lite-on CS1 CS1 Information(Background)-Information(Background)-RMA parts shipped to Flex TJ caused high blemish issue.Lite-on produced 580

2、pcs defective cameras with abnormal AWB golden sample value in EEPROM,1.5K phones are RMA back to Foxconn from customer.2015/1：Valocia 13M OIS2015/3:Valocia 13M OISLens glue damaged after Moto ALT drop test.2015/1:DVX 1.26MStop production line without official inform Moto and without root cause.OTP

3、re-programmed imagers failed focusing at infinity 2,8 K and 1 field return with defocusing at infinity(only 1X OTP allowed by Motorola)2014/07:DVX Big 8M AF 2014/04:ELX 5M FF2015/4:Valocia 13M OIS Removed testing production line without inform Moto officially.2014/04:DVX 5M AF 53K Sorted out good pa

4、rts for LSC setting incorrect that Lite-on shipped out still failed RU 7.5 DPHU at Moto G phone observed at the first lot of 80 units control run2nd OTP parts for LSC setting incorrect failed RU again with 0.01%defect rate since no following up SDE instruction to have FLT validation100%LSC spec sett

5、ing incorrect(60%LSC spec)caused 20%RU failed at Moto G phone2014/05:DVX 5M AF 2014/05:DVX 5M AF Lite-on has 1.16%MTF defect rate in Foxconn due to Lite-on DC2 test with defocusing DAC value.2014/04:DVX 5M AF 2014/05:Ultra 10M AF Removed K area production while PCN has not approved for production mo

6、ving from K area to C areaRemoved testing production line without inform Moto officially3OTP Failurea.Incorrect program-AWB Failureb.Wrong DAC value-MTF Failurec.Double OTP in the same page-Focusing Failured.Incorrect LSC setting-RI Failuree.Different OTP read-out sequence and method with customer-R

7、I Failuref.Backlight aberrance-RI FailureOTP Issue 6件件 Chance Management 4件件RMA Processing1件件Reliability Failure1件件KeyIssue CategoryChange Managementa.Remove Ultra 10M AF production line without customer official approval.b.Remove DVX 5M AF production line without customer official approval.c.Remove

8、 13M OIS production line without customer official approval.d.Stop production line without customer official approval.Reliability Failurea.The 2dots lens glue meets Lite-on reliability test,but cannot meet Moto ALT.-ALT FailureRMA Processinga.Sort the RMA parts and the good parts reship to customer.

9、-Blemish Issue.OTP Failure6件Change Management4件Chance Management 4件件Reliability Failure1件RMA Processing1件qLite-on CS1 Information(Background)-Lite-on CS1 Information(Background)-OTP Improvement ReportParticle Improvement ReportOptimize the change managementOptimize Product Design document45BeforeBef

10、oreAfterAfterComparison Comparison Incorrect LSC setting-RI FailureIncorrect LSC setting-RI FailureDifferent OTP read-out sequence and method with Different OTP read-out sequence and method with customercustomerBacklight Backlight aberrance-RI Failureaberrance-RI FailureDouble OTP in the same page-F

11、ocusing FailureDouble OTP in the same page-Focusing FailureDVX(5M AF)Ultra(10M AF)Four actions for RI FailureFour actions for RI Failure0 case same issue0 case same issueTwo actions for Focusing FailureTwo actions for Focusing Failure0 case same issue0 case same issueDVX(5M AF)Q2 2014Q2 20143Ultra(1

12、0M AF)1Valocia(13M OIS)After Q2 20152After Q3 2014After Q3 20140Valocia(13M OIS)Incorrect program-AWB FailureIncorrect program-AWB FailureWrong DAC value-MTF Wrong DAC value-MTF FailureFailureSeven actions for AWB&MTF FailureSeven actions for AWB&MTF Failure0 case same issue0 case same issueqOTP Iss

13、ue Performance Review-OTP Issue Performance Review-Q1 2015DVX 5M AFUltra 10M AFValocia 13M OIScases123cases12300BeforeBefore Improved ImprovedAfterAfter Improved ImprovedBeforeBeforeAfterAfterDVX 5M AFDVX 5M AFOTP IssueOTP IssueBeforeBefore Improved ImprovedUltra 10M AFUltra 10M AFOTP IssueOTP Issue

14、BeforeBefore Improved ImprovedValocia 13M OISValocia 13M OISOTP IssueOTP IssueAfterAfter Improved ImprovedAfterAfter Improved Improved0pcs OTP defect0pcs OTP defect64Kpcs OTP defects64Kpcs OTP defectsBeforeBeforeAfterAfter0pcs OTP defect0pcs OTP defect90Kpcs OTP defects90Kpcs OTP defects0pcs OTP def

15、ect0pcs OTP defect50Kpcs OTP defects50Kpcs OTP defectsBeforeBeforeAfterAfterDVX 5M AFDVX 5M AFOTP IssueOTP IssueUltra 10M AFUltra 10M AFOTP IssueOTP IssueValocia 13M OISValocia 13M OISOTP IssueOTP Issue24%76%67Kpcs67Kpcs100%100%100%516Kpcs516Kpcs6082kpcs6082kpcsqOTP Issue Performance Review-OTP Issu

16、e Performance Review-0%0%0%1%92%99%8%OTP Issue ActionsNo.ProblemBeforeAfterAttachment1Incorrect LSC setting-RI Failure1.No low/upper limit for image illumination after LSC setting is applied to sensor1.Shading test item with low/upper limit to check image illumination after LSC setting is applied to

17、 sensor.Different OTP read-out sequence and method with customer-RI Failure2.The OTP read-out method isnt defined clearly2.Sync OTP read-out method and judgment method between customers tester/phone and Lite-on test system,and define the OTP read-out sequence and method in data sheet(test plan).Back

18、light aberrance-RI Failure3.Lite-on didnt detect the illumination change of retest software.3.Control the Y value of illumination by program.4.Lock the backlight switch of LSC&AWB test station 2Double OTP in the same page-Focusing Failure1.No any function to check if OTP data is blank or not before

19、write-in1.Lenovo/Motorola projects must add function to check if OTP data is blank or not before writ-in.2.No final checksum item in last testing station.2.Lenovo/Motorola projects add final checksum item to last testing station.qOTP Improvement Report-OTP Improvement Report-7q OTP Improvement Repor

20、t-OTP Improvement Report-8OTP Issue ActionsNo.ProblemBeforeAfterAttachment3Incorrect program-AWB Failure1.Different version of SW save in the same PC.1.Use DCC to centralize control all test SW and golden sample SW version automatically,and keep the latest version SW in server.5.4.3.2/5.4.3.32.No sy

21、stem control for test SW.3.No lock for test PC.2.All the test PC are locked and controlled by password.5.2.5/5.2.64.No check after OTP burning.3.Lenovo/Motorola projects add check AWB range during burning and double check image in next station if the sensor support apply LSC and AWB or check image b

22、y cell-phone(sample size 1%).5.No system control for software version4.SFCS check the software version.4Wrong DAC value-MTF Failure1.No DAC range control1.Lenovo/Motorola projects must add the DAC range check and stop sensor for“Relay lens”function.5.2.8/2.No stop sensor at“relay lens”for fool-proof

23、2.All programs must check if the program had add the sensor fool-proof.5.2.83.No daily check for cylinder and relay lens moving status.3.Add cylinder lens moving status check to IPQC checklist.qOTP Improvement Report-OTP Improvement Report-9FW FAI ChecklistFW FAI ChecklistTo ensure risks can be capt

24、ured at design phase To ensure risks can be captured at design phase DQA ChecklistDQA ChecklistTo ensure risks can be captured at NPI phase To ensure risks can be captured at NPI phase Fool-Proof&Fool-Proof&重工作業規重工作業規範範To ensure the illumination is within specTo ensure the illumination is within spe

25、cBacklight Backlight Switch Switch LockedLockedqOTP Improvement Report-OTP Improvement Report-10ABCDV Valocia alocia 13M OIS-AWB Issue13M OIS-AWB IssueA.文件與資料管制作業程序B.多姿态光箱操作及維護保養作業規範C.FAI ChecklistD.Software version fool-proof.qOTP Improvement Report-OTP Improvement Report-Design CheckDesign CheckPr

26、ogram CheckProgram CheckIPQC CheckIPQC CheckMTF IMTF Issuessue_01_01MTF IssueMTF Issue_02_02MTF Issue_03MTF Issue_0311To optimize the change managementuUpdated MP change control document and generated change document signatories list to make the person in charge clear.uStep 1Step 2Step 3Step 4qOptim

27、ize the change management-Optimize the change management-uTo make customer special requirements clear for every CFT members,all the customer special request need to register to uChange the person who is responsible for notifying the change from Sales to CQE.uuTo centralize control all the informatio

28、n of Lenovo&Motorola,Create Newcastle folder on the DCC system 12qOptimize the change management-Optimize the change management-PART_04BeforeELX 5M FFELX 5M FFUltra 10M AFUltra 10M AFAfterApr.2014Apr.2014May 2015May 2015Jun.2015Jun.2015Stop production lineRemove production lineRemove production line

29、DVX 5M AFDVX 5M AFValocia 13M OISValocia 13M OISRemove production areTotaTotal l:4cases:4casesThe 2015 after-improvement summary(After Apr.2015)TotaTotal l:0:0 Apr.2014Apr.2014Apr.2014Apr.2014Apr.2015Apr.2015Jul.2015Jul.2015AugAug.2015.2015SepSep.2015.2015OctOct.2015.2015123400casescases13qMake the

30、change documentMake the change document signatoriessignatories list clear-list clear-1415qMake the change documentMake the change document signatoriessignatories list clear-list clear-qGenerate customer special requestGenerate customer special request listlist16qIdentify change owner who will inform

31、 customerIdentify change owner who will inform customer17qCreate Newcastle folder on DCC SystemCreate Newcastle folder on DCC System18qParticle Improvement Report-Particle Improvement Report-19Optimize the LVCM clean method1Reduce the contribution of incoming particle.Optimize the module design 2Red

32、uce the contribution of moving particle and environment.AA process for Lenovo/Moto3Reduce the contribution of assemble process.Cleanroom Improvement4Improve the contribution of cleanroom.Valocia 13M OIS Particle DDPM TrendGoal(was)Goal(now)20M AF Particle DDPM TrendOptimize LVCM clean methoOptimize

33、LVCM clean method dUse hollow protective filmUse hollow protective filmqParticle Improvement Report-Particle Improvement Report-Other improvement actionsOther improvement actions2021vOptimize LVCM clean methodqParticle Improvement Report-Particle Improvement Report-22vOptimize the module design:cont

34、rol the moving particle by dust trap glueNo dust trap glue Add dust trap glue qParticle Improvement Report-Particle Improvement Report-23vOptimize the module design:control the environment particle by hollow protective film.vAdvantage:1.Reduce the influence of environment particle.2.Reduce the risk

35、of person to touch lens.vDisadvantage:1.Need to modify all the test jigs.2.Need to purchase extra protective film.vExtend:Study to modify the tray as Hollow Tray.ongoing in exist 20M project.qParticle Improvement Report-Particle Improvement Report-24qParticle Improvement Report-Particle Improvement

36、Report-vUse AA machine(ASM AA)to assemble HM project.Nora:3 axis AA Nora:3 axis AA UPH 60UPH 60AA method:Lens AAAA method:Lens AAWide FOV,Focusing any distanceWide FOV,Focusing any distanceBefore NORA Before NORA After ASM IS600GSAfter ASM IS600GSASM IS600:6 axis AA ASM IS600:6 axis AA UPH for Dual

37、200UPH for Dual 200UPH for Single 600UPH for Single 600AA method:VCM AAAA method:VCM AASchedule Schedule First M/C:9/21First M/C:9/21SecondSecond M/C:10/20M/C:10/20ThirdlyThirdly M/C:11/17M/C:11/17NORA:Made in NORA:Made in Lite-onLite-onASM IS600GS:Purchase from ASMASM IS600GS:Purchase from ASM25Ite

38、mLITEON-NORAASM-IS600GSAA 模組3 軸 AA*1 站位6 軸 AA*4 站位組裝類型夾持 Lens 進行 AA夾持 VCM 進行 AA優點1.低成本,易調校2.對焦距離無限制(Relay Lens 虛距)3.適用廣角(FOV=100)4.直接驅動產品 VCM1.使用一般 VCM 及 Lens 部件2.光學中心可補償(X,Y Shift 補償)3.自動進出料,減少人工污染4.可單機分次組裝完成雙模料件缺點1.無 X,Y shift 修正2.VCM 動態 Tilt 無補償1.設備成本高2.AA 前須進行 VCM+Lens 預組裝3.僅支援 FOV 80vAA Machine

39、 Advantage and WeaknessqParticle Improvement Report-Particle Improvement Report-26qParticle Improvement Report-Particle Improvement Report-vExtend:Study to remove the mask,only use the shielding layer in COB bunny suit headgear.ongoing in exist 20M project.n Create design check list for Lenovo/Moto

40、customersn Update design check list according to the feedback of customer and plant timely(for glue dispensing,and Burn spec check)n Implement DFX methodology for Lenovo/Moto new project,and extend to all new projects.qOptimize product design documentOptimize product design document2728qCustomer Cus

41、tomer Service Service Flow-Exit Criteria 1B Flow-Exit Criteria 1B 1.Initial ComplainCustomer Service Workflow-Got mail/telephone/site complain by customer.2.Confirmation(Within 4 hrs.)-Confirm defect module(appearance and function)-Confirm F/R and inventory.3.Return defect device-Send back defect mo

42、dule for analysis.4.Containment strategy(within 48 hrs.)-FA Lab finish analysis,including electronics/EDX/X-ray/waveformanalysis.-CQE discuss to come out containment strategy-Update to MCAR5.Preliminary report(within 72 hrs.)-Preliminary report and S/T solutions.-Update to MCAR6.Final report(within

43、5 days.-Final report,including root cause,L/T solution and prevent strategy-Update to MCAR Initial complaint to be handled by FAE Failure Analysis by Lite-Ons FA team within 3-5 days CQE to generate 8D report and follow-up to closure Final report of component issue will be completed within 14 workin

44、g days(sensor 1month).Previous lead time follow 1,3,7 principle(Final report:7days)Previous report of component issue:1 month Previous lead time 25days.(Now 7days)29qQuality System Improvement-Quality System Improvement-Exit Criteria 2&4Exit Criteria 2&475%20%20%40%40%60%60%80%80%100%100%TSA Perform

45、anceTSA Performance1 10%0%6565%78%78%20%20%40%40%60%60%80%80%1 10%0%100%100%QSA PerformanceQSA Performance4040808077%77%TSA score comparisonTSA question comparison59%59%78781 12014201420152015111122222014201420152015201420142015201519192014201420152015QSA score comparisonQSA question comparisonONGOI

46、NG QUESTIONSONGOING QUESTIONSCLOSED QUESTIONSONGOING QUESTIONSONGOING QUESTIONSCLOSED QUESTIONS30qQuality System Improvement-Quality System Improvement-Exit Criteria 2&4Exit Criteria 2&42014 TSA QuestionQuestionQuestionActionActionStudy to remove the mask,only use the shielding layer in COB bunny su

47、it headgear.ongoing in exist 20M project.YEAR/ItemYEAR/ItemTSA&QSA Ongoing Question ReviewTSA&QSA Ongoing Question ReviewDue DateDue DatePendingSuggest BB operator remove the face masks,and use new type of garments with face masks which can cover the nose.qCS1 Exit Criteria Summary ReviewCS1 Exit Cr

48、iteria Summary Review31lSupporting Team for Lenovo/MotorolaPastPastu No CFT which only service Lenovo/Motorola projects.PresentPresentCreate the CFT which only service Lenovo/Motorola Projects.Special CFT for Lenovo/MotorolaItemItemCS1 Exit Criteria ReviewCS1 Exit Criteria ReviewSlide showSlide show

49、lCustomer service workflowu Lead time follow 1,3,7 principle(Confirm 1day,Preliminary Report 3days,Final Report 7days).u Final report of component issue needs 1 month delay.Lead time follow 4,48,72,5 principle(Confirm 4hours,Containment strategy 48huors,Preliminary Report 72hours,Final Report 5days.

50、)Final report of component issue will be completed within 14 working days.lVOC Tracking Systemu No Tracking system to trace each customer complaints to make sure the required cycle time meet customer requirement.Create VOC Tracking System to meet Lite-On lead time(Confirm 4hours,Containment strategy

51、 48huors,Preliminary Report 72hours,Final Report 5days.)lParticle Controlu No Particle DPPM goal for each projects.Set particle DPPM goal for each particle test stations.lQuality System Improvementu PSO Audit for Motorola new projects.u QSA&TSA Audit 1 time per year by Motorola.Lite-on completed PSO

52、 audit for 8M AF(Titan)on July 13th,and completed QSA&TSA audit on July 31st.The result were pass and the documents were double checked by Moto PE.QE shall perform internal buy-off and CQE performs PSO audit for Lenovo/Motorola new projects before customer PSO audit.Perform internal PSO/QSA/TSA audi

53、t annually by CQE/QS/QE and invite Lenovo/Motorola to double check the results before the official auditlProduct design improvementu No formal test program release flowu No risk evaluation report at FRA stage for all RD functionu No design checklist for customer special requirementu No particle eval

54、uation for VCM verificationGenerated formal test program release flowAdded risk evaluation report at FRA stageGenerated design checklist for Lenovo/Motorola.Added VCM particle risk evaluation item into VCM verification report.New customer service workflowVOC Tracking systemParticle control actionQua

55、lity system improvementProduct design improvement32q Organization of Supporting Team-Exit Criteria 1AOrganization of Supporting Team-Exit Criteria 1ATaipei Support TeamDirector Michael HungPMThomas ChenPLTony YangAMJoe LiangAVP Jeff Lee/COO Jerry Wu Factory Support TeamDirector Danny ChyouMFGRober P

56、angPEMax LeeTEBudd HuangDQAHsiung WangSMTSunny YaoCOBXiaolan HeBBDavid LuoCQERambo DuanQEDonald LiPE AFZY LuPE OISJerry XingPE FFScott ChenRDBenson GuoTE AFLufy ZhangTE OISAnren LiuTE FFMH ZhouDQARobby XiangPLMartin LiuIELeo WangIEChris ChenIEXiaoxu LiuQCWenen LuoQRADanny Chyou33q Organization of Su

57、pporting Team-Exit Criteria 1AOrganization of Supporting Team-Exit Criteria 1AFAE LeaderPaili Kuan武漢武漢1深圳深圳5AVP Jeff Lee/COO Jerry Wu Factory Support TeamDirector Danny ChyouOVERSEAcustomer*5NON-HW Customer*8HWCQE 3DQA 1CQE 4PE 2TE 3NBCustomer*6CQE 6TE 3Team 1Lenovo/MotoPE 3IE 1DQA 1IE 0.5PE 3TE 2DQ

58、A 1IE 1CQE 6PE 8TE 4DQA 3IE 2CQE 6PE 4TE 3DQA 2IE 2On-site Support TeamDirector Danny Chyou廈門廈門1華北華北5Flex TJ1Lenovo WH1FIH GL1Lenovo XM134qVOC Tracking System-Exit Criteria 1CVOC Tracking System-Exit Criteria 1CSenderReceiverSubmit Info.Feedback Info.RPN Affected Qty Failure model Projects Customer

59、info.Root cause,L/T solution,prevent strategy (within 5 days)S/T solution (within 72hrs.)Containment strategy(within 48hrs.)Time remindingTime remindingTime reminding35qProjects Performance Improvement-Exit Criteria 1DProjects Performance Improvement-Exit Criteria 1DvTo meet Lenovo/Motorola DPPM goa

60、l(Imager 5M 500 DPPM,5M=Imager 10M 1500 DPPM),Lite-on production line sets the DPPM goal for each station of every project.Imager5MCMT DPPM goal15000DC DPPM goal2000OBA DPPM goal500OBA tighten 2005M=Imager =10MCMT DPPM goal20000DC DPPM goal2500OBA DPPM goal1000OBA tighten10MCMT DPPM goal25000DC DPPM

61、 goal3500OBA DPPM goal1500OBA tightenl目前已可實現模組整體、目前已可實現模組整體、connector、Lens面的檢測面的檢測如下：如下：38qProjects Performance Improvement-Exit Criteria 1DProjects Performance Improvement-Exit Criteria 1D1.Demo Machine:9/M2.預計導入預計導入:2016.Q139qQuality System Improvement-Quality System Improvement-Exit Criteria 2&4E

62、xit Criteria 2&4vAll Lenovo/Motorola Projects management improvement planp PSO audit for Moto new projectsp QSA&TSA audit 1 time per yearAfternLite-on completed PSO audit for 8M AF(Titan)on July 13th,and completed QSA&TSA audit on July 31st.The result were pass and the documents were double checked

63、by Moto PE.nQE shall perform internal buy-off and CQE perform PSO audit for Lenovo/Motorola new projects before customer PSO audit.nPerform internal PSO/QSA/TSA(QPA)audit annually by CQE/QS/QE and invite Lenovo/Motorola to double check the results before official audit.Lite-on completed PSO/TSA/QSA

64、audit in July,and the documents were double checked by Motorola PE.Combine the PSO audit items to Lite-on internal buy-off checklist.Combine the TSA audit items to Lite-on internal QPA.PLM(Product Life cycle management)Follow PPAP/APQPqProduct design improvement-Exit Criteria 3Product design improve

65、ment-Exit Criteria 3v Plan to drive and implement corporate level zero defect planp No formal test program release flowp Test program released control by SW department.AfterTest program release flow.FW FAI check list/DQA OTP check list.Test program control procedure.Create the formal test program re

66、lease flownFW:need verify DLL and output the file:DLL/Setting List&DLL/Setting Change History&DLL Verify Report.nSW:Need to verify and create the file:Testing SW List&Testing SW Change History&Testing SW Check List&Testing SW Verify ReportnFor the new test program,need DQA/FW/SW buyoff the program and need to create the FW FAI check list and Calibration check list and DQA OTP check listnDCC upload the test program to the sever after confirm the completeness for the changing including verify repo