品质改善报告

ExitCS1QualityImprovementReportPreparedby:RamboDuanReviewedby:Billy.BApprovedby:DannyChyouDate:27thOct.,2015Contents2CS1ExitCriteriaReviewCS1BackgroundKeyIssueandImprovementActions124CustomerService&QualitySystemReview32014/04:Ultra10MAFLite-onCS1Information(Background)--①RMApartsshippedtoFlexTJcausedhighblemishissue.Lite-onproduced580pcsdefectivecameraswithabnormalAWBgoldensamplevalueinEEPROM,1.5KphonesareRMAbacktoFoxconnfromcustomer.2015/1：Valocia13MOIS2015/3:Valocia13MOISLensgluedamagedafterMotoALTdroptest.2015/1:DVX1.26MStopproductionlinewithoutofficialinformMotoandwithoutrootcause.OTPre-programmedimagersfailedfocusingatinfinity~2,8Kand1fieldreturnwithdefocusingatinfinity(only1XOTPallowedbyMotorola)2014/07:DVXBig8MAF2014/04:ELX5MFF2015/4:Valocia13MOISRemovedtestingproductionlinewithoutinformMotoofficially.2014/04:DVX5MAF53KSortedoutgoodpartsforLSCsettingincorrectthatLite-onshippedoutstillfailedRU~7.5DPHUatMotoGphoneobservedatthefirstlotof80unitscontrolrun2ndOTPpartsforLSCsettingincorrectfailedRUagainwith~0.01%defectratesincenofollowingupSDEinstructiontohaveFLTvalidation100%LSCspecsettingincorrect(60%LSCspec)caused~20%RUfailedatMotoGphone2014/05:DVX5MAF2014/05:DVX5MAFLite-onhas1.16%MTFdefectrateinFoxconnduetoLite-onDC2testwithdefocusingDACvalue.2014/04:DVX5MAF2014/05:Ultra10MAFRemovedKareaproductionwhilePCNhasnotapprovedforproductionmovingfromKareatoCareaRemovedtestingproductionlinewithoutinformMotoofficially3OTPFailureIncorrectprogram---AWBFailureWrongDACvalue---MTFFailureDoubleOTPinthesamepage---FocusingFailureIncorrectLSCsetting---RIFailureDifferentOTPread-outsequenceandmethodwithcustomer---RIFailureBacklightaberrance---RIFailureOTPIssue6件ChanceManagement4件RMAProcessing1件ReliabilityFailure1件KeyIssueCategoryChangeManagementRemoveUltra10MAFproductionlinewithoutcustomerofficialapproval.RemoveDVX5MAFproductionlinewithoutcustomerofficialapproval.Remove13MOISproductionlinewithoutcustomerofficialapproval.Stopproductionlinewithoutcustomerofficialapproval.ReliabilityFailureThe2dotslensgluemeetsLite-onreliabilitytest,butcannotmeetMotoALT.---ALTFailureRMAProcessingSorttheRMApartsandthegoodpartsreshiptocustomer.---BlemishIssue.OTPFailure6件ChangeManagement4件ChanceManagement4件ReliabilityFailure1件RMAProcessing1件Lite-onCS1Information(Background)--②OTPImprovementReportParticleImprovementReportOptimizethechangemanagementOptimizeProductDesigndocument45BeforeAfterComparisonIncorrectLSCsetting---RIFailureDifferentOTPread-outsequenceandmethodwithcustomerBacklightaberrance---RIFailureDoubleOTPinthesamepage---FocusingFailureDVX(5MAF)Ultra(10MAF)FouractionsforRIFailure0casesameissueTwoactionsforFocusingFailure0casesameissueDVX(5MAF)Q22014Q220143Ultra(10MAF)1Valocia(13MOIS)AfterQ220152AfterQ32014AfterQ320140Valocia(13MOIS)Incorrectprogram---AWBFailureWrongDACvalue---MTFFailureSevenactionsforAWB&MTFFailure0casesameissueOTPIssuePerformanceReview--①Q12015DVX5MAFUltra10MAFValocia13MOIScases123cases12300BeforeImprovedAfterImprovedBeforeAfterDVX5MAFOTPIssueBeforeImprovedUltra10MAFOTPIssueBeforeImprovedValocia13MOISOTPIssueAfterImprovedAfterImproved0pcsOTPdefect64KpcsOTPdefectsBeforeAfter0pcsOTPdefect90KpcsOTPdefects0pcsOTPdefect50KpcsOTPdefectsBeforeAfterDVX5MAFOTPIssueUltra10MAFOTPIssueValocia13MOISOTPIssue24%76%67Kpcs100%100%100%516Kpcs6082kpcsOTPIssuePerformanceReview--②0%0%0%1%92%99%8%OTPIssueActionsNo.ProblemBeforeAfterAttachment1IncorrectLSCsetting---RIFailure1.Nolow/upperlimitforimageilluminationafterLSCsettingisappliedtosensor1.Shadingtestitemwithlow/upperlimittocheckimageilluminationafterLSCsettingisappliedtosensor.<FWFAICHECKLIST>.<FWFAIChecklist><DQAChecklist>DifferentOTPread-outsequenceandmethodwithcustomer---RIFailure2.TheOTPread-outmethodisn’tdefinedclearly2.SyncOTPread-outmethodandjudgmentmethodbetweencustomer’stester/phoneandLite-ontestsystem,anddefinetheOTPread-outsequenceandmethodindatasheet(testplan).Backlightaberrance---RIFailure3.Lite-ondidn’tdetecttheilluminationchangeofretestsoftware.3.ControltheYvalueofilluminationbyprogram.<重工作業規範>4.LockthebacklightswitchofLSC&AWBteststation<Evidence>2DoubleOTPinthesamepage---FocusingFailure1.NoanyfunctiontocheckifOTPdataisblankornotbeforewrite-in1.Lenovo/MotorolaprojectsmustaddfunctiontocheckifOTPdataisblankornotbeforewrit-in.<FWFAIChecklist><FWFAIChecklist><DQAChecklist>2.Nofinalchecksumiteminlasttestingstation.2.Lenovo/Motorolaprojectsaddfinalchecksumitemtolasttestingstation.<DQAChecklist>OTPImprovementReport--③7OTPImprovementReport--④8OTPIssueActionsNo.ProblemBeforeAfterAttachment3Incorrectprogram---AWBFailure1.DifferentversionofSWsaveinthesamePC.1.UseDCCtocentralizecontrolalltestSWandgoldensampleSWversionautomatically,andkeepthelatestversionSWinserver.<文件與資料管制作業程序>5.4.3.2/5.4.3.3<文件與資料管制作業程序>2.NosystemcontrolfortestSW.3.NolockfortestPC.2.AllthetestPCarelockedandcontrolledbypassword.<多姿态光箱操作及維護保養作業規範>5.2.5/5.2.6<多姿態光箱操作與維護保養作業規範>4.NocheckafterOTPburning.3.Lenovo/MotorolaprojectsaddcheckAWBrangeduringburninganddoublecheckimageinnextstationifthesensorsupportapplyLSCandAWBorcheckimagebycell-phone(samplesize1%).<FWFAIChecklist>.<FWFAIChecklist>5.Nosystemcontrolforsoftwareversion4.SFCScheckthesoftwareversion.<Evidence>4WrongDACvalue---MTFFailure1.NoDACrangecontrol1.Lenovo/MotorolaprojectsmustaddtheDACrangecheckandstopsensorfor“Relaylens”function.<多姿態光箱操作及維護保養作業規範>5.2.8/<FWFAIChecklist><多姿態光箱操作與維護保養作業規範><FWFAIChecklist>2.Nostopsensorat“relaylens”forfool-proof2.Allprogramsmustcheckiftheprogramhadaddthesensorfool-proof.<多姿態光箱操作及維護保養作業規範>5.2.8<多姿態光箱操作與維護保養作業規範>3.Nodailycheckforcylinderandrelaylensmovingstatus.3.AddcylinderlensmovingstatuschecktoIPQCchecklist.<IPQCchecklist>OTPImprovementReport--③9FWFAIChecklistToensureriskscanbecapturedatdesignphaseDQAChecklistToensureriskscanbecapturedatNPIphaseFool-Proof&重工作業規範ToensuretheilluminationiswithinspecBacklightSwitchLockedOTPImprovementReport--④10ABCDValocia13MOIS-AWBIssueA.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.FAIChecklistD.Softwareversionfool-proof.OTPImprovementReport--⑤DesignCheckProgramCheckIPQCCheckMTFIssue_01MTFIssue_02MTFIssue_0311TooptimizethechangemanagementUpdatedMPchangecontroldocumentandgeneratedchangedocumentsignatorieslisttomakethepersoninchargeclear.<簽核一覽表>MakethechangedocumentsignatorieslistclearStep1GeneratecustomerspecialrequirementslistStep2IdentifychangeownerwhowillinformcustomerStep3CreateNewcastlefolderontheDCCsystemStep4Optimizethechangemanagement--①TomakecustomerspecialrequirementsclearforeveryCFTmembers,allthecustomerspecialrequestneedtoregisterto<客戶對變更的特別要求信息登記表>ChangethepersonwhoisresponsiblefornotifyingthechangefromSalestoCQE.<量產變更管制作業規範5.3.2.5>TocentralizecontrolalltheinformationofLenovo&Motorola,CreateNewcastlefolderontheDCCsystem<Lenovo/Motorola客戶信息使用DCC管控>12Optimizethechangemanagement--②PART_04BeforeELX5MFFUltra10MAFAfterApr.2014May2015Jun.2015StopproductionlineRemoveproductionlineRemoveproductionlineDVX5MAFValocia13MOISRemoveproductionareTotal:4casesThe2015after-improvementsummary(AfterApr.2015)Total:0Apr.2014Apr.2014Apr.2015Jul.2015Aug.2015Sep.2015Oct.2015123400casescases13Makethechangedocumentsignatorieslistclear--①1415Makethechangedocumentsignatorieslistclear--②Generatecustomerspecialrequestlist16Identifychangeownerwhowillinformcustomer17CreateNewcastlefolderonDCCSystem18ParticleImprovementReport--①19OptimizetheLVCMcleanmethod1Reducethecontributionofincomingparticle.Optimizethemoduledesign2Reducethecontributionofmovingparticleandenvironment.AAprocessforLenovo/Moto3Reducethecontributionofassembleprocess.CleanroomImprovement4Improvethecontributionofcleanroom.Valocia13MOISParticleDDPMTrendGoal(was)Goal(now)20MAFParticleDDPMTrendOptimizeLVCMcleanmethodUsehollowprotectivefilmParticleImprovementReport--②Otherimprovementactions2021OptimizeLVCMcleanmethodParticleImprovementReport--③22Optimizethemoduledesign:controlthemovingparticlebydusttrapglueNodusttrapglueAdddusttrapglueParticleImprovementReport--④23Optimizethemoduledesign:controltheenvironmentparticlebyhollowprotectivefilm.Advantage:1.Reducetheinfluenceofenvironmentparticle.2.Reducetheriskofpersontotouchlens.Disadvantage:1.Needtomodifyallthetestjigs.2.Needtopurchaseextraprotectivefilm.Extend:StudytomodifythetrayasHollowTray…..ongoinginexist20Mproject.ParticleImprovementReport--⑤24ParticleImprovementReport--⑥UseAAmachine(ASMAA)toassembleHMproject.Nora:3axisAAUPH>60AAmethod:LensAAWideFOV,Focusing@anydistanceBeforeNORAAfterASMIS600GSASMIS600:6axisAAUPHforDual200UPHforSingle600AAmethod:VCMAAScheduleFirstM/C:9/21SecondM/C:10/20ThirdlyM/C:11/17NORA:MadeinLite-onASMIS600GS:PurchasefromASM25ItemLITEON-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優點低成本,易調校對焦距離無限制(RelayLens虛距)適用廣角(FOV<=100°)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,YShift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無X,Yshift修正VCM動態Tilt無補償設備成本高AA前須進行VCM+Lens預組裝3.僅支援FOV<80°AAMachineAdvantageandWeaknessParticleImprovementReport--⑦26ParticleImprovementReport--⑧Extend:Studytoremovethemask,onlyusetheshieldinglayerinCOBbunnysuitheadgear…..ongoinginexist20Mproject.CreatedesignchecklistforLenovo/MotocustomersUpdatedesignchecklistaccordingtothefeedbackofcustomerandplanttimely(forgluedispensing,andBurnspeccheck)ImplementDFXmethodologyforLenovo/Motonewproject,andextendtoallnewprojects.Optimizeproductdesigndocument2728CustomerServiceFlow--ExitCriteria1BInitialComplainCustomerServiceWorkflow-Gotmail/telephone/sitecomplainbycustomer.2.Confirmation(Within4hrs.)-Confirmdefectmodule(appearanceandfunction)-ConfirmF/Randinventory.3.Returndefectdevice-Sendbackdefectmoduleforanalysis.4.Containmentstrategy(within48hrs.)-FALabfinishanalysis,includingelectronics/EDX/X-ray/waveform…analysis.-CQEdiscusstocomeoutcontainmentstrategy-UpdatetoMCAR5.Preliminaryreport(within72hrs.)-PreliminaryreportandS/Tsolutions.-UpdatetoMCAR6.Finalreport(within5days.-Finalreport,includingrootcause,L/Tsolutionandpreventstrategy-UpdatetoMCARInitialcomplainttobehandledbyFAEFailureAnalysisbyLite-On’sFAteamwithin3-5daysCQEtogenerate8Dreportandfollow-uptoclosureFinalreportofcomponentissuewillbecompletedwithin14workingdays(sensor1month).Previousleadtimefollow1,3,7principle(Finalreport:7days)Previousreportofcomponentissue:1monthPreviousleadtime25days.(Now7days)29QualitySystemImprovement--ExitCriteria2&475%20%40%60%80%100%TSAPerformance10%65%78%20%40%60%80%10%100%QSAPerformance408077%TSAscorecomparisonTSAquestioncomparison59%78120142015112220142015201420151920142015QSAscorecomparisonQSAquestioncomparisonONGOINGQUESTIONSCLOSEDQUESTIONSONGOINGQUESTIONSCLOSEDQUESTIONS30QualitySystemImprovement--ExitCriteria2&42014TSAQuestionQuestionActionStudytoremovethemask,onlyusetheshieldinglayerinCOBbunnysuitheadgear…..ongoinginexist20Mproject.YEAR/ItemTSA&QSAOngoingQuestionReviewDueDatePendingSuggestBBoperatorremovethefacemasks,andusenewtypeofgarmentswithfacemaskswhichcancoverthenose.CS1ExitCriteriaSummaryReview31SupportingTeamforLenovo/MotorolaPastNoCFTwhichonlyserviceLenovo/Motorolaprojects.PresentCreatetheCFTwhichonlyserviceLenovo/MotorolaProjects.SpecialCFTforLenovo/MotorolaItemCS1ExitCriteriaReviewSlideshowCustomerserviceworkflowLeadtimefollow1,3,7principle(Confirm1day,PreliminaryReport3days,FinalReport7days).Finalreportofcomponentissueneeds1monthdelay.Leadtimefollow4,48,72,5principle(Confirm4hours,Containmentstrategy48huors,PreliminaryReport72hours,FinalReport5days.)Finalreportofcomponentissuewillbecompletedwithin14workingdays.VOCTrackingSystemNoTrackingsystemtotraceeachcustomercomplaintstomakesuretherequiredcycletimemeetcustomerrequirement.CreateVOCTrackingSystemtomeetLite-Onleadtime(Confirm4hours,Containmentstrategy48huors,PreliminaryReport72hours,FinalReport5days.)ParticleControlNoParticleDPPMgoalforeachprojects.SetparticleDPPMgoalforeachparticleteststations.QualitySystemImprovementPSOAuditforMotorolanewprojects.QSA&TSAAudit1timeperyearbyMotorola.Lite-oncompletedPSOauditfor8MAF(Titan)onJuly13th,andcompletedQSA&TSAauditonJuly31st.TheresultwerepassandthedocumentsweredoublecheckedbyMotoPE.QEshallperforminternalbuy-offandCQEperformsPSOauditforLenovo/MotorolanewprojectsbeforecustomerPSOaudit.PerforminternalPSO/QSA/TSAauditannuallybyCQE/QS/QEandinviteLenovo/MotorolatodoublechecktheresultsbeforetheofficialauditProductdesignimprovementNoformaltestprogramreleaseflowNoriskevaluationreportatFRAstageforallRDfunctionNodesignchecklistforcustomerspecialrequirementNoparticleevaluationforVCMverificationGeneratedformaltestprogramreleaseflowAddedriskevaluationreportatFRAstageGenerateddesignchecklistforLenovo/Motorola.AddedVCMparticleriskevaluationitemintoVCMverificationreport.NewcustomerserviceworkflowVOCTrackingsystemParticlecontrolactionQualitysystemimprovementProductdesignimprovement32OrganizationofSupportingTeam--ExitCriteria1ATaipeiSupportTeamDirectorMichaelHungPMThomasChenPLTonyYangAMJoeLiangAVPJeffLee/COOJerryWuFactorySupportTeamDirectorDannyChyouMFGRoberPangPEMaxLeeTEBuddHuangDQAHsiungWangSMTSunnyYaoCOBXiaolanHeBBDavidLuoCQERamboDuanQEDonaldLiPEAFZYLuPEOISJerryXingPEFFScottChenRDBensonGuoTEAFLufyZhangTEOISAnrenLiuTEFFMHZhouDQARobbyXiangPLMartinLiuIELeoWangIEChrisChenIEXiaoxuLiuQCWenenLuoQRADannyChyou33OrganizationofSupportingTeam--ExitCriteria1AFAELeaderPailiKuan武漢1深圳5AVPJeffLee/COOJerryWuFactorySupportTeamDirectorDannyChyouOVERSEAcustomer*5NON-HWCustomer*8HWCQE3DQA1CQE4PE2TE3NBCustomer*6CQE6TE3Team1Lenovo/MotoPE3IE1DQA1IE0.5PE3TE2DQA1IE1CQE6PE8TE4DQA3IE2CQE6PE4TE3DQA2IE2On-siteSupportTeamDirectorDannyChyou廈門1華北5FlexTJ1LenovoWH1FIHGL1LenovoXM134VOCTrackingSystem--ExitCriteria1CSenderReceiverSubmitInfo.FeedbackInfo.RPNAffectedQ’tyFailuremodelProjectsCustomerinfo.Rootcause,L/Tsolution,preventstrategy(within5days)S/Tsolution(within72hrs.)Containmentstrategy(within48hrs.)ServerTimeremindingTimeremindingTimereminding35ProjectsPerformanceImprovement--ExitCriteria1DTomeetLenovo/MotorolaDPPMgoal(Imager<5M500DPPM,5M<=Imager<=10M1000DPPM,Imager>10M1500DPPM),Lite-onproductionlinesetstheDPPMgoalforeachstationofeveryproject.Imager<5MCMTDPPMgoal<15000DCDPPMgoal<2000OBADPPMgoal<500OBAtighten<2005M<=Imager<=10MCMTDPPMgoal<20000DCDPPMgoal<2500OBADPPMgoal<1000OBAtighten<500Imager>10MCMTDPPMgoal<25000DCDPPMgoal<3500OBADPPMgoal<1500OBAtighten<800TheDPPMmustmeettheOBADPPMgoalbeforeshipping.ShouldtightenthanIQCDPPM.OptimizedLVCMcleanmethod.Adddusttrapgluetocontrolmovingparticle.Addprotectfilmonmoduletopreventparticledropintomodule.UseAAmachinetoassembleHMprojects.UseautoVMImachine.MP機種外觀不良比例約0.5%~1%VMI人員需訓練有素，以檢出Lens表面：刮傷、殘膠、黑印、壓傷Lens通光孔：刮傷、髒污、白點、毛絲Lens點膠：漏點膠、缺膠、溢膠、橫膠尺寸FPC：刮傷、破損、毛邊、印刷不符、銀膜破損、shiftHolder：刮傷、殘膠、壓傷VCM：pin空焊、鐵殼壓傷、殘膠、刮傷Connector：殘膠、連錫、脫落、下陷、壓傷、歪斜、殘留錫珠，錫渣金手指：壓傷、刮傷、殘膠Mylar/輔材：漏貼、貼歪Pad：黏錫、漏銅36ProjectsPerformanceImprovement--ExitCriteria1DAutoVMImachine:人工VMI機台自動VMI完全靠人員判斷，標準因人而異，有機率漏檢到OBA或客戶端。自動VMI機台可確保100%外觀不良檢出率；有誤判率但能調整成overkill。無追溯性，無法判斷是廠內或客戶端造成。有追溯性，能記錄SN上傳SFC及保存外觀圖片。一條線需2~3個VMI人員一條線需1個VMI人員(Load/unload)5~6個獨立攝像頭&照明，可檢測模組六個面（上下面和四個側面）；可檢測外觀不良並量測尺寸；可自動從Tray盤取放,自動檢測；檢測記錄含照片可保存,過站記錄可上傳SFC；1pcs檢測完成Cycletime初步約2~3秒鐘（依檢測項目多寡而定）37ProjectsPerformanceImprovement--ExitCriteria1D可從圖片中擷取2Dbarcode，自動轉換成SN。=>目前已可實現模組整體、connector、Lens面的檢測如下：38ProjectsPerformanceImprovement--ExitCriteria1D1.DemoMachine:9/M2.預計導入:2016.Q139QualitySystemImprovement--ExitCriteria2&4AllLenovo/MotorolaProjectsmanagementimprovementplanBeforePSOauditforMotonewprojectsQSA&TSAaudit1timeperyearAfterLite-oncompletedPSOauditfor8MAF(Titan)onJuly13th,andcompletedQSA&TSAauditonJuly31st.TheresultwerepassandthedocumentsweredoublecheckedbyMotoPE.QEshallperforminternalbuy-offandCQEperformPSOauditforLenovo/MotorolanewprojectsbeforecustomerPSOaudit.PerforminternalPSO/QSA/TSA(QPA)auditannuallybyCQE/QS/QEandinviteLenovo/Motorolatodoublechecktheresultsbeforeofficialaudit.Lite-oncompletedPSO/TSA/QSAauditinJuly,andthedocumentsweredoublecheckedbyMotorolaPE.CombinethePSOaudititemstoLite-oninternalbuy-offchecklist.CombinetheTSAaudititemstoLite-oninternalQPA.PLM(ProductLifecyclemanagement)FollowPPAP/APQPProductdesignimprovement--ExitCriteria3PlantodriveandimplementcorporatelevelzerodefectplanBeforeNoformaltestprogramreleaseflowTestprogramreleasedcontrolbySWdepartment.AfterTestprogramreleaseflow.FWFAIchecklist/DQAOTPchecklist.Testprogramcontrolprocedure.CreatetheformaltestprogramreleaseflowFW:needverifyDLLandoutputthefile:DLL/SettingList&DLL/SettingChangeHistory&DLLVerifyReport.SW:Needtoverifyandcreatethefile:TestingSWList&TestingSWChangeHistory&TestingSWCheckList&TestingSWVerifyReportForthenewtestprogram,needDQA/FW/SWbuyofftheprogramandneedtocreatetheFWFAIchecklistandCalibrationchecklistandDQAOTPchecklistDCCuploadthetestprogramtotheseverafterconfirmthecompletenessforthechangingincludingverifyreportandchecklistetc.4041Productdesignimprovement--ExitCriteria3ToensureriskscanbecapturedatdesignphaseBeforeAfterNoriskevaluationreportatFRAStageforallR&DfunctionNothedesignchecklistforcustomerspecialrequirementNoparticleevaluationforVCMverificationOutputriskevaluationreportatFRA(Feasibilityresearchanalysis)stage.CreatedesignchecklistforLenovo/Motocustomers,updatedesignchecklistaccordingtothefeedbackofcustomerandplanttimely(forgluedispensing,andBurnspeccheck)AddVCMparticleriskevaluationitemintoVCMverificationreportandactionsRiskevaluatereport(willshowinthenewproject)DesignChecklistforgluedispensing<COBmoduledesignchecklistforLenovo/Moto>FWFAIchecklist(Checkiftheburnspeccanmeetthecustomerspec)VCMVerificationCheckListQuality--First,Delivery--Second,Cost--Third.ThankYou!42ALTFailureIssueAttachment43Definethelensgluedispensingtomoduledesignchecklistanddrawing44VCMVerificationCheckListProductdesignimprovementAttachment