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Foxconn International Holdings Ltd.
CMOAG-0015
PAGE
Content
Revision
1
Purpose
2
Scope
3
Responsibility
4
Flow Description
5
Basic Terminology Introduction
6
Application And Revision
7
Procedure Flow Chart
8
Appendix
APPROVED CHECKED PREPARED
BY 張光美DATE 2005.03.14
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統Product Development Procedure
新產品Pilot Run作業辦法New Product Pilot Run Procedure
**** 目 錄 ****
項 目 ITEM 內 容 DESCRIPTION 頁 次 PAGE
目 錄
修 訂 履 歷
目 的
范 圍
職 責
流 程 說 明
基 本 術 語 介 紹
實 施 與 修 訂
流 程 圖
附 頁
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
CMOAG-0015
1 OF 7 REV B
1
2
3
3
3~4
4
5
5
6
7~8
ISSUED BY:
文件編號(DOCUMENT NO):
頁 次 PAGE
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
Foxconn International Holdings Ltd
CMOAG-0015
PAGE
Revision History
REV ECN NO
A
B
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統Product Development Procedure
新產品Pilot Run作業辦法New Product Pilot Run Procedure
* * * * * 修 訂 履 歷 * * * * *
修 訂 頁 次 Revision Pages
系統文件整合,初版發行
1. 修改5.10初件試產方式 2. 更新NPI check list
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
CMOAG-0015
2 OF 7 REV B
Remarks
文件編號(DOCUMENT NO):
Foxconn International Holdings Ltd
CMOAG-0015
PAGE
To establish samples control procedure to ensure process quality of new samples before mass production
Control the problems that may happen in the process of new products in time and improve ASAP to meet the need of customers
Production of samples of new products and NPI control procedure
Engineering Chart and document change (ECN) Fill Description CQOAG-0008
Coresponding related departments principal and making up NPI team.
4.2.9 NPI Report
4.3.1 SIP
4.3.2 ESD Check
4.3.3 SMD Process and FAI Check
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統Product Development Procedure
新產品Pilot Run作業辦法New Product Pilot Run Procedure
1. 目的 Purpose: 旨在建立一個新產品量產前樣品制作的管制作業程序,以保証新產品樣品的制作品質.
及時掌握新產品作業時可能發生的問題,並及早作出改善,以滿足客戶需要.
2. 範圍 Scope: 本辦法適用於WLBG主机板制造處新產品樣品制作及NPI管制作業.
3. 參考文件 Reference :
3.1 工程圖面與文件變更(ECN)填寫說明 CQOAG-0008
3.2 SMT製程品管作業辦法 CQOAG-0012 SMT Quality Control ProcedureCQOAG-0012
3.3 不合格品管制作業辦法 CQOAG-0010 Defect Quality Control Procedure CQOAG-0010 4. 職責 Responsibility 4.1 市場單位 MP Department 4.1.1 從客戶段獲取NPI Get NPI from customers
4.1.2 客戶認可通知或客戶認可書之取得 Gain the Customers Acceptance Inform or Customers Acceptance
4.2 產品設計/制造工程單位 Product Design/ Prodcution Engineering Department 4.2.1主導NPI Lead NPI. 4.2.2 确定NPI進度,制定Pilot Run schedule. Confirm NPI Schedule and make Pilot Run schedule
4.2.3 產品說明會Product Introduction Meeting
4.2.4協調各單位負責人組成 NPI team
4.2.5 CQP文件主導及完成 CQP Document Introduction and Finish
4.2.6 治工具准備 Fixture Preparation
4.2.7 相關工程文件制作與Update.Making and update of related engineering document
4.2.8 新產品教育訓練 New Products Education Training
4.3 品管單位 QA Department
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
CMOAG-0015
3 OF7 REV B
文件編號(DOCUMENT NO):
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
Foxconn International Holdings Ltd
CMOAG-0015
PAGE 4 OF 7 REV
4.3.4 Program and parameter Check:
Related inspection fixture making and supply. Samples procedure quality status collection and
quality information supply
Confirm the quality, function status of first product and supply the related inspection document(FAI test list) and report
Corresponding related departments to handle quality problems
Materials procurement and perparation
NPI work order for issuing materials to product lines
4.5.2 Barcode label ready
Support of haman power, fixture, and production equipment when samples trial run
4.6.1 SFC ready
MP get the new products request and NPI from customers, and convey NPI to Product Engineer of Engineering Dep.
send the electronic file of customer data to DCC.
Product engineers get the related specification and documents of process (BOM, DWG,CAD data) form customers after possibility
evaluation is OK. Send the Eng. documentation of new product to the Quality Dept. and Quality Dept. will check
those with the original customer data.
Product engineers make the NPI schedule, hold the New Product Description Meeting to trace and
supervise the process of related departments
Product engineers lead to finish CQP documents (PMP,Process flow chart,Tooling Plan) and make
the related engineering documents (such as Barcode description)
Product engineers confirm the preparation of materials, tools and human power.
Engineering Dep. is responsible for samples making after the preparation of SMT program, materials and tools
Do the tape board first & take to measure the FAI, after tape board start the 1st piece production. The 1st pcs must be checked by microscope
& X-ray & get approval by Engineering/ QA dept. After 1st piece passed , then can start below quantity: 1st pcs-->5pcs-->10pcs-->50pcs
( every stage must 100% X-ray checking & Engineering/QA/Technician call a meeting to review the quality, to determine to re-start this stage
or continue next stage ). After 50 panel production & no defect happened, then we can start the mass production.
Remark: If there are any difference in Golden sample and 1st picec, must double confirm with the customer before NPI continue.
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO):
產品開發作業系統Product Development Procedure
新產品Pilot Run作業辦法New Product Pilot Run Procedure
4.3.5 相關檢驗量治具的制作與提供及樣品制作製程品質狀況之收集與品質資料之提供
4.3.6 确認初件之品質,功能狀況,並提供相關檢驗文件(FAI 測試表)與檢驗報告.
4.3.7 協調相關單位對各項品質問題之處理事宜.
4.4企劃單位 Planning Department
4.4.1 物料采購,准備.
4.4.2 NPI派工令發料至產線.
4.5制造單位 Production Department
4.5.1 SMT程式制作 SMT Program Making
4.5.3 試產時提供人力,治工具,維修﹐生產設備的支援.
4.6 資訊單位 IT Department
5. NPI流程說明 NPI Process Flow Description
5.1市場單位從客戶段獲取新產品需求及NPI,並將NPI轉達給工程部產品工程師.
5.2產品工程師獲取NPI后,將客戶文件(電子檔)交于資料中心,並就現有狀況初步評估新產品制作的可行性.
Product engineers make the first evaluation on the possibility of new products manufacturing after receiving NPI notice and
5.3 可行性評估OK以后,產品工程師著手從客戶段獲取新產品的相關規格以及新產品制作所必須的 工程文件如(BOM,DWG,CAD data,Gerber file等),同時將新產品之工程文件發于品工.品工依客 戶提供之資料確認,工程BOM
5.4產品工程師召開新產品說明會,制定NPI進度表, 組織NPI team,並對相關單位的具体工作進行跟催監督.
5.5NPI team對製程及設備進行FMEA失效模式分析.Making the FMEA of process and equipment by NPI team
5.6產品工程師主導完成CQP文件(PMP,Process flow chart,Tooling Plan等),並制作相關工程文件(如Bar-
-code說明等)
5.7產品工程師确認物料治工具人力准備情況.
5.8生技制作SMT程式Equipment engineers make the SMT program
5.9SMT程式,物料及治工具准備好以后由工程部負責主導樣品制作
5.10首先進行雙面膠板制作, 以作為FAI檢驗依據。雙面膠板打完後, 開始進行初件生產, 初件需在顯微鏡下進行檢驗 , 在工程/ 品保確認無不良, 並且X-ray檢驗無不良下, 方可進行下面數量的生產 : 初件-->5panel-->10 panel-->50 panel (每個階段都須100%由生產單位照X-ray , 並由工程/ 品保/ 生技 召開檢討,
如有不良發生 , 則該階段重新生產 ; 如無不良方可進行下一階段 ), 在50 panel生產無不良後, 方可進行量產。 注:若客戶有提供Golden Sample, 初件與Golden Sample比對有不同時,需經客戶確認無誤后方可繼續NPI
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
CMOAG-0015
B
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
Foxconn International Holdings Ltd
CMOAG-0015
PAGE
After NPI, Planning responsible for out-going of new products. QA and Engineering trace NPI quality status. And after Pilot Run, engineering hold the review meeting on Pilot Run
Engineer Dept is responsible for collecting all the NPI record and trimming NPI Report which mainly includes: 5.12.1 Project Name 5.12.2 NPI plan: Date and Qty 5.12.3· HWID 5.12.4 Project Team 5.12.5 First article report summary: Critical components and LCR parts summary 5.12.6 Production yield: each inspection station and composite yield 5.12.7 DOA result 5.12.8 Corrective action report 5.12.9 Capacity estimation 5.12.10 Ramp up plan 5.12.11Review meeting minutes
DOA SMD Result<= 7000PPM, DOA Mat. Result<=10000PPM. Mass production can proceed
If DOA Result is higher than the above datas
Lodge the related improvement measure. After judged by customers, mass production can proceed
Production is changed from trial run to mass prodcution according to customers' request of out-going ways and 6.1
After approved, the file is in operation. Revised as well.
Appendix: NPI CHECK LIST (CMOAG-0015-01B)
PILOT RUN report (CMOAG-0015-02B)
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統Product Development Procedure
新產品Pilot Run作業辦法New Product Pilot Run Procedure
5.11 NPI以后,企劃部負責新產品出貨.品保,工程負責跟催NPI品質狀況,並在Pilot Run后由工程召開 Pilot Run檢討會
5.12工程單位負責匯整所有NPI紀錄並整理NPI Report.NPI Report主要內容包括:
6.量產放行條件 Mass Prodcution Discharge Condition 6.1.DOA SMD Result<= 7000PPM, DOA Mat. Result<=10000PPM.即可量產.
6.2 若DOA Result高于上述數据,
6.2.1 提出相應改善措施,經客戶裁定后方可正式量產.
6.2.2 按客戶制定出貨方式出貨並達到6.1之要求,則試產轉為量產.
7.基本術語介紹 Basic Terminology Introduction
7.1 FMEA(Failure mode effect analysis):失效模式分析 7.2 CQP:Component Quality Plan,主要包括PMP,Process flow chart,Tooling plan,FMEA等.
7.3 NPI:New Product Introduction ,新產品導入.
8.實施與修訂 Implementation and Revision
本文件呈制造處主管核准后,即可實施修訂亦同.
8.附頁 : NPI CHECK LIST (CMOAG-0015-01B)
PILOT RUN總結報告(CMOAG-0015-02B)
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
CMOAG-0015
5 OF 7 REV B
文件編號(DOCUMENT NO):
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
Foxconn International Holdings Ltd
CMOAG-0015
PAGE 6 OF 7
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※ ※ ※
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統 Product Development Procedure
新產品Pilot Run作業辦法 New Product Pilot Run Procedure
NPI 流程圖
客戶Customer
市場 PM 工程 ME 企劃 PMC 品管 QA
NPI
Delivery
客戶產品
無庫存
有庫存
NG
OK
OK
NG
采購
LCR Meter
獲取 NPI
獲取新產品規格及相關工程資料
新產品說明會並制定 NPI Schedule
CQP 及相關工程文件制定
OK
NG
治工具准備
V/I
OK
物料准備
IQC
NG
新產品制作可行性确認
協調各單位負責人組成 NPI team
檢查 ESD
SMD 制程檢查
程式參數檢查
SIP
教育訓練
NPI report
組織 NPI team
Kick-off meeting
OK
檢查工程文件
比對樣品板
獲取新產品規格及相關工程資料
OK
NG反饋客戶確認
反饋客戶確認OK
NG
CMOAG-0015
6 OF 7 REV B
制造
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※ ※ ※
文件編號(DOCUMENT NO):
流程圖
資訊 IT
領出並上料
新產品說明會並制定 NPI Schedule
初件制作
Pilot Run
V/I
維修
Discarding
Unrepairable
Repairable
OK
SMT 程式制作
雙面膠板制作
SMT 程式修訂
Kick-off meeting
SFC ready
Foxconn International Holdings Ltd
CMOAG-0015
PAGE 7OF 7
NPI flow chart
系統名稱(SYSTEM): 主題(SUBJECT): 文件編號(DOCUMENT NO)
產品開發作業系統 Product Development Procedure
新產品Pilot Run作業辦法 New Product Pilot Run Procedure
客戶Customer
市場 PM 工程 ME 企劃 PMC 品管 QA
※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
NPI
Delivery
Customer production
Empty
Inventory
NG
OK
OK
NG
Buyer
LCR Meter
Receive NPI
Get the related specification and documents of process
Product Introduction Meeting and make NPI schedule
Making CQP and related engineering document
OK
NG
Fixture Preparation
V/I
OK
Material preparation
IQC
NG
Make the first evaluation on the possibility of new products
manufacturing
Coresponding related departments principal and making up NPI team
ESD check
SMD Process Check
Program and parameter Check
SIP
Training
NPI report
Make up NPI team
Kick-off meeting
OK
Check Engineering documents
Compare with golden sample
Get the related specification and documents of process
OK
NGConfirm
OK
NG
Notice custormer
Confirm Notice custormer
CMOAG-0015
7OF 7 REV B
NPI flow chart
制造
文件編號(DOCUMENT NO):
資訊 IT
PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※
Feeding
Product Introduction Meeting and make NPI schedule
First production making
Pilot Run
V/I
Repair
Discarding
Unrepairable
Repairable
OK
SMTprogram making
Double sides board making
SMTprogram revising
Kick-off meeting
SFC ready
Get the related specification and documents of process
NPI CHECK LISTProject name: ENO P/N : PCBA P/N:
HWID: SWID : 3.10 PCB P/N:
N0 CHECK ITEMSchedule ( March)
Responsible Person1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1
Customer Doc.:
Gerber file
CAD Data
Component vendor list
Packing spec.
PCB & PCA Golden Sample
2
Documentation:
BOM
SAP system key in
SOP
CQP (Tooling plan,Flow chart,FMEA ,PMP)
Inspection Drawing
POP
Component feeding list
MHS&ESD component list
SIP
3
Tool:
Stencil
Printer (Vacuum Support)
PCBA Rework & V/I Fixture
De-panel mold
Profile measuring board
Special fixture
4
Chemical:
Paste(Type)
Cleaner(Multicore prozone SC-01)
Wipe paper
Flux(Multifix 450-01)
Solder wire (Multicore Solders Crystal 502 Sn62)
5
Solder Paste Printer
Chip Shooter(feeder,nozzle)
AOI
IC Mounter(feeder,nozzle)
Reflow Oven
Router
BGA rework station
Customer BOM(final version)
Others:
Others:
Others:
Equipment:
5
Others:
6
Solder Paste Printer
Mounterr(feeder,nozzle)
AOI
Reflow Oven
Router
Barcode Label
7
Material preparation:
PCB
Component preparation
Package material
Get some scarp component for FA training
8
Back End (Testing) :
White box
Adaptor
FA tooling
Test plan readiness
FA layout
Depanelling program in Router
Others :
9
Manpower review
SMT Training
FA training
Testing training
10
Diagnostic training
SFC ready
Quality Acceptance Requirement
Others
11
Internal Audit:
FAI check list
ESD & SMT Process Check
Program and parameter Check:
12
Tape board / First article
FAI
Pilot run
Quality & yeild rate data
Cycle Time Measurement
Line Capacity Calculation
NPI Report
Program and parameter:
Others:
Others:
Production:
Others:
Pilot Run:
Others:
NPI CHECK LISTPCBA P/N:
PCB P/N: PCB REV:
Due Date Status
CMOAG-0015-01B
****PILOT RUN REPORT **** PILOT RUN DATE:
Items Reasons Principal Provisional solution Long-term solution
1
2
3
4
5
6
7
8
9
10
11
12
CMOAG-0015-02B
Project name:
****PILOT RUN REPORT ****(Appendix2)
Long-term solution
CMOAG-0015-02B
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