品质改善报告

ExitCS1QualityImprovementReport,Preparedby:RamboDuanReviewedby:Billy.BApprovedby:DannyChyouDate:27thOct.,2015,Contents,CS1ExitCriteriaReview,CS1Background,KeyIssueandImprovementActions,1,2,4,CustomerService&QualitySystemReview,3,2014/04:Ultra10MAF,Lite-onCS1Information(Background)-,RMApartsshippedtoFlexTJcausedhighblemishissue.,Lite-onproduced580pcsdefectivecameraswithabnormalAWBgoldensamplevalueinEEPROM,1.5KphonesareRMAbacktoFoxconnfromcustomer.,2015/1：Valocia13MOIS,2015/3:Valocia13MOIS,LensgluedamagedafterMotoALTdroptest.,2015/1:DVX1.26M,StopproductionlinewithoutofficialinformMotoandwithoutrootcause.,OTPre-programmedimagersfailedfocusingatinfinity2,8Kand1fieldreturnwithdefocusingatinfinity(only1XOTPallowedbyMotorola),2014/07:DVXBig8MAF,2014/04:ELX5MFF,2015/4:Valocia13MOIS,RemovedtestingproductionlinewithoutinformMotoofficially.,2014/04:DVX5MAF,53KSortedoutgoodpartsforLSCsettingincorrectthatLite-onshippedoutstillfailedRU7.5DPHUatMotoGphoneobservedatthefirstlotof80unitscontrolrun,2ndOTPpartsforLSCsettingincorrectfailedRUagainwith0.01%defectratesincenofollowingupSDEinstructiontohaveFLTvalidation,100%LSCspecsettingincorrect(60%LSCspec)caused20%RUfailedatMotoGphone,2014/05:DVX5MAF,2014/05:DVX5MAF,Lite-onhas1.16%MTFdefectrateinFoxconnduetoLite-onDC2testwithdefocusingDACvalue.,2014/04:DVX5MAF,2014/05:Ultra10MAF,RemovedKareaproductionwhilePCNhasnotapprovedforproductionmovingfromKareatoCarea,RemovedtestingproductionlinewithoutinformMotoofficially,3,OTPFailureIncorrectprogram-AWBFailureWrongDACvalue-MTFFailureDoubleOTPinthesamepage-FocusingFailureIncorrectLSCsetting-RIFailureDifferentOTPread-outsequenceandmethodwithcustomer-RIFailureBacklightaberrance-RIFailure,OTPIssue6件,ChanceManagement4件,RMAProcessing1件,ReliabilityFailure1件,KeyIssueCategory,ChangeManagementRemoveUltra10MAFproductionlinewithoutcustomerofficialapproval.RemoveDVX5MAFproductionlinewithoutcustomerofficialapproval.Remove13MOISproductionlinewithoutcustomerofficialapproval.Stopproductionlinewithoutcustomerofficialapproval.,ReliabilityFailureThe2dotslensgluemeetsLite-onreliabilitytest,butcannotmeetMotoALT.-ALTFailure,RMAProcessingSorttheRMApartsandthegoodpartsreshiptocustomer.-BlemishIssue.,OTPFailure6件,ChangeManagement4件,ChanceManagement4件,ReliabilityFailure1件,RMAProcessing1件,Lite-onCS1Information(Background)-,OTPImprovementReport,ParticleImprovementReport,Optimizethechangemanagement,OptimizeProductDesigndocument,4,5,Before,After,Comparison,IncorrectLSCsetting-RIFailureDifferentOTPread-outsequenceandmethodwithcustomerBacklightaberrance-RIFailure,DoubleOTPinthesamepage-FocusingFailure,DVX(5MAF),Ultra(10MAF),FouractionsforRIFailure,0casesameissue,TwoactionsforFocusingFailure,0casesameissue,DVX(5MAF),Q22014,Q22014,3,Ultra(10MAF),1,Valocia(13MOIS),AfterQ22015,2,AfterQ32014,AfterQ32014,0,Valocia(13MOIS),Incorrectprogram-AWBFailureWrongDACvalue-MTFFailure,SevenactionsforAWB&MTFFailure,0casesameissue,OTPIssuePerformanceReview-,Q12015,DVX5MAF,Ultra10MAF,Valocia13MOIS,cases,1,2,3,cases,1,2,3,0,0,BeforeImproved,AfterImproved,Before,After,DVX5MAFOTPIssue,BeforeImproved,Ultra10MAFOTPIssue,BeforeImproved,Valocia13MOISOTPIssue,AfterImproved,AfterImproved,0pcsOTPdefect,64KpcsOTPdefects,Before,After,0pcsOTPdefect,90KpcsOTPdefects,0pcsOTPdefect,50KpcsOTPdefects,Before,After,DVX5MAFOTPIssue,Ultra10MAFOTPIssue,Valocia13MOISOTPIssue,24%,76%,67Kpcs,100%,100%,100%,516Kpcs,6082kpcs,OTPIssuePerformanceReview-,0%,0%,0%,1%,92%,99%,8%,OTPImprovementReport-,7,OTPImprovementReport-,8,OTPImprovementReport-,9,FWFAIChecklist,Toensureriskscanbecapturedatdesignphase,DQAChecklist,ToensureriskscanbecapturedatNPIphase,Fool-Proof&重工作業規範,Toensuretheilluminationiswithinspec,BacklightSwitchLocked,OTPImprovementReport-,10,A,B,C,D,Valocia13MOIS-AWBIssue,A.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-,DesignCheck,ProgramCheck,IPQCCheck,MTFIssue_01,MTFIssue_02,MTFIssue_03,11,Tooptimizethechangemanagement,UpdatedMPchangecontroldocumentandgeneratedchangedocumentsignatorieslisttomakethepersoninchargeclear.,Makethechangedocumentsignatorieslistclear,Step1,Generatecustomerspecialrequirementslist,Step2,Identifychangeownerwhowillinformcustomer,Step3,CreateNewcastlefolderontheDCCsystem,Step4,Optimizethechangemanagement-,TomakecustomerspecialrequirementsclearforeveryCFTmembers,allthecustomerspecialrequestneedtoregisterto,ChangethepersonwhoisresponsiblefornotifyingthechangefromSalestoCQE.,TocentralizecontrolalltheinformationofLenovo&Motorola,CreateNewcastlefolderontheDCCsystem,12,Optimizethechangemanagement-,13,Makethechangedocumentsignatorieslistclear-,14,15,Makethechangedocumentsignatorieslistclear-,Generatecustomerspecialrequestlist,16,Identifychangeownerwhowillinformcustomer,17,CreateNewcastlefolderonDCCSystem,18,ParticleImprovementReport-,19,Valocia13MOISParticleDDPMTrend,Goal(was),Goal(now),20MAFParticleDDPMTrend,OptimizeLVCMcleanmethod,Usehollowprotectivefilm,ParticleImprovementReport-,Otherimprovementactions,20,21,OptimizeLVCMcleanmethod,ParticleImprovementReport-,22,Optimizethemoduledesign:controlthemovingparticlebydusttrapglue,Nodusttrapglue,Adddusttrapglue,ParticleImprovementReport-,23,Optimizethemoduledesign:controltheenvironmentparticlebyhollowprotectivefilm.,Advantage:1.Reducetheinfluenceofenvironmentparticle.2.Reducetheriskofpersontotouchlens.Disadvantage:1.Needtomodifyallthetestjigs.2.Needtopurchaseextraprotectivefilm.Extend:StudytomodifythetrayasHollowTray.ongoinginexist20Mproject.,ParticleImprovementReport-,24,ParticleImprovementReport-,UseAAmachine(ASMAA)toassembleHMproject.,Nora:3axisAAUPH60AAmethod:LensAAWideFOV,Focusinganydistance,BeforeNORA,AfterASMIS600GS,ASMIS600:6axisAAUPHforDual200UPHforSingle600AAmethod:VCMAA,ScheduleFirstM/C:9/21SecondM/C:10/20ThirdlyM/C:11/17,NORA:MadeinLite-on,ASMIS600GS:PurchasefromASM,25,AAMachineAdvantageandWeakness,ParticleImprovementReport-,26,ParticleImprovementReport-,Extend:Studytoremovethemask,onlyusetheshieldinglayerinCOBbunnysuitheadgear.ongoinginexist20Mproject.,CreatedesignchecklistforLenovo/MotocustomersUpdatedesignchecklistaccordingtothefeedbackofcustomerandplanttimely(forgluedispensing,andBurnspeccheck)ImplementDFXmethodologyforLenovo/Motonewproject,andextendtoallnewprojects.,Optimizeproductdesigndocument,27,28,CustomerServiceFlow-ExitCriteria1B,29,QualitySystemImprovement-ExitCriteria2&4,30,QualitySystemImprovement-ExitCriteria2&4,2014TSAQuestion,Question,Action,Studytoremovethemask,onlyusetheshieldinglayerinCOBbunnysuitheadgear.ongoinginexist20Mproject.,YEAR/Item,TSA&QSAOngoingQuestionReview,DueDate,Pending,SuggestBBoperatorremovethefacemasks,andusenewtypeofgarmentswithfacemaskswhichcancoverthenose.,CS1ExitCriteriaSummaryReview,31,32,OrganizationofSupportingTeam-ExitCriteria1A,33,OrganizationofSupportingTeam-ExitCriteria1A,34,VOCTrackingSystem-ExitCriteria1C,Sender,Receiver,SubmitInfo.,FeedbackInfo.,RPN,AffectedQty,Failuremodel,Projects,Customerinfo.,Rootcause,L/Tsolution,preventstrategy(within5days),S/Tsolution(within72hrs.),Containmentstrategy(within48hrs.),Server,Timereminding,Timereminding,Timereminding,35,ProjectsPerformanceImprovement-ExitCriteria1D,TomeetLenovo/MotorolaDPPMgoal(Imager10M1500DPPM),Lite-onproductionlinesetstheDPPMgoalforeachstationofeveryproject.,Imager5M,CMTDPPMgoal15000DCDPPMgoal2000OBADPPMgoal500OBAtighten200,5M=Imager=10M,CMTDPPMgoal20000DCDPPMgoal2500OBADPPMgoal1000OBAtighten10M,CMTDPPMgoal25000DCDPPMgoal3500OBADPPMgoal1500OBAtighten目前已可實現模組整體、connector、Lens面的檢測如下：,ProjectsPerformanceImprovement-ExitCriteria1D,1.DemoMachine:9/M2.預計導入:2016.Q1,39,QualitySystemImprovement-ExitCriteria2&4,AllLenovo/MotorolaProjectsmanagementimprovementplan,Before,PSOauditforMotonewprojectsQSA&TSAaudit1timeperyear,After,Lite-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/APQP,40,Productdesignimprovement-ExitCriteria3,Plantodriveandimplementcorporatelevelzerodefectplan,Before,NoformaltestprogramreleaseflowTestprogramreleasedcontrolbySWdepartment.,After,Testprogramreleaseflow.FWFAIchecklist/DQAOTPchecklist.Testprogramcontrolprocedure.,CreatetheformaltestprogramreleaseflowFW:needverifyDLLandoutputthefile:DLL/SettingList&DLL/SettingChangeHistory&DLLVerifyReport.SW:Needtoverifyandcreatethefile:TestingSWList&TestingSWChangeHistory&TestingSWCheckList&TestingSWVerifyReportForthenewtestprogram,needDQA/FW/SWbuyofftheprogramandneedtocreatetheFWFAIchec