最新FMQAI-50215-New-Line-Qualification-Procedure-新生产线资格验收程序资料

1、精品文档FLEXTRONICSWORK INSTRUCTION作业指导书DOC. No. /文件编号：FMQAI-502REV./版本号：15PRODUCT/ 产品:Microsoft ProjectsTITLE / 标题：New Line Qualification Procedure新生产线资格验收程序PAGE/页数1 OF 15REVISION HISTORY /版本记录REVISION版本CHANGE DESCRIPTION修改内容ISSUER发布者RELEASE DATE发行日期010203040506070809101112First release/ 首次发行Updated ne

2、w line qualification target for console project 6.5.Add new line qualification target for Kinect 6.5.Update console new Safe Launch process as per MS requirement.Update PCBA Manufacturing Process Qualification audit Checklist, add Kinect content. Cancel Zune content. Update Appendix 1 Add Kincet PCB

3、A buy off checklist.Update Appendix 3 Kinect BB buy off checklist.Update Appendix 3 Form.Update Appendix 4: Safe Launch yield ReportCancel 5.1, 6.6.2 and Appendix 3、4、5 Agra content for AgraEOL; Add 6.1 Safe Launch Trigger and Timing; Combine 6.10 into 6.5; Combine 6.8 and 6.9 into 6.6 Update 6.6.2

4、and 6.6.3;Cancel Monaco content for it EOLUpdate PCBA manufacturing process qualification audit check list: FMQAI-502-F1, add Box Build manufacturing process qualification audit check list FMQAI-502-F12Add 3.6 EHS dept.Add 5.6 EHS New EHS checklist.Add EHS safety compliance into 6.5Add EHS check lis

5、tAdd the requirement 100% checking X-ray for whole PCBA into 6.6.1.1 phase I-10pcs FAIUpdate item 6.5: added CP into documentation buyoff.Update the Console line buyoff check list FMQAI-502-F12Add the Durango BB Line layout check for cosmetic impact in 6.3 and update Kinect line qualification check

6、list FMQAI-502-F8.Update the Durango Target in 6.6.1.1/ 更新 Buyoff 点检表 /6.3增加检查线体设置是否影响外观/更新6.6.1.1Durango的目标和更新Kinect Buyoff 点检表1. Update the version of XBOX One PCBA ManufacturingProcess Qualification audit Checklist from FMQAI-502-F1.03 to FMQAI-502-F1.04 更新XBOX One PCBA 线验收清单2. Updated item 6.1 t

7、o add New Line for Special Builds更新条款6.1增加新生产线的特殊生产3. Update KPI Target for XBOX One and add ESD engineer for FSD responsibilityJolley WangJolley WangMartin ChenJames FuCandy Tang Taylor Dai Tony leeCandy Tang Taylor DaiJames Fu Cissy MaAmol LinCissy MaAdman WuTony Lee Elina ZuoCissy Ma Tony Lee Xul

8、ork Fan06/28/088/10/092010/11/122011/8/132012/01/182012/04/232012/05/242012/09/192013- 5-272013-8-12014- 4-212014-6-20REVISION版本CHANGE DESCRIPTION修改内容ISSUER发布者RELEASE DATE发行日期1314151. Update the version of Maya PCBA Manufacturing Process Qualification audit Checklist from FMQAI-502-F7.01 to FMQAI- 5

9、02-F7.02 and add Lithium PCBA 、Petra PCBA Manufacturing Process Qualification audit Checklist FMQAI-502-F14.01and FMQAI-502-F15.01更新 Maya PCBA 线验收清单，增加 Lithium PCBA、Petra PCBA 线验收清单 FMQAI-502-F14.01 and FMQAI-502-F15.012. Due to GC and Boron EOL,update the 5.9.1.3 For Lithium/Homer/Marge/Caddy targe

10、t因为GC及Boron机种停产，更新 5.9.1.3 Lithium/Homer/Marge/Caddy目标。3. Update the BB Line Buyoff Checklist (From FMQAI-502- F12.02 to FMQAI-502-F12.03) for replacing PMP by Control Plan更新Console BB 线验收清单，Add Baker project safe launch yield target5.9.1.4 andBaker line qualification audit check lists FMQAI-502-16.

11、01& FMQAI-502-17.01 & FMQAI-502-18.01Combine BB and PCBA line qualification audit check list from different projects.Delete FMQAI-502-F1 、-F7、-F8、-F9、-F11、-F12、-F14、-F15、-F16、- F17、- F18 and Add FMQAI-502- F19.01a nd FMQAI-502- F20.01删除 FMQAI-502-F1、-F7、-F8、-F9、-F11、-F12、- F14、-F15、-F16、- F1

12、7、- F18 和增加 FMQAI-502- F19.01a nd FMQAI-502- F20.01Quanping Qiu Xulork FanElina ZuoVince Gao2014- 11-082015- 04-152015-05-26REMARK备注APPROVALDEPARTMENTNAMETITLE部门名字职位QASF TohMa nagerTEHW BoeySr. Man agerPEGeorge LiuDirectorMBUGuoFe ng LiMa nagerMBUEric QiaoMan agerMBUTony LiManager1. Purpose 目的To est

13、ablish the qualificati on procedure for new product on lines and en sure the mach ines have bee n evaluated, operators, related docume nts and related materials have bee n prepared before mass producti on. 为新生产线建立一套资格验收程序以确保机器在产品批量生产前得到评估人员，相关文件及物料等在批量生 产前准备就绪。2. Scope 范围精品文档The procedure applies to

14、 the new lines set up and line move, lay out change for all Microsoft projects in Flextronics Manufacturing (Zhuhai) Co, Ltd.此程序适用于伟创力制造 (珠海 )有限公司所有微软项目新建生产线,线体移动 ,布局的改变。3. Responsibility 职责3.1 IE Dept.IE is responsible for designing and setting up new line and follow up the status. IE 负责统筹和建立新的生产 线

15、并跟进生产线的状态。3.2 EE/PE/TE Dept.:EE/PE/TE is responsible for evaluating the capacity the machines/testers etc. (e.g. GR&R, Cpk.).EE/PE/TE 部负责对机器，测试仪设备能力等进行评估(如 GR&R, Cpk) 。3.3 MBU Dept.:MBU is responsible for preparing the hardcopies of necessary documents, personal training, materials and other

16、s necessary on the production lines.MBU 负责准备生产线上所需用的文件 , 人员培训 , 物料等等。3.4 CQE Engineers/Auditors:CQE Engineers/Auditors is responsible for performing the qualification audit for new production lines and requesting corrective action for the non-conformance, verifying the result of provided corrective

17、actions. CQE 工程师 /稽查员负责对新生产线进行稽查，并针对稽查中所发现的不符合项，要求相关的负责人提供相 应的改善行动，并对改善行动的结果进行验证。3.5 All Departmental Managers/Supervisors:Departmental Managers/Supervisors are responsible for providing necessary supports for the qualification audit and ensure the departmental operations comply with the requirement

18、. The effective corrective actions need to be provided for any deviation, which is found during the audit.所有部门经理 /主管 /工程师：负责对资格限定稽查提供必要的支持，并确保本部门的运作符合相关的控制要求， 并针对稽查过程中发现的任何不符合项采取纠正改善措施。3.6 EHS Dept.:EHS is responsible for safety evaluating the compliance of line/machines /tool etc.EHS 负责对产线、机器和工具等进行

19、安全符合性评估。3.7 ESD Engineers:ESD Engineers is responsible for ESD evaluation the compliance of line/machines/tool etc.ESD 工程师负责对产线、机器和工具等进行 ESD 符合性评估。4. Definitions 定义4.1 PCBA: Printed Circuit Board Assembly.PCBA: 印刷线路板装配4.2 BB: Box-Build Assembly.BB: 外壳组装4.3 ESD: Electro-Static Discharge.ESD: 静电释放 新产线

20、安全评估表 - FMAQAI-502-F135. Procedure 程序5.1 Safe Launch Trigger CriteriaSafe Launch 的触发条件When met any of the following criteria, need trigger and follow Safe Launch process当达到以下任何条件，需要触发Safe Lau nch过程Setup new lines additional to the existing MP line for ramp support在MP阶段增加新线>25% new operators in tr

21、oduce to an exist ing MP line超过25%的新员工加入现有量产的生产线。Resumed a MP Line which idle for more tha n 3 mon ths在MP阶段，重新使用闲置超过三个月的产线Moved a MP line from one place to ano ther place搬动MP产线New Line for Special Builds新生产线的特殊生产Notes: this applies for a product which already in MP stage only; qualify a new material

22、, new product follow the sta ndardized PV process which not cover in this process.注意：Safe Launch只针对MP阶段的产品；验证新的物料，新的产品安装PV过程标准执行，不适用于Safe Launch过程。5.2 IE Engineers prepare Sequenee of Events (SOE) , layout for the new project， calculate the requiredqua ntity of operators and prepare schedule for ESD

23、 system buy off, and no tice the related departme ntsto set up the new line. IE工程师准备事件顺序表(SOE),新生产线工位布置图，计算需求人数并准备ESD验收进度表，同时通知相关部门。5.3 PE,TE,FE, and EE technicians will perform the ESD system buy off for the new production line after itwas set up, QA auditors will verify the ESD system when receive

24、d the PE' s checking results and sendthe reports to the team members. PE, TE, FE 和EE技术员在新生产线建成后对ESD系统进行验收，QA稽查员收到验收结果之后对新生产线进行ESD验证并将结果通知项目组成员。5.4 Program should notice Quality Engineer and team members to perform the new production linequalification audit when the documents, Equipment, tooling

25、and fixtures, KANBAN, ESD etc. have been prepared.当文件，机器，夹具，看板，ESD等准备就绪后，商务负责通知品质工程师及项目组成员对此生产线进行验收。5.5 Quality Engineer prepares the process qualification audit checklist for the new production lines base on the checklists (Appendix 1) and performs the audit with the team members. Complete the audi

26、t, summarize the non-con forma nces in the Qualificati on Audit Findings and Acti ons Report of FMQAI- 502-F3.02 and send it to the related departme ntal resp on sible pers ons. (Remark: Score base on rati ng scale Tabel-1) 。The process follow chart of every project is not the same, check list can a

27、djust.品质部工程师根据稽查表建立适用新生产流程的稽查清单(附件1)，并和项目成员一起对新生产线进行资格验收。完成验收，将不合格项汇总在FMQAI-502-F3.02 ，通知相关部门。(备注：评分依据等级量表-1.)针对各个项目的流程不同，检查表可以做适当的调整。Table-1/ 表-1Milestone Readiness %Rating ColorRating Explanation100%GRNQualification of Element is completed/符合所有要求50%YELFew part of the Qualification Element is not c

28、ompleted/部分要求未满足0%REDQualification Element is not started/所有要求未执行.Pre-build line audit and buy off on areas listed below产线buy off检查需包括以下内容： Docume ntation buyoff (PMP/CP, WI, Quality Alert Notice) 文件 buyoff ( PMP/CP, WI, 品质警报线) Operator Training and Certification 操作员培训记录和上岗证明 Machine, Testers, Fixtu

29、re and Tools calibration and maintenance schedules 设备、测试机、夹具和工具的校准以及维护记录在有效期内 Product specific Critical processes, process sequence, tools and fixture compliance. 关键工序、工艺流程、工夹具符合 TQCI 和 WI 要求 ESD and MSD control (if applicable) ESD 和 MSD 控制 SFCS and TCS validation(if applicable) SFCS 和 TCS 控制 Module

30、 capability demonstration for machine and tooling (CPK， GR&R, etc) 设备和工具的验证( CPK ， GR&R ) Strain Measurement data for each new line of Console and Kinect Project. 在 Console 和 Kinect 项目必须进行应力测量 EHS safety compliance EHS 安全符合性 Check the line layout impact the product during product transfer. 检

31、查产品在传动的过程中线体设置会影响产品产品外观。5.6 If the total score of the new production is less than 90%, the production line must be stopped to improve. The relative Departmental Managers/Supervisors/ Engineers provide the effective corrective actions for the non- conformance, Quality Supervisor/ Engineer verify the

32、result of provided corrective actions. If the result is accepted, next step can be run. Otherwise, responsible department should continue to provide the effective action till the result is accepted. All of the items should be closed in 24h.如果稽查得分低于 90%, 此条生产线必须停止生产进行改进，相关部门经理/主管 /工程师对稽查过程中发现的任何不符合项提

33、供有效的改善措施，品质主管/工程师对改善结果进行验证，如果改善结果可以接受下一阶段的安排方可进行，否则，责任部门应继续提供有效措施直到改善结果被接受为止。所有的不合 格项目必须在 24 小时之内完成。5.7 If the result is accepted, QA should summarize all line buy off reports, and then submit this to Microsoft FM team within 12 hours to do a final approved for new line buy off. Once FM team approve

34、, QA can agree MBU go ahead phase by phase on condition that hit determined acceptable goals for each phase, send the phase data to customer within 12 hours, only can move to next phase when current phase data be reviewed by customer and meeting the defined goals. QA respond for collecting data and

35、TE should do deep dive FA for every failed unit. Corrective action is also need till all of open item was closed. If the result is still good, go to 3rd phase, two weeks trial run. Once completed this controlrun.QA should collect all function station' s yield and OBA performance. TE should perfo

36、rm failureanalysis on defective units and find root cause. Corrective action is also needed，QE should follow upon all Open Item till closed.如果稽查的结果可以接受， QA 应该收集所有的生产线 buy off 的报告，在 12 小时之内提交给微软 FM 做一个最后的批准，一旦 FM 批准， QA 可以同意生产部安排各阶段的生产， 每个阶段必须满足设定的 目标并在 12 小时内发送给客户审批，经客户审批后才能进行下一阶段的生产。每个阶段一完成， QA 应该收

37、集所有功能测试站的良率和 OBA 的 DPPM,TE 负责分析所有的不良，针对每一片不良，需要有 改善措施 .直到所有的问题被关闭 , QE 工程师负责所有的问题被关闭。Notes: No. of phase and Qty. for each Phase may change based on product complexity and UPH, Tier1 factory need come up the proposal for FM approval.注意：每个阶段的数量可以根据产线 UPH 进行调整，并得到客户认可。5.85.9 After Microsoft FM team re

38、viewed the phase report and approved, all of the finished goods which inphase 1,2 and 3 can be shipped. Producti on line can proceed to mass producti on and con ti nue to mon itor the yield for 2 weeks.客户批准阶段报告后，1,2,3阶段的产品可以正常岀货。产线可以开始批量生产，持续跟踪2周5.9.1 Gen eral Target Sett ing Guideli nesPhase 2 FPY

39、target follow exist ing MP line - 2 SigmaPhase 2 FPY 目标参照现有的 MP线数据减去 2倍SigmaPhase 3 FPY target follow exist ing MP line-1 SigmaPhase 3 FPY 目标参照现有的 MP线数据减去1倍SigmaPhase 4 FPY target follow existi ng MP linePhase 4 FPY 目标参照现有的MP线数据ProjectStati onPhase -1Phase -2Phase -3Phase -410 (FAI)100 (Hourly out p

40、ut)1000 (shifty out put)2 Weeks out putTargetTargetTargetTargetCon soleICT100%98.33%98.55%Collect recent three mon ths average yield data as base lineXT100%92.12%93.45%ACT100%98.38%98.65%OBA100%100%100%NormalOBA Sample Size100%100%10%Normal Sample Size5.9.1.1 For Con soleRemark: The 1 s phase as qua

41、lification phases and need100% check X-ray for whole PCBA, the 2 n , 3r phasesas the Safe Launch phases; all phases successes can treat as Safe Launch finished; If the 2n andrd3 Safe Lau nch phase failed, the new line must re-qualify the previous three phases. In phase 1, we should in sure all X-str

42、ess test carts were covered.When we qualify X-stress test station , if there ' s any deviation received for Safe Launch from customer, follow the deviati on.备注：第1阶段属于新线资格检查阶段并且需100%对PCBA全部位置照X-Ray，第2, 3阶段属于SafeLaunch阶段，所有的阶段成功完成才能被认定Safe Launch完成，如果第2, 3阶段不能够符合要求，这条新线必须重新进行资格检查。在新线试跑第1阶段的时候，验证老化

43、测试架时，必须涵盖所有的测试架。如果客户发岀DEV#要求暂时执行新的Safe Launch,将按DEV#执行。5.9.1.2 For Kin ectSMT & BB lines UPH are differently, and will be qualified separately, and OBA testing not applicable for SMT lines. SMT 和BB过程UPH不同，需要分开验证，OBA测试不适用 SMT过程。PCBA Safe Launch criteria/goals for each phase( For Maya and Petra )P

44、CBA Safe Launch个阶段目标(For Maya and Petra )ProjectPhase -1Phase -2Phase -3Phase -436 (FAI)380(Hourly in put)3000 (Shifty in put)2 Weeks in putTargetTargetTargetTargetMaya/PetraICT100.00%99.47%99.70%Collect rece nt three mon ths average yield data as base lineFCT100.00%98.95%99.10%PCBA ETE100.00%98.43%

45、98.80%Note: Above target will be fine tuned, if needed, after reviewed with MS team regularly. 注意：以上目标可以被适当调整，并得到客户同意BB Safe Lau nch criteria/goals for each phase( for INCA and Paradise )BB Safe Launch个阶段目标(for INCA and Paradise )ProjectStationPhase -1Phase -2Phase -3Phase -415 (FAI, 5pcs/assembly l

46、ine)450(Hourly in put)2000 (4Hour In put)Two weeks' mon itorTargetTargetTargetTargetINCAIn itializati on100%99%99.12%Collect recent three mon ths average yield data as base lineCalibrati on100%99%99.50%M&A100%99%97.07%X-tress100%98%98.05%Performa nee100%99%99.24%MCT100%99%99.45%BB ETE100%93.

47、20%92.64%OBA100%100%100%Normal Sample SizeOBA Sample Size100%50%10%Normal Sample SizeProjectStationPhase -1Phase -2Phase -3Phase -415 (FAI,5pcs/assembly line)450(Hourly in put)2000 (4 Hour In put)Two weeks' mon itorTargetTargetTargetTargetParadiseConn ectivity check100%98.68%98.79%Collect recent

48、 three mon ths average yield data as base lineIllum in ati onSystem100%98.82%98.92%Run in100%99.73%99.77%Power check100%98.99%98.77%P0 Calbiratio n100%99.13%99.37%Geometrical registratio n100%99.65%99.71%Performa nee100%97.47%98.63%Audio100%99.39%99.49%MCT100%99.59%99.71%Note: Above target will be f

49、ine tun ed, if n eeded, after reviewed with MS team regularly. Before Phase 3, we should in sure all X-stress test cart locati ons were covered whe n we qualify X-stress test stati on.注意：以上目标可以被适当调整，并得到客户同意。在新线试跑第3阶段之前，验证老化测试架时，必须涵盖所有的测试架上所有的位置591.3 For Lithium/Homer/Marge/CaddyProjectStati onPhase

50、-1Phase -2Phase -3Phase -410 (FAI)100(Hourly output)1000(shifty output)2 Weeks out putTargetTargetTargetTargetSMT VI100%99%99.80%Collect recent three mon ths average yield data as base line, OBA(Normal sample size) Target is 100%,W/S VI100%99%99.80%LithiumBase Band100%99%99.50%FVMI100%99%99.80%OBA10

51、0%100%100%OBA Sample Size100%100%10%FPY-E-E100%99%99.50%MargeSMT VI100%99%99.80%W/S VI100%99%99.80%FVMI100%99%99.80%OBA100%100%100%OBA Sample Size100%100%10%FPY-E-E100%99.0%99.80%HomerSMT VI100%99%99.80%W/S VI100%99%99.30%Baseband100%99%99.70%RF Test100%99%99.70%Fi nal VI100%99%99.90%OBA100%100%100%

52、OBA Sample Size100%100%10%FPY ETE100%98%99%Caddy (Lobo R)VI for HDDM100%99%99.40%Image Test100%99%99.30%VI for package100%99%99.90%OBA100%100%99.90%OBA Sample Size100%100%10%FPY ETE100%99%99.3%591.4 for Baker ProjectProjectProcessPhase -1Phase -2Phase -3Phase -4Station10 (FAI)100 (Hourly output)1000

53、 (shifty output)2 Weeks out putTargetTargetTargetTargetBakerSMTSMT BB test99.30%99.30%99.30%Collect rece nt three mon ths average yield data as base line, OBA(Normal sample size)Target is 100%,W/S VI99.60%99.60%99.60%BoxBuildMotor98.50%98.50%99.00%Charged99.50%99.50%99.80%FF0198.50%98.50%98.90%WAT99

54、.50%99.50%99.80%CaAD0198.30%98.30%98.50%FFT0299.50%99.50%99.70%GAS99.00%99.00%99.30%Audio99.00%99.00%99.50%UV&ALS98.50%98.50%99.20%SIT97.80%97.80%98.00%Charge0299.90%99.90%99.90%BT99.80%99.80%99.80%FVI (CaAD02)97.50%97.50%98.30%LockBit99.90%99.90%99.90%FPY-ETE86%86%90%5.10 Quality Engin eer shou

55、ld submit Safe Lau nch yield report and TE FA report to Quality man ager for final review, then QA manager send to customer for approve. Release the new production line once customer approved. Please refer to Appendix 4.1 Qualification yield Report.QE工程师需要提交 Safe Launch的良率报告和 FA报告给品质部门经理做最终审核，然后由 QA经理发送给 客户批准。一旦客户批准可释放新的生产线。报告格式见附件