FMQAI50215NewLineQualificationProcedure新生产线资格验收程序

1、WORK 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 new li

2、ne 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 PCBA

3、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 Agra EOL; 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-F12 Add 3.6 EHS dept.Add 5.6 EHS New EHS checklist.Add EHS safety compliance into 6.5Add EHS check l

5、istAdd 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 chec

6、k list FMQAI-502-F8./更新Buyoff 点检表/6.3 增加检查线体设置是否影响外观/更新Durango 的目标 和更新Kinect Buyoff 点检表1. Update the version of XBOX One PCBA Manufacturing Process 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 to add New Line for Special Builds更新 条款6.1

7、增加新生产线的特殊生产3. Update KPI Target for XBOX One and add ESD engineer for ESD responsibility.Jolley WangJolley WangMartin ChenJames FuCandy TangTaylor DaiTony leeCandy TangTaylor DaiJames FuCissy MaAmol LinCissy MaAdman WuTony LeeElina ZuoCissy MaTony LeeXulork Fan06/28/088/10/092010/11/122011/8/132012/

8、01/182012/04/232012/05/242012/09/192013-5-272013-8-12014-4-21 2014-6-20REVISION 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-502-F7.02 and add Lithium PCBA、Petra PCBA Manuf

9、acturing 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 target 因为GC及Boron机种停产，更新5.9.1.3 Lithium/Homer/Marge/Caddy

10、 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 target 5.9.1.4 and Baker line qualification audit check lists FMQAI-502-16.01 & FMQAI-502-17.01 & FMQAI-502-18.01Comb

11、ine 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- F19.01and FMQAI-502- F20.01删除 FMQAI-502-F1、-F7、-F8、-F9、-F11、-F12 、-F14、-F15、-F16、- F17、- F18 和增加 FMQAI-502- F19.01and FMQAI-502- F20.0

12、1Quanping QiuXulork FanElina ZuoVince Gao2014-11-082015-04-152015-05-26REMARK备注APPROVALDEPARTMENTNAMETITLE部门名字职位QASF Toh ManagerTEHW BoeySr. ManagerPEGeorge LiuDirectorMBUGuoFeng LiManagerMBUEric QiaoManagerMBU Tony LiManager1. Purpose 目的To establish the qualification procedure for new production li

13、nes and ensure the machines have been evaluated, operators, related documents and related materials have been prepared before mass production.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The procedure applies to the new lines set up and line move, lay out change for all Microsoft

14、 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并跟进生产线的状态。3.2 EE/PE/TE Dept.: EE/PE/TE is responsible for evaluating the

15、 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 others 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

16、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 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

17、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. The effective corrective actions need to be provided for any deviation, wh

18、ich 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、机器和工具等进行安全符合性评估。3.7 ESD Engineers:ESD Engineers is responsible for ESD evaluation the c

19、ompliance 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 新产线安全评估表- FMAQAI-502-F135. Procedure 程序 5.1 Safe Launch Trigger Criteria Safe

20、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 Launch过程l Setup new lines additional to the existing MP line for ramp supportl 在MP阶段增加新线l >25% new operators introduce to an existing MP linel 超过25%的新员工加入现有量产的生产线。l Resumed a MP Line

21、 which idle for more than 3 monthsl 在MP阶段，重新使用闲置超过三个月的产线l Moved a MP line from one place to another placel 搬动MP产线l New Line for Special Buildsl 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, new product follow the standardized PV process which not

22、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 Sequence of Events (SOE) , layout for the new project， calculate the required quantity of operators and prepare schedule for ESD system buy off, and notice the related departments to set

23、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 it was set up, QA auditors will verify the ESD system when received the PEs checking results and send the reports to the t

24、eam 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 line qualification audit when the documents, Equipment, tooling and fixtures, KANBAN, ESD etc. have been prepared.当文件，机器，夹

25、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 audit, summarize the non-conformances in the Qualification A

26、udit Findings and Actions Report of FMQAI-502-F3.02 and send it to the related departmental responsible persons. (Remark: Score base on rating scale Tabel-1) 。The process follow chart of every project is not the same, check list can adjust. 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

27、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 completed/部分要求未满足0%REDQualification Element is not started/所有要求未执行

28、.Pre-build line audit and buy off on areas listed below产线buy off检查需包括以下内容： Documentation 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, Fixture and Tools calibration and maintenance schedules 设备、测试机、夹具和工具的校准以及

29、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 capability demonstration for machine and tooling (CPK，GR&R, etc) 设备和工具

30、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%

31、, 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 result of provided corrective actions. If the result is accepted, next step can be ru

32、n. 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

33、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, QA can agree MBU go ahead phase by phase on condition that hit determined acceptable g

34、oals 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 TE should do deep dive FA for every failed unit. Corrective action is also need till all

35、 of open item was closed. If the result is still good, go to 3rd phase, two weeks trial run. Once completed this control run.QA should collect all function stations yield and OBA performance. TE should perform failure analysis on defective units and find root cause. Corrective action is also needed，

36、QE should follow up on 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. f

37、or 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。5.8 After Microsoft FM team reviewed the phase report and approved, all of the finished goods which in phase 1, 2 and 3 can be shipped. Production lin

38、e can proceed to mass production and continue to monitor 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出货。产线可以开始批量生产，持续跟踪2周。5.9.1 General Target Setting Guidelines Phase 2 FPY target follow existing MP line - 2 Sigma Phase 2 FPY目标参照现有的MP线数据减去2倍SigmaPhase 3 FPY target follow existing MP line 1 SigmaP

39、hase 3 FPY目标参照现有的MP线数据减去1倍SigmaPhase 4 FPY target follow existing MP linePhase 4 FPY目标参照现有的MP线数据5.9.1.1 For ConsoleProjectStationPhase -1Phase -2Phase -3Phase -410  (FAI)100 (Hourly out put)1000 (shifty out put)2 Weeks out putTargetTargetTargetTargetConsoleICT100%98.33%98.55%Collect recent thre

40、e months 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 Size Remark: The 1st phase as qualification phases and need 100% check X-ray for whole PCBA, the 2nd, 3rd phases as the Safe Launch phases; all phases successes c

41、an treat as Safe Launch finished; If the 2nd and 3rd Safe Launch phase failed, the new line must re-qualify the previous three phases. In phase 1, we should insure all X-stress test carts were covered.When we qualify X-stress test station， if theres any deviation received for Safe Launch from custom

42、er, follow the deviation.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Safe Launch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，验证老化测试架时，必须涵盖所有的测试架。如果客户发出DEV#要求暂时执行新的Safe Launch, 将按DEV# 执行。5.9.1.2 For KinectSMT & BB lines UPH are differently, and will be qualified

43、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）PCBA Safe Launch个阶段目标（For Maya and Petra） ProjectStationPhase -1Phase -2Phase -3Phase -436 (FAI)380(Hourly input)3000 (Shifty input)2 Weeks i

44、nputTargetTargetTargetTargetMaya/PetraICT100.00%99.47%99.70%Collect recent three months average yield data as base lineFCT100.00%98.95%99.10%PCBA ETE100.00%98.43%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 Launch crite

45、ria/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 line)450(Hourly input)2000 (4 Hour Input)Two weeks monitorTargetTargetTargetTargetINCAInitialization100%99%99.12%Collect recent th

46、ree months average yield data as base lineCalibration100%99%99.50%M&A100%99%97.07%X-tress100%98%98.05%Performance100%99%99.24%MCT100%99%99.45%BB ETE100%93.20%92.64%OBA100%100%100%Normal Sample SizeOBA Sample Size100%50%10%Normal Sample SizeProjectStationPhase -1Phase -2Phase -3Phase -415 (F

47、AI, 5pcs/assembly line)450(Hourly input)2000 (4 Hour Input)Two weeks monitorTargetTargetTargetTargetParadiseConnectivity check100%98.68%98.79%Collect recent three months average yield data as base lineIllumination System100%98.82%98.92%Run in100%99.73%99.77%Power check100%98.99%98.77%P0 Calbiration1

48、00%99.13%99.37%Geometrical registration100%99.65%99.71%Performance100%97.47%98.63%Audio100%99.39%99.49%MCT100%99.59%99.71%Note: Above target will be fine tuned, if needed, after reviewed with MS team regularly. Before Phase 3, we should insure all X-stress test cart locations were covered when we qu

49、alify X-stress test station.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5.9.1.3 For Lithium/Homer/Marge/CaddyProjectStationPhase -1Phase -2Phase -3Phase -410  (FAI)100 (Hourly output)1000 (shifty output)2 Weeks out putTargetTargetTargetTargetLithiumSMT VI100%99%99.80%Collect rec

50、ent three months average yield data as base line, OBA(Normal sample size) Target is 100%,W/S VI100%99%99.80% Base Band100%99%99.50%FVMI100%99%99.80%OBA100%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%Final VI100%99%99.90%OBA100%100%100%OBA Sample Size100%100%10%FPY ETE 100%98%99%Caddy (Lobo