Npi Operation Methodupdated

Foxconn International Holdings Ltd.

系統名 稱 (SYSTEM): 產品開發作業系統 Product Development Procedure

主題 (SUBJECT):

目

ITEM

CMOAG-0015

新產品Pilot Run作業辦法 New Product Pilot Run Procedure ****

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文件編 號 (DOCUMENT NO):

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目

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DESCRIPTION

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錄

1

歷

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Revision 目

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2

Purpose 范

圍

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Scope 職

責

3~4

4

Responsibility 流 程

明

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Flow Description 基 本 術 語

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Basic Terminology Introduction 實 施 與 修 訂

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Application And Revision 流 程 圖

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Procedure Flow Chart 附

目 Content 修 訂

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錄 容

PAGE

履

說 介

紹

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PAGE

5

7~8

Appendix

APPROVED

CHECKED

PREPARED

BY

張光美

DATE

2005.03.14

ISSUED BY:

※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※

B

Foxconn International Holdings Ltd

系統名稱

(SYSTEM):

產品開發作業系統 Product Development Procedure

主題 (SUBJECT): 新產品Pilot Run作業辦法 New Product Pilot Run Procedure *****

REV A B

ECN NO

文件編號

修

修 訂 Revision

履 歷 History

訂

次

頁

(DOCUMENT NO):

CMOAG-0015 PAGE

2 OF 7

REV

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*****

Revision Pages

Remarks

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. ※ ※

Foxconn International Holdings Ltd

系統名 稱 (SYSTEM):

主題 (SUBJECT):

產品開發作業系統 Product Development Procedure

文件編 號 (DOCUMENT NO):

新產品Pilot Run作業辦法 New Product Pilot Run Procedure

CMOAG-0015 PAGE

3 OF7

REV

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. To establish samples control procedure to ensure process quality of new samples before mass production 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. Control the problems that may happen in the process of new products in time and improve ASAP to meet the need of customers 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. Production of samples of new products and NPI control procedure 3. 參考文件 Reference : 3.1 工程圖面與文件變更(ECN)填寫說明 CQOAG-0008 Engineering Chart and document change (ECN) Fill Description 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 Coresponding related departments principal and making up NPI team. 4.2.5 CQP文件主導及完成 4.2.6 治工具准備

CQP Document Introduction and Finish

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

4.2.9 NPI Report 4.3 品管單位 QA Department 4.3.1 SIP 4.3.2 ESD Check 4.3.3 SMD Process and FAI Check

※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※

B

Foxconn International Holdings Ltd

系統 名稱 (SYSTEM): 產品開發作業系統 Product Development Procedure

主題 (SUBJECT): 新產品Pilot Run作業辦法 New Product Pilot Run Procedure

文件 編號 (DOCUMENT NO): CMOAG-0015 PAGE

4 OF 7

REV

B

4.3.4 Program and parameter Check: 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 Related inspection fixture making and supply. Samples procedure quality status collection and quality information supply 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. Confirm the quality, function status of first product and supply the related inspection document(FAI test list) and report 4.3.7 協調相關單位對各項品質問題之處理事宜. Corresponding related departments to handle quality problems 4.4企劃單位 Planning Department 4.4.1 物料采購,准備. Materials procurement and perparation 4.4.2 NPI派工令發料至產線. NPI work order for issuing materials to product lines 4.5制造單位 Production Department 4.5.1 SMT程式制作 SMT Program Making 4.5.2 Barcode label ready 4.5.3 試產時提供人力,治工具,維修﹐生產設備的支援. Support of haman power, fixture, and production equipment when samples trial run 4.6 資訊單位 IT Department 4.6.1 SFC ready 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. MP get the new products request and NPI from customers, and convey NPI to Product Engineer of Engineering Dep. 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 send the electronic file of customer data to DCC. 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 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. 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. Product engineers make the NPI schedule, hold the New Product Description Meeting to trace and supervise the process of related departments 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) Product engineers lead to finish CQP documents (PMP,Process flow chart,Tooling Plan) and make the related engineering documents (such as Barcode description) 5.7產品工程師确認物料治工具人力准備情況. Product engineers confirm the preparation of materials, tools and human power. 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 Engineering Dep. is responsible for samples making after the preparation of SMT program, materials and tools 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 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.

※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※

Foxconn International Holdings Ltd

系統名稱

(SYSTEM):

產品開發作業系統 Product Development Procedure

主題 (SUBJECT): 新產品Pilot Run作業辦法 New Product Pilot Run Procedure

文件編號

(DOCUMENT NO):

CMOAG-0015 PAGE

5 OF 7

REV

B

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 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 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: 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 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. DOA SMD Result<= 7000PPM, DOA Mat. Result<=10000PPM. Mass production can proceed 6.2 若DOA Result高于上述數据, If DOA Result is higher than the above datas 6.2.1 提出相應改善措施,經客戶裁定后方可正式量產. Lodge the related improvement measure. After judged by customers, mass production can proceed 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. Production is changed from trial run to mass prodcution according to customers' request of out-going ways and 6.1 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. After approved, the file is in operation. Revised as well. 8.附頁 : NPI CHECK LIST (CMOAG-0015-01B) PILOT RUN總結報告(CMOAG-0015-02B) Appendix: NPI CHECK LIST (CMOAG-0015-01B) PILOT RUN report (CMOAG-0015-02B)

※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※

Foxconn International Holdings Ltd

系統名稱

(SYSTEM):

主題 (SUBJECT):

文件編號

新產品Pilot Run作業辦法 產品開發作業系統 New Product Pilot Run Product Development Procedure Procedure

(DOCUMENT NO):

CMOAG-0015 PAGE

6 OF 7

REV

B

NPI 流程圖 客戶 Customer 客戶 產品

市場 PM

工程 ME

企劃 PMC

品管 QA

資訊 IT

制造

獲取 NPI

NPI

NG

獲取新產品規格 及相關工程資料

獲取新產品規格 及相關工程資料

新產品制作可 行性确認 OK 新產品說明會並制定 NPI Schedule

確認

NG

反饋客戶

檢查工程文件 OK

組織 NPI team 物料准備 協調各單位負責人 組成 NPI team

有庫存 OK

無庫存 采購

SMT 程式制 作

IQC

CQP 及相關工 程文件制定

SIP 檢查 ESD NG

治工具准備 SMD 制程檢查 教育訓練

SFC ready

程式參數檢查 OK Kick-off meeting

領出並上料

SMT 程式修訂 NG LCR Meter

雙面膠板制作

OK 初件制作 確認

NG

反饋客戶

比對樣品板 OK

NG

Discarding

V/I OK

Unrepairabl e

V/I

Repairable

OK

維修

NPI report

Delivery Pilot Run

※ ※

PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD.

※ ※

Foxconn International Holdings Ltd

系統名 稱 (SYSTEM):

主題 (SUBJECT):

文件編 號 (DOCUMENT NO):

新產品Pilot Run作業辦法 產品開發作業系統 New Product Pilot Run Product Development Procedure Procedure

CMOAG-0015 PAGE

7OF 7

REV

B

NPI flow chart 客戶 Customer Customer production

市場 PM NPI

工程 ME

企劃 PMC

品管 QA

資訊 IT

制造

Receive NPI Get the related specification and documents of process

Get the related specification and documents of process

NG OK Make the first evaluation on the possibility of new products manufacturing Product Introduction Meeting and make NPI schedule

Confirm

NG

Notice custormer

Check Engineering documents OK

Make up NPI team Coresponding related departments principal and making up NPI team

Material preparation

Inventory OK

Empty Buyer

IQC

Making CQP and related engineering document

SMTprogram making

SIP ESD check NG SMD Process Check

Fixture Preparation

SFC ready

Program and parameter Check

Training

OK Kick-off meeting

Feeding SMTprogram revising

NG LCR Meter

Double sides board making

OK First production making Confirm

NG

Notice custormer

Compare with golden sample

Discarding

OK NG

V/I OK

Unrepairabl e

V/I

Repairable

OK

Repair

NPI report

Delivery Pilot Run

※ ※ PROPRIETARY INFORMATION OF FOXCONN INTERATIONAL HOLDINGS LTD. ※ ※

NPI CHECK LIST Project name:

ENO P/N :

HWID:

SWID : 3.10

N0

CHECK ITEM Customer Doc.: Gerber file CAD Data Customer BOM(final version)

1 Component vendor list Packing spec. PCB & PCA Golden Sample Others： Documentation: BOM SAP system key in SOP CQP (Tooling plan,Flow chart,FMEA ,PMP) 2

Inspection Drawing POP Component feeding list MHS&ESD component list SIP Others： Tool: Stencil Printer (Vacuum Support)

3

PCBA Rework & V/I Fixture De-panel mold Profile measuring board Special fixture Chemical: Paste(Type) Cleaner(Multicore prozone SC-01)

4

Wipe paper Flux(Multifix 450-01) Solder wire (Multicore Solders Crystal 502 Sn62) Others： Equipment： Solder Paste Printer Chip Shooter(feeder,nozzle) AOI

5

IC Mounter(feeder,nozzle) Reflow Oven Router BGA rework station

Schedule ( March) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PCBA P/N: PCB P/N: Responsible Person

PCB REV: Due Date

Status

5

Others：

Program and parameter： Solder Paste Printer Mounterr(feeder,nozzle) AOI 6 Reflow Oven Router Barcode Label Others： Material preparation: PCB Component preparation 7 Package material Get some scarp component for FA training Others： Back End (Testing) : White box Adaptor FA tooling 8 Test plan readiness FA layout Depanelling program in Router Others : Production： Manpower review 9

SMT Training FA training Testing training Others： Diagnostic training

10 SFC ready Quality Acceptance Requirement Others Internal Audit: FAI check list 11 ESD & SMT Process Check Program and parameter Check: Pilot Run： Tape board / First article FAI Pilot run 12 Quality & yeild rate data Cycle Time Measurement Line Capacity Calculation NPI Report Others：

CMOAG-0015-01B

****PILOT RUN REPORT **** Project name: Items

PILOT RUN DATE: Reasons

Principal

Provisional solution

(Appendix2) Long-term solution

1

2

3

4

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8

9

10

11

12

CMOAG-0015-02B