Keep the Customer Satisfied. Dick van Hees /D&E Event

Transcription

1 Keep the Customer Satisfied Dick van Hees /D&E Event

2 Slide 2 Agenda Customer Expectation Translate Expectation Specification Prediction Methodologies Part Quality Prediction

3 Slide 3 Customer Expectation Translate Expectation Specification Prediction Methodologies Part Quality Prediction

4 Customer Expectation Slide 4 Expose Wafers Resolution (..nm) Expose Wafers: /exposure System Availability Field size Overlay (..*..mm) (.nm) System Cost of Operation System Delivery Time Throughput ( wph) Cost of Operation (. /exposure) Functional Breakdown Operational Breakdown

5 Slide 5 Customer Expectation Translate Expectation Specification Prediction Methodologies Part Quality Prediction

6 Translate Expectation Specification Slide 6 Operational Requirements Availability (SEMI) Reliability (MTBI, MTBF) Serviceability (MTTR) Cost System Cost Delivery Performance Cycle Time (CT) Part Quality (FPY, ZHDR)

7 Translate Expectation Specification Slide 7 Availability (wpy) Up Time Down Time Non Scheduled Time

8 Translate Expectation Specification /exposure Cost Of operation Maintenance Cost Gas/fluids/electricity Repair cost System Cost Part Cost (Supplier Parts) Build Cost Slide 8 Delivery Performance Time to Complete a system Cycle time (build and test) Disturbance Time (Part Quality/Part Availability/ )

9 Translate Expectation Specification Slide 9 Functional Requirement/Part Operational Requirement/Part Part Quality (FPY & Zero Hour Defect Rate) Part Cost ( ) Cycle Time (h) Reliability (Hits/part/year) Serviceability (MTTR)

10 Slide 10 Customer Expectation Translate Expectation Specification Prediction Methodologies Part Quality Prediction

11 Prediction Methodologies Slide 11 Operational Requirement/Part Part Quality (Zero Hour Defect Rate) Part Cost ( ) Cycle time (h) Reliability (Hits/part/year) Serviceability (MTTR)

12 Available Prediction Methodologies Slide 12 Operational Requirements Part Quality FPY % ZHDR %/ppm Reliability Hits/part/year Servicability Diagnostic h Repair h Recovery h Part Cost Cycle Time h PCB PCBA Electro Mechanical Mechanics Mechatronics

13 Prediction Methodologies Slide 13 Operational Requirement/Part Part Quality (Zero Hour Defect Rate) Reliability (Hits/part/year) Serviceability (MTTR) Part Cost ( ) Cycle time (h)

14 Slide 14 Customer Expectation Translate Expectation Specification Prediction Methodologies Part Quality Prediction

15 Zero Hour Defect Rate (ZHDR) Definition Zero Hour Defect Rate (ZHDR) Definition Slide 15 Definition: ZERO HOUR DEFECT RATE = # Accepted DEFECTS # DELIVERED Maximum accepted failure rate during system build (%) measured over an agreed period of time. Specification Requirement ID Requirement Text Min. Typ. Max. Unit First Pass Yield (FPY). Required ability to manufacture part without rework or test. % Zero Hour Defect Rate (ZHDR). Maximum allowed part failure rate. % DPMO Verification method Status Source ID Prediction Requirement ID Requirement Text Min. Typ. Max. Unit First Pass Yield (FPY). Calculated ability to manufacture part without rework or test. % Zero Hour Defect Rate (ZHDR). Calculated % maximum allowed part failure rate. DPMO Zero Hour Defect Rate (ZHDR) % Manufacturing DPMO Zero Hour Defect Rate (ZHDR) Design % DPMO Verification method Status Source ID

16 Part Quality (ZHDR) Prediction Part Defect Opportunities Slide 16 Parts Mounting Connect Assembly Process Defect Part Missing Part Fastening Cleaning Functional out of spec Wrong Part Glueing Adjusting Physical out of spec Misoriented Part Soldering Excess parts Misplaced Part Bonding Testing Connecting elec,fluids gas Riveting ZHDR 1 DO i 1 [1 DPMO i 10 6 ]

17 Parts Quality (ZHDR) Prediction Process ZHDR Slide 19 ZHDR OK OK False OK Process False OK Test NOK Reworked OK Output Test False OK ZHDR = False OK False OK + OK Rework Not Reworkable NOK Scrap

18 Parts Quality (ZHDR) Methodology Slide 20 New Product Introduction (NPI) Predict Supplier/Factory Part Quality in Design Phase Based on the Preliminary BOM (PBOM) Risk Calculator Risk Knowledge base

19 Parts Quality (ZHDR) Prediction Outcome is the Zero Hour Defect Rate DPMO Slide DPMO Risk mitigation to bring the ZHDR at specified level Design Change Process change at Supplier/factory Test

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