New Product Introduction
… and the Importance of Advanced Quality Planning
1-1
Quality Strategy Master © 2001
新產品導入
… 先期品質計劃的重要性
1-2
Quality Strategy Master © 2001
FACTORY QUALITY SYSTEM
START- UP & NPI
• NPI Checklist • FMEA • Product Training • Post Mortem Analysis • Production Release Criteria
PROCESS CONTROLS
• SPC • PCS • ESD • SFCS • PVS • QAN • AOI • Yield trigger
R&D Activities Concurrent Engineering Activities
Gate Criteria Early information sharing DFM Reviews R&D treat factory as internal customer Emphasize Advanced Quality Planning, process defect prevention. Define process set-ups, test programs, and initial process parameters
Pilot Run Preparation
Collect necessary data, verify all process set-ups, test programs, and determine mass production process parameters. Minimum Process Yields and First Pass Yields are met. Process and test issues are known and addressed. Mass production process parameters have been defined.
設計

1
制造
- 產品評核 - NPI - 制程管制 - 品質提升
產品
3
材料
- 材料評核 - 供應商選擇 & 評核 - 持續改善
已認可的材 料
客 戶
材料需要
2
支援体系
- 改變管理 - 品質 評估 & 稽核 -文件管制
Quality Strategy Master © 2001
- 培訓 -客戶資料報告 5-2 -產品規程及安全性
PRODUCTION TECHNOLOGY CENTER
- Design for PCB - Component guidelines - Design inherent quality - Process Research
PRODUCT DESIGN
Design Rules
1
Design
- Product Qualification - Design for Reliability, Manufactueability, Test
Approved Materials
C US T O M ER
2
SUPPORT SYSTEMS
- Change Management - Quality Assessments & Audits - Document Control
Quality Strategy Master © 2001
- Training - Customer Data Reporting - Product Regulations & Safety 5-1
Quality Strategy Master © 2001 * ADAPTED FROM FORD’S APQP MANUAL
新產品開發 & 導入時間表*
設想開始 實施/認可 方案認可 原型 試產 導入
同步工程
計劃 產品設計 & 開發 制程設計 & 開發 產品 & 制程確認
制造準備
生產
反饋評估及校正措施 3-2
2-1
Quality Strategy Master © 2001
訓練班目的
• 重新認識新產品導入階段在品質策略中的重要性和在此階 段中一些典型的易犯錯誤. • 重新認識同步工程(CE)的思想和它為何及如何使新產品導入 (NPI) 順利進行. • 探討同步工程 (CE) 團隊及其活動關鍵的成功因素. • 重新認識¦在產品開發和新產品導入階段，將制程或品質控 制關卡作為一項管理工具的思想. • 闡述量產前作為制造準備就緒的評估和問題系統預防的技 巧，而確立新產品導入的戰略重要性. • 明确新產品導入(NPI) 的關鍵活動,包括前期控制關卡, 事后 （post-mortem）分析, 量產前的控制關卡.
Quality Strategy Master © 2001 * ADAPTED FROM FORD’S APQP MANUAL
Strategies (from a failure rate perspective… )
RISK ASSESSMENT PREVENTION OPTIMIZATION & DETECTION Strategy #3 Early Process Optimization during MP DOE, SPC, CLCA, & other CIPs Strategy #4 Quality Escalation (external failures) Detect, contain & recovery Present Competition Future R&D, • Purchasing
更高級別的 QA體系 – 實例 體系
客戶支援
- 品質績效反饋 - 品質 & 方法推廣 - 確定品質目標 -問題解決 - 客戶制造支援 客戶反餽 和投訴
生產技朮中心
- 為PCB板進行設計 - 元件的指導方針 - 設計內在品質 - 制程研究
生產技朮 設計規 則
產品設計
-產品評核 -適於可靠性, 可制造性及 測試的設計
起點 & NPI
• NPI查驗表 • FMEA • 產品培訓 • Post Mortem 分析 • 投產標准
制程管制
• SPC • PCS • ESD • SFCS • PVS • QAN • AOI • Yield trigger
輸入
來料
• AQL • MRB • VFAR • VCAR
輸出
生產黑盒子 OQM
Manufacturing
- Product Qualification - NPI - Process Control - Quality Escalation
Product
Production Technologies Material Requirements
3
MATERIALS
- Material Qualification - Supplier Selection & Qual. - Continuous Improvement
• AQL • VOQA • FOQA
客戶
持續改善
• 品質提升 •品質改善計划 • 定期客戶評估討論會
品質支援
•品質稽核 •校正 / 預防措施 • 文件管制體系 • 校准體系 • 培訓
6-2
Quality Strategy Master © 2001
The NPI Process
Milestone Definitions Design Reviews
Concurrent Engineering
PLANNING PRODUCT DESIGN & DEV.
Manufacturing Readiness
PROCESS DESIGN & DEVELOPMENT PRODUCT & PROCESS VALIDATION PRODUCTION
FEEDBACK ASSESSMENT & CORRECTIVE ACTION 3-1
INPUT
INCOMING
• AQL • MRB • VFAR • VCAR
OUTPUT
OQM
• AQL • VOQA • FOQA
MANUFACTURING BLACK BOX
CUSTOMER
CONTINUOUS IMPROVEMENT
• Quality Escalation • Quality Improvement Programs • Regular Customer Review Forums
QUALIY SUPPORTS
• Quality Audit • Corrective/preventive action • Doc Con system • Calibration system • Training
6-1
Quality Strategy Master © 2001
工廠品質體系 - 實例
Quality Strategy Master © 2001
HIGHER LEVEL QA SYSTEM
CUSTOMER SUPPORT
- Quality Performance Feedback - Quality & Methods Marketing - Set Quality Goals - Problem Resolution - Customer Manufacturing Support Customer Feedback & Complaints