SAFE-LAUNCH教學(xué)講解課件

Lite-OnSupplierSafeLaunchprocess

May2007Ver.6

PreparedByEdwardA.Liu1Lite-OnSupplierSafeLaunchpSafeLaunchModel模式光寶供應(yīng)商safelaunch模式

Asvolumeincreases…qualityincreases產(chǎn)品品質(zhì)與產(chǎn)量同步提升管理模式。2SafeLaunchModel模式光寶供應(yīng)商safeOccasions時(shí)機(jī)DevelopmentCycleISO9001

(DesignInput)DesignOutputDesignVerificationDesignValidation

Lite-On’sNPIEVTDVTMVT(PhaseReviewProcess)SamplebuildPilotRunPre-MassproductionSupplierSafeLaunchProcessR&DSampleapprovalPilotBuild

ControlledRampPPAPcompliancePPAP:ProductionPartApprovalProcess3Occasions時(shí)機(jī)DevelopmentCyclCompareS.L.withDellandLite-On戴爾vs.光寶模式Lite-OnNPIEVTDVTMVTLite-On(PhaseReviewProcess)SampleRunPilotRunPre-MassproductionPPAPapprovalDell,totally

7gatesLite-On’sNPIphasesLite-Onsupplier3gatesLite-On’ssupplieradopt3gates:ComponentlevelPilotInitiatives

SupplierNPIEVTDVTMVT

Supplier

SafeLaunchProcessSamplebuildPilotBuild

Gate1ControlledRampGate1+Gate2PPAPcompliance4CompareS.L.withDellandLitResponsibility權(quán)責(zé)Commodityteam:whenpartcreated,PM,R&D,andSQMinvolvedtheNPIasonecommodityteam,defineyield/gates,RTSandMRBdecision.

產(chǎn)品小組：由PM,R&D與SQE共同組成，光寶RSQE與小組成員共同定義產(chǎn)品與製程的良率/階段要求、時(shí)程管理、與階段特採決議。PM：RTStimingmanagement,productionquantitydefinitionofDVTandMVTphases.

產(chǎn)品管理：產(chǎn)品開發(fā)至上市總時(shí)程管理、DVT,MVT生產(chǎn)數(shù)量定義。

Lite-OnJQE:InvolvetheMRBdecisionmakingwithcommodityteam.

客戶JQE：與commodityteam共同參與試產(chǎn)特採決定。Lite-OnSQE：Processreviewforeachgate;ismanagingtheproduct/programisresponsibleforimplementationandadherencetothisprocess.

本程序之製程審查;管理本程序之供應(yīng)商試產(chǎn)（Pilotbuild,Controlramp）、紀(jì)錄審查、與供應(yīng)商製程改善活動(dòng)。R&D：Productreviewforeachgate;definetheCTQofindividualpartdiagram,solvethecriticaldesignissuewhenitbefoundinsafelaunchprocess.

本程序之產(chǎn)品審查;定義產(chǎn)品重要功能特性（CTQ）、並描述於零件承認(rèn)書圖面中；解決本程序中供應(yīng)商生產(chǎn)所發(fā)現(xiàn)之設(shè)計(jì)面重大問題。RTS:ReadytoshipmentCTQ:Criticaltoquality5Responsibility權(quán)責(zé)CommodityteaYields/Gates良率/階段的定義Processyield-gateswillbedefinedanddocumentedforboththepilotandcontrolledramppriortothefirstpilotbuild.Lite-Oncommodityteamdefinesthesegatesandtargets.Gatesaresetwithriskmanagementinmindthatisbasedonquality.Seetablebelowasanexample.Goalswillnotbechangedwithouttheagreementofthecommodityteam.

本程序的各個(gè)階段良率由光寶commodityteam共同定義之，基本上是由品質(zhì)風(fēng)險(xiǎn)的角度來設(shè)定，如下表案例。一旦各個(gè)階段良率目標(biāo)定義後，就不再變更。目標(biāo)變更，須經(jīng)由產(chǎn)品小組同意。CommodityTypeDVTMVTPilotBuild

Gate1ControlledRamp

Gate1ControlledRamp

Gate2QuantityFPYQuantityFPYQuantityFPYPCB3280%30085%50090%Plasticsmolding5085%10090%30095%Metalstamping12080%30%DM85%60%DM90%QuantityandFPYtargetsarerecommendation.DM:DemandofMarket6Yields/Gates良率/階段的定義ProcessSafeLaunchFlowChart流程圖ControlledRampGate1+

Gate2PilotbuildGate1MVTSafeLaunchProcessDVTFlowChartSampleverificationEVTNPIPhaseR&D新零件開發(fā):P1(G1,G2)供應(yīng)商,R&Dnewpartdevelopment:P(G1,G2)supplier樣品核準(zhǔn)Sampletest&verification供應(yīng)商試產(chǎn)Supplierpilot-runProductreviewbyLiteOnR&DProcessreviewbyLite-OnSQM發(fā)行零件承認(rèn)書Issueanapprovalsheet供應(yīng)商試產(chǎn)SupplierControlledRampCorrectiveActionCorrectiveActionMRBMRBFailFailPassPass供應(yīng)商樣品SuppliersamplebuildProductreviewbyLiteOnR&DProcessreviewbyLite-OnSQM*MRBmember:PM,R&D,JQEandSQE*Productreview:ByLite-OnR&D

Processreview:byLite-OnSQE7SafeLaunchFlowChart流程圖ContContentofSafeLaunchprocess內(nèi)容5.1. SafeLaunchModel光寶供應(yīng)商safelaunch模式 5.2. Occasions應(yīng)用時(shí)機(jī) 5.3. Yields/Gates良率/階段的定義 5.4. SafeLaunchGateRulesandCorrectiveActions

規(guī)則與改善行動(dòng)要求 5.5.MRBforfailedGate特採5.6. ProcessestobeMonitored,Guidelines製程監(jiān)督與指引5.7. DataCollection/Reporting資訊蒐集與報(bào)告 5.8. PostBuildmeetings生產(chǎn)後會(huì)議5.9. SupplierNPRRcompliancereview 5.10. ControlofQualityRecords品質(zhì)紀(jì)錄管制 5.11. 「SupplierSafelaunch程序」更新P1ofG1,G2supplierlist,22Nov2006SOPandworksheetSafeLaunchprojectcalendar8ContentofSafeLaunchprocessPurpose目的Thisproceduretoestablishacommoditysafelaunchprocessthatwillprovideaphasedapproachtowardsprocessvalidation,ameansoffine-tuningaprocessbeforevolumeramp,processforbuildinginqualityanddevelopmentofsupplierprocessesthatwillhelptheSuppliertomeetLite-On’squalityexpectations.對(duì)光寶重點(diǎn)供應(yīng)商，制定一「供應(yīng)商safelaunch程序」要求；本程序展現(xiàn)了光寶科技對(duì)供應(yīng)商生產(chǎn)個(gè)別產(chǎn)品製程的階段性核可要求，也是在量產(chǎn)前的製程能力提昇要求，以達(dá)成本公司良好進(jìn)料品質(zhì)的期望。9Purpose目的ThisproceduretoeScope範(fàn)圍ThisprocedurewillbeappliedforP1(Lite-OnDesignParts:PlasticInjection,MetalStamping,PCB)ofG1(highrisk,highspend)andG2(highrisk,lowspend)levelkeysuppliers’SafeLaunchrequirement,thekeysuppliersdefinitioncombinedwithspendandqualityriskelements,thekeysupplierlistintegratedboth2factorsbySQMdepartment.本程序適用本公司供應(yīng)商管理部所定義的P1(Lite-OnDesignParts:PlasticInjection,MetalStamping,PCB)供應(yīng)商之G1(highrisk,highspend)與G2(highrisk,lowspend)類型廠商之管理要求，重點(diǎn)供應(yīng)商名冊(cè)會(huì)依照營業(yè)額與品質(zhì)風(fēng)險(xiǎn)綜合評(píng)比後定義。10Scope範(fàn)圍ThisprocedurewillbThesuppliersafelaunchshouldbeusedinthefollowingsituations.下述情形供應(yīng)商應(yīng)導(dǎo)入本程序Newproduct新產(chǎn)品NewManufacturingfacility,existingsupplier

新生產(chǎn)設(shè)備導(dǎo)入NewSupplier新供應(yīng)商Significantform/functionchangestoexistingproduct現(xiàn)有產(chǎn)品重要功能變更MultipleLinequalificationwithexistingproduct.

現(xiàn)有產(chǎn)品之衍生生產(chǎn)線核可Occasions-211ThesuppliersafelaunchshoulSafelaunchtimeline導(dǎo)入時(shí)間表導(dǎo)入時(shí)間表ThepilotstartsintheDVTphase.Thisphasewillbecompletedandgatesmet/exceededpriortotheControlledRampstartoftheMVTphase.

Pilotbuild起自DVT階段，達(dá)成/超過既定目標(biāo)後，才能進(jìn)行MVT的ControlledRamp階段。IntheMVTphase,RTSatthesuppliersitestartsthecontrolledrampprocess.ControlledRampwillcontinueuntilallgatesaremetfor2consecutivegates.

在MVT的ControlledRamp階段，產(chǎn)品出貨品質(zhì)要求，仍須符合controlledramp的量產(chǎn)管制的目標(biāo)定義。12Safelaunchtimeline導(dǎo)入時(shí)間表導(dǎo)入時(shí)ApplyingGatestosafelaunch生產(chǎn)階段定義本程序之生產(chǎn)階段定義TheLite-Oncommodityteamwilldeterminethegatesbaseduponexperience,supplierinputs,qualityhistoryandthequalityrequirementsforthenexthigherassembly.Lite-OnR&Dimplementsproductreview,Lite-OnSQEimplementsprocessreview.

光寶commodityteam會(huì)依據(jù)經(jīng)驗(yàn)、供應(yīng)商建議、品質(zhì)履歷、與下階段組配品質(zhì)要求、、等，來定義生產(chǎn)階段與品質(zhì)目標(biāo)。產(chǎn)品面審查由光寶R&D執(zhí)行，製程面審查由光寶SQE執(zhí)行。Pilotgateswillbesetforatleast1pilotphase.MeanwhilesuppliershallcomplywithLite-On’sPPAPprocedurerequirements（C-SQM-015）.

Pilotbuild階段，至少進(jìn)行一次生產(chǎn)評(píng)估。除了FPY良率要求外，本階段供應(yīng)商也必須符合光寶PPAP程序（C-SQM-015）相關(guān)要求。Controlledrampbuildsgateswillbeset(by2times)andwillincreaseinincrementsasdefinedbytheLITE-ONcommodityteam.MeanwhilesuppliershallcomplywithLite-On’sPPAPprocedurerequirements（C-SQM-015）.

Controlledramp階段，至少進(jìn)行連續(xù)兩次的生產(chǎn)評(píng)估。除了FPY良率要求外，本階段供應(yīng)商也必須符合光寶PPAP程序（C-SQM-015）相關(guān)要求。13ApplyingGatestosafelaunchSafeLaunchGateRulesandCorrectiveActions規(guī)則與改善行動(dòng)要求5.4.1In-processandaftereachPilotPhaseorControlledRampbuildphases(typicallyproductiondays),therequiredyieldsandPPAPareevaluatedvs.theestablishedgates.Aformaldailyreviewofresultswillbecompletedafterallbuilds.TheLITE-ONJQEshallhostthismeeting,SQEmayattenditasrequired.

不論在Pilotbuild或是ControlledRamp階段進(jìn)行中、或是在完成後，都須進(jìn)行良率與目標(biāo)，以光寶相關(guān)要求（PPAP）的評(píng)估。光寶JQE必須主導(dǎo)每日的正式檢討會(huì)議，SQE適時(shí)參加。5.4.2ViolationofaGate階段未達(dá)目標(biāo)時(shí)

Duringanybuild,ifagateisviolatedthebuildmuststop.TheSupplierwillensurethatroot-causeandcorrectiveactionsaredefined/implementedforallissuesidentified,LITE-ONcommodityteamapprovalisrequiredpriortoDVTphase.CorrectiveactionsthatareimplementedwillbeverifiedbyLite-OnSQE/JQEtore-initialorcontinuenextbuild.

在每一個(gè)生產(chǎn)階段中，一旦良率不符目標(biāo)，則本階段生產(chǎn)即停止。供應(yīng)商對(duì)每一件確認(rèn)的品質(zhì)問題都須提供改善措施的定義與執(zhí)行，光寶commodityteam必須在DVT階段完成前核準(zhǔn)供應(yīng)商所有的品質(zhì)狀況與改善績效。改善行動(dòng)的執(zhí)行的情形，必須在經(jīng)由光寶SQE/JQE確認(rèn)後決議再次生產(chǎn)或是逕行進(jìn)入下階段。14SafeLaunchGateRulesandCorThepilotphasewillberepeateduntilallofthephasegatesareachievedorexceeded.Thecontrolledrampmayalsobeextendedifgatesarenotmet(atthediscretionoftheLITE-ONcommodityteam).

在生產(chǎn)良率目標(biāo)達(dá)成前，Pilotbuild階段將會(huì)重複進(jìn)行與延長。須由光寶commodityteam審慎考量後決定之。

Correctiveactionsthatarelongertermandcannotbeimplementedintheappropriatetimeperiodmaybeleftopen.Thenextbuildmayproceedaslongacontainmentplanisdefined/validatedandapprovedbytheLITE-ONSQE.

有關(guān)長期的改善措施，在短期間可留下未結(jié)案事項(xiàng)。在下生產(chǎn)階段時(shí)SQE仍需持續(xù)監(jiān)控、結(jié)案。

GateviolationwillbecodedREDontheSafeLaunchreport/datacollectiontemplate.

未達(dá)目標(biāo)的生產(chǎn)階段將會(huì)在工作表中標(biāo)註為「紅色」，以為警示。GatesthatareachievedorexceedthewillbecodedasGREENontheSafeLaunchreport.

每一階段達(dá)成或是超越目標(biāo)時(shí)，工作表上就會(huì)以「綠色」顯示良好狀態(tài)。ThepilotphasewillbGreen/RedcodeofGatesreviewGreencodeRedcodeGreencodeGreencode16Green/RedcodeofGatesreviewMRBforfailedGate特採AccordingtotheRTSmanagement,iftheproductionbuilddoesn’tmeetFPYrequirement,CommodityteamcouldholdaMRBreview.theMRBdispositionmakingwouldbedonebycommoditymembersandcustomerJQE.

產(chǎn)品小組可依照產(chǎn)品開發(fā)上市時(shí)程，對(duì)於未達(dá)目標(biāo)的生產(chǎn)階段，進(jìn)行特採管理，需經(jīng)過產(chǎn)品小組與客戶JQE共同決議之。MRBreviewshalladoptworksheetofthisprocedure.

特採作業(yè)需保留書面審查紀(jì)錄，依照附表格核準(zhǔn)之。WaiverecordshallberecordedinPilotControlledbuildsPlan.

特採作業(yè)需在PilotControlledbuildsPlan中註記特採紀(jì)錄，與核準(zhǔn)人員。Afterwaivedecisionmaking,TheSuppliershallfollowchapter5.4.2ensureroot-causeandcorrectiveactionsaredefined/implemented,LITE-ONcommodityteamapprovalisrequiredpriortoDVTMVTphase,andCorrectiveactionsthatareimplementedwillbeverifiedbyLite-OnSQE/JQEtore-initialorcontinuenextbuild.

特採作業(yè)決定後，仍需要依照5.4.2章節(jié)要求，進(jìn)行改善措施的執(zhí)行，在DVT階段完成前核準(zhǔn)供應(yīng)商所有的品質(zhì)狀況與改善績效，改善行動(dòng)的執(zhí)行的情形，必須在經(jīng)由光寶SQE/JQE確認(rèn)後決議再次生產(chǎn)或是逕行進(jìn)入下階段。17MRBforfailedGate特採AccordinDataCollection/Reporting資訊蒐集與報(bào)告

5.7.1Thesupplierisrequiredtomonitoreachoftheprocessesidentifiedduringeachofthebuildsperthegatesestablished.Thiscanbecompletedthroughautomatedshopfloorcontrolsystemsormanualcollection/reporting.Thesupplierwillstopbuildingimmediatelywhenthegateisviolated.Thesuppliershallcapturethedata/resultsasrealtimeaspossible.

供應(yīng)商必須在生產(chǎn)階段定義後，監(jiān)督每一個(gè)生產(chǎn)步驟；可以SFIS系統(tǒng)、或是人力進(jìn)行蒐集生產(chǎn)資訊與報(bào)告。供應(yīng)商必須在無法達(dá)成良率目標(biāo)時(shí)，立即停止生產(chǎn)，此時(shí)供應(yīng)商無法完成生產(chǎn)作業(yè)，進(jìn)而獲得生產(chǎn)資訊，供應(yīng)商必須儘可能的即時(shí)的進(jìn)行生產(chǎn)資訊蒐集。5.7.2SafeLaunchPilotandControlledRampDataCollectionTemplateandActionPlanRegister–worksheet（C-SQM-023-01）willbeusedforallbuilds.

供應(yīng)商必須以附表進(jìn)行生產(chǎn)結(jié)果記錄。5.7.3ThesupplierJQEwillprovideadailysummaryreportforeachbuild/phaseimmediatelyafteritiscompletedthroughthesafelaunchperiod.Itwillcontainalloftheappropriateyieldsvs.gates,allissuesidentifiedandcorrectiveactionplans.Seetemplatenotedinsection5.8.2forcompletedatacollectiondetails.

供應(yīng)商JQE即時(shí)提供的每日生產(chǎn)總結(jié)報(bào)告，並應(yīng)包含良率資訊、問題與改善計(jì)畫，參照5.8.2節(jié)進(jìn)行。18DataCollection/Reporting資訊蒐集PostBuildmeetings&SQRCcompliancereview5.8生產(chǎn)後會(huì)議JQELite-Onshallorganizeadailypostbuildmeetingaftereverybuild/phase.LITE-ONSQEmayattendthisasrequired.

光寶JQE必須主導(dǎo)在每生產(chǎn)階段期間召開每日生產(chǎn)後會(huì)議，光寶SQE適時(shí)參加。5.9SQRC審查Lite-OnSQEwillimplementSQRC(supplierqualityreportcard)reviewasaproductreadinesscompliancereviewbeforemassproductionwhichbasedonLite-OnPPAPrequirement.

光寶SQE將進(jìn)行SQRC審查,以為產(chǎn)品量產(chǎn)前查核,此審查以光寶供應(yīng)商的PPAP要求為基礎(chǔ).19PostBuildmeetings&SQRCcomSupplierNPRRPerformanceReviewNPRR:Newproductreadinessreview20SupplierNPRRPerformanceReviSafeLaunchprojectcalendaritemProjectstep2007TargetMarAprMayJunJulAug1DevelopdraftversionSOP40Suppliers

ofP1(G1,G2):PlasticInjection,MetalStamping,PCB

V

2SOPcrossfunctionapproval

VV

3Internaltraining:PM,R&DandSQE

V

4SupplierKickOffmeeting:Lite-OnSQEvs.supplierlist

V

5ProjectmonthlyreviewRSQMassistvisit

V

V

V

V

21SafeLaunchprojectcalendaritsupplierlistApr200742SuppliersadoptLite-Onsafelaunchprocess.SupplierselectionprinciplesP1suppliers(Lite-Ondesignparts)G1,G2,G3suppliersRelatedwithBUserveKeycustomer

重點(diǎn)客戶的供應(yīng)商,如:Dell,HP,此標(biāo)準(zhǔn)則不侷限供應(yīng)商G1,G2類別,G3也可以.There’renewproductsdevelopmentatcoming3~6months

wouldliketoco-workwithLite-On有配合意願(yuàn),光寶能主動(dòng)要求的供應(yīng)商.(低配合度供應(yīng)商,請(qǐng)協(xié)助刪除.)

22supplierlistApr200742SupplDocumentandworksheetSafeLaunchSOPWorksheetSafeLaunchgatereviewchecklistWorkonit.23DocumentandworksheetSafeLauThankYou24ThankYou24PPAPkeysupplierdefinitionThisprocedureshallbeappliedforP1typesuppliers(Lite-OnDesignParts:PlasticInjection,MetalStamping,andPCB).andsuitedforG1,G2levelsuppliers.HighHighLowLowSPENDRISKGroupII(34Suppliers)PerformanceisimportanttoproductperformanceOneormorerestrictedsourcesFewOptionsTemporaryorinherentriskHighRiskLowSpendGroupI(49Suppliers)GroupIII(255Suppliers)ManyOptionsManySourcesLittlebrandpreferenceLowRiskLowSpendCriticaltoproductperformancetechnicallyirreplaceableLossordelayhasmajorimpactFewalternativesorcosttochangesuppliersishighHighriskHighspendCommondesignsLossordelayhaslessimpactManyalternativesourcesManysourcesLargemarketcapacityLowRiskHighspendSurveillancePartnershipContractualTransactionalGroupIV(1,716Suppliers)“KeySupplier”“KeySupplier”“KeySupplier”25PPAPkeysupplierdefinitionTProcurementtypedefinitionProcurementTypeDefinitionLite-OnQualityAssuranceP1:Lite-OnDesignPartsPlasticInjection,MetalStamping,PCBLite-OnProcess100%TestingandInspectionP2:IndustryStandardPartsEE,ME,EMPartsPurchasedfromSupplierProductCatalogLite-OnProcess100%TestingandInspectionP3:RawMaterialPlasticResin,SheetMetalLite-OnProcess100%TestingandInspectionP4:AccessoryPartsforPackingAdapter,Headset,Cable,BatterySet,CarryBag,…Without100%TestingandInspectionandDirectlyShippingP5:PackingMaterialsCarton,Cover,Box,Partition,CornerBoard,PEBag,Label,…Lite-OnProcess100%TestingandInspectionP6:DocumentationforPackingCD,Manual,Handbook,….Without100%TestingandInspectionandDirectlyShippingP7:SemiconductorandManufacturerthruDistributorInboundandOutboundSemiconductorSuppliersLite-OnProcess100%TestingandInspection26ProcurementtypedefinitionPrCTQdefinedatdiagraminapprovalsheetCTQ(CriticaltoQuality)definitionPartdiagramSPEC.CHARNominal+TOL-TOLCpk

requirementLocation1

asapprovalsheet

Location2

asapprovalsheet

Location3

asapprovalsheet

Location4

asapprovalsheet

Location5

asapprovalsheet

…

asapprovalsheet

…

asapprovalsheet

…

asapprovalsheet

…

asapprovalsheet

…

asapprovalsheet

27CTQdefinedatdiagraminapprPPAPRequirementsPPAP應(yīng)用時(shí)機(jī)個(gè)別的產(chǎn)品專案/光寶料號(hào)之零件承認(rèn)管理要求。對(duì)象G1(highrisk,highspend),G2(highrisk,lowspend)重點(diǎn)供應(yīng)商使用工具產(chǎn)品規(guī)格定義（RSV,CTQ）試產(chǎn)首件檢查報(bào)告（FAI）製程能力分析、GR&R、材質(zhì)成分證明、製造流程圖、製程FMEA、製程管理計(jì)畫（PMP）與圖面生產(chǎn)組裝、檢測工作說明書。PPAP:ProductionPartApprovalProcess28PPAPRequirementsPPAP應(yīng)用時(shí)機(jī)個(gè)別的產(chǎn)品Lite-OnSupplierSafeLaunchprocess

May2007Ver.6

PreparedByEdwardA.Liu29Lite-OnSupplierSafeLaunchpSafeLaunchModel模式光寶供應(yīng)商safelaunch模式

Asvolumeincreases…qualityincreases產(chǎn)品品質(zhì)與產(chǎn)量同步提升管理模式。30SafeLaunchModel模式光寶供應(yīng)商safeOccasions時(shí)機(jī)DevelopmentCycleISO9001

(DesignInput)DesignOutputDesignVerificationDesignValidation

Lite-On’sNPIEVTDVTMVT(PhaseReviewProcess)SamplebuildPilotRunPre-MassproductionSupplierSafeLaunchProcessR&DSampleapprovalPilotBuild

ControlledRampPPAPcompliancePPAP:ProductionPartApprovalProcess31Occasions時(shí)機(jī)DevelopmentCyclCompareS.L.withDellandLite-On戴爾vs.光寶模式Lite-OnNPIEVTDVTMVTLite-On(PhaseReviewProcess)SampleRunPilotRunPre-MassproductionPPAPapprovalDell,totally

7gatesLite-On’sNPIphasesLite-Onsupplier3gatesLite-On’ssupplieradopt3gates:ComponentlevelPilotInitiatives

SupplierNPIEVTDVTMVT

Supplier

SafeLaunchProcessSamplebuildPilotBuild

Gate1ControlledRampGate1+Gate2PPAPcompliance32CompareS.L.withDellandLitResponsibility權(quán)責(zé)Commodityteam:whenpartcreated,PM,R&D,andSQMinvolvedtheNPIasonecommodityteam,defineyield/gates,RTSandMRBdecision.

產(chǎn)品小組：由PM,R&D與SQE共同組成，光寶RSQE與小組成員共同定義產(chǎn)品與製程的良率/階段要求、時(shí)程管理、與階段特採決議。PM：RTStimingmanagement,productionquantitydefinitionofDVTandMVTphases.

產(chǎn)品管理：產(chǎn)品開發(fā)至上市總時(shí)程管理、DVT,MVT生產(chǎn)數(shù)量定義。

Lite-OnJQE:InvolvetheMRBdecisionmakingwithcommodityteam.

客戶JQE：與commodityteam共同參與試產(chǎn)特採決定。Lite-OnSQE：Processreviewforeachgate;ismanagingtheproduct/programisresponsibleforimplementationandadherencetothisprocess.

本程序之製程審查;管理本程序之供應(yīng)商試產(chǎn)（Pilotbuild,Controlramp）、紀(jì)錄審查、與供應(yīng)商製程改善活動(dòng)。R&D：Productreviewforeachgate;definetheCTQofindividualpartdiagram,solvethecriticaldesignissuewhenitbefoundinsafelaunchprocess.

本程序之產(chǎn)品審查;定義產(chǎn)品重要功能特性（CTQ）、並描述於零件承認(rèn)書圖面中；解決本程序中供應(yīng)商生產(chǎn)所發(fā)現(xiàn)之設(shè)計(jì)面重大問題。RTS:ReadytoshipmentCTQ:Criticaltoquality33Responsibility權(quán)責(zé)CommodityteaYields/Gates良率/階段的定義Processyield-gateswillbedefinedanddocumentedforboththepilotandcontrolledramppriortothefirstpilotbuild.Lite-Oncommodityteamdefinesthesegatesandtargets.Gatesaresetwithriskmanagementinmindthatisbasedonquality.Seetablebelowasanexample.Goalswillnotbechangedwithouttheagreementofthecommodityteam.

本程序的各個(gè)階段良率由光寶commodityteam共同定義之，基本上是由品質(zhì)風(fēng)險(xiǎn)的角度來設(shè)定，如下表案例。一旦各個(gè)階段良率目標(biāo)定義後，就不再變更。目標(biāo)變更，須經(jīng)由產(chǎn)品小組同意。CommodityTypeDVTMVTPilotBuild

Gate1ControlledRamp

Gate1ControlledRamp

Gate2QuantityFPYQuantityFPYQuantityFPYPCB3280%30085%50090%Plasticsmolding5085%10090%30095%Metalstamping12080%30%DM85%60%DM90%QuantityandFPYtargetsarerecommendation.DM:DemandofMarket34Yields/Gates良率/階段的定義ProcessSafeLaunchFlowChart流程圖ControlledRampGate1+

Gate2PilotbuildGate1MVTSafeLaunchProcessDVTFlowChartSampleverificationEVTNPIPhaseR&D新零件開發(fā):P1(G1,G2)供應(yīng)商,R&Dnewpartdevelopment:P(G1,G2)supplier樣品核準(zhǔn)Sampletest&verification供應(yīng)商試產(chǎn)Supplierpilot-runProductreviewbyLiteOnR&DProcessreviewbyLite-OnSQM發(fā)行零件承認(rèn)書Issueanapprovalsheet供應(yīng)商試產(chǎn)SupplierControlledRampCorrectiveActionCorrectiveActionMRBMRBFailFailPassPass供應(yīng)商樣品SuppliersamplebuildProductreviewbyLiteOnR&DProcessreviewbyLite-OnSQM*MRBmember:PM,R&D,JQEandSQE*Productreview:ByLite-OnR&D

Processreview:byLite-OnSQE35SafeLaunchFlowChart流程圖ContContentofSafeLaunchprocess內(nèi)容5.1. SafeLaunchModel光寶供應(yīng)商safelaunch模式 5.2. Occasions應(yīng)用時(shí)機(jī) 5.3. Yields/Gates良率/階段的定義 5.4. SafeLaunchGateRulesandCorrectiveActions

規(guī)則與改善行動(dòng)要求 5.5.MRBforfailedGate特採5.6. ProcessestobeMonitored,Guidelines製程監(jiān)督與指引5.7. DataCollection/Reporting資訊蒐集與報(bào)告 5.8. PostBuildmeetings生產(chǎn)後會(huì)議5.9. SupplierNPRRcompliancereview 5.10. ControlofQualityRecords品質(zhì)紀(jì)錄管制 5.11. 「SupplierSafelaunch程序」更新P1ofG1,G2supplierlist,22Nov2006SOPandworksheetSafeLaunchprojectcalendar36ContentofSafeLaunchprocessPurpose目的Thisproceduretoestablishacommoditysafelaunchprocessthatwillprovideaphasedapproachtowardsprocessvalidation,ameansoffine-tuningaprocessbeforevolumeramp,processforbuildinginqualityanddevelopmentofsupplierprocessesthatwillhelptheSuppliertomeetLite-On’squalityexpectations.對(duì)光寶重點(diǎn)供應(yīng)商，制定一「供應(yīng)商safelaunch程序」要求；本程序展現(xiàn)了光寶科技對(duì)供應(yīng)商生產(chǎn)個(gè)別產(chǎn)品製程的階段性核可要求，也是在量產(chǎn)前的製程能力提昇要求，以達(dá)成本公司良好進(jìn)料品質(zhì)的期望。37Purpose目的ThisproceduretoeScope範(fàn)圍ThisprocedurewillbeappliedforP1(Lite-OnDesignParts:PlasticInjection,MetalStamping,PCB)ofG1(highrisk,highspend)andG2(highrisk,lowspend)levelkeysuppliers’SafeLaunchrequirement,thekeysuppliersdefinitioncombinedwithspendandqualityriskelements,thekeysupplierlistintegratedboth2factorsbySQMdepartment.本程序適用本公司供應(yīng)商管理部所定義的P1(Lite-OnDesignParts:PlasticInjection,MetalStamping,PCB)供應(yīng)商之G1(highrisk,highspend)與G2(highrisk,lowspend)類型廠商之管理要求，重點(diǎn)供應(yīng)商名冊(cè)會(huì)依照營業(yè)額與品質(zhì)風(fēng)險(xiǎn)綜合評(píng)比後定義。38Scope範(fàn)圍ThisprocedurewillbThesuppliersafelaunchshouldbeusedinthefollowingsituations.下述情形供應(yīng)商應(yīng)導(dǎo)入本程序Newproduct新產(chǎn)品NewManufacturingfacility,existingsupplier

新生產(chǎn)設(shè)備導(dǎo)入NewSupplier新供應(yīng)商Significantform/functionchangestoexistingproduct現(xiàn)有產(chǎn)品重要功能變更MultipleLinequalificationwithexistingproduct.

現(xiàn)有產(chǎn)品之衍生生產(chǎn)線核可Occasions-239ThesuppliersafelaunchshoulSafelaunchtimeline導(dǎo)入時(shí)間表導(dǎo)入時(shí)間表ThepilotstartsintheDVTphase.Thisphasewillbecompletedandgatesmet/exceededpriortotheControlledRampstartoftheMVTphase.

Pilotbuild起自DVT階段，達(dá)成/超過既定目標(biāo)後，才能進(jìn)行MVT的ControlledRamp階段。IntheMVTphase,RTSatthesuppliersitestartsthecontrolledrampprocess.ControlledRampwillcontinueuntilallgatesaremetfor2consecutivegates.

在MVT的ControlledRamp階段，產(chǎn)品出貨品質(zhì)要求，仍須符合controlledramp的量產(chǎn)管制的目標(biāo)定義。40Safelaunchtimeline導(dǎo)入時(shí)間表導(dǎo)入時(shí)ApplyingGatestosafelaunch生產(chǎn)階段定義本程序之生產(chǎn)階段定義TheLite-Oncommodityteamwilldeterminethegatesbaseduponexperience,supplierinputs,qualityhistoryandthequalityrequirementsforthenexthigherassembly.Lite-OnR&Dimplementsproductreview,Lite-OnSQEimplementsprocessreview.

光寶commodityteam會(huì)依據(jù)經(jīng)驗(yàn)、供應(yīng)商建議、品質(zhì)履歷、與下階段組配品質(zhì)要求、、等，來定義生產(chǎn)階段與品質(zhì)目標(biāo)。產(chǎn)品面審查由光寶R&D執(zhí)行，製程面審查由光寶SQE執(zhí)行。Pilotgateswillbesetforatleast1pilotphase.MeanwhilesuppliershallcomplywithLite-On’sPPAPprocedurerequirements（C-SQM-015）.

Pilotbuild階段，至少進(jìn)行一次生產(chǎn)評(píng)估。除了FPY良率要求外，本階段供應(yīng)商也必須符合光寶PPAP程序（C-SQM-015）相關(guān)要求。Controlledrampbuildsgateswillbeset(by2times)andwillincreaseinincrementsasdefinedbytheLITE-ONcommodityteam.MeanwhilesuppliershallcomplywithLite-On’sPPAPprocedurerequirements（C-SQM-015）.

Controlledramp階段，至少進(jìn)行連續(xù)兩次的生產(chǎn)評(píng)估。除了FPY良率要求外，本階段供應(yīng)商也必須符合光寶PPAP程序（C-SQM-015）相關(guān)要求。41ApplyingGatestosafelaunchSafeLaunchGateRulesandCorrectiveActions規(guī)則與改善行動(dòng)要求5.4.1In-processandaftereachPilotPhaseorControlledRampbuildphases(typicallyproductiondays),therequiredyieldsandPPAPareevaluatedvs.theestablishedgates.Aformaldailyreviewofresultswillbecompletedafterallbuilds.TheLITE-ONJQEshallhostthismeeting,SQEmayattenditasrequired.

不論在Pilotbuild或是ControlledRamp階段進(jìn)行中、或是在完成後，都須進(jìn)行良率與目標(biāo)，以光寶相關(guān)要求（PPAP）的評(píng)估。光寶JQE必須主導(dǎo)每日的正式檢討會(huì)議，SQE適時(shí)參加。5.4.2ViolationofaGate階段未達(dá)目標(biāo)時(shí)

Duringanybuild,ifagateisviolatedthebuildmuststop.TheSupplierwillensurethatroot-causeandcorrectiveactionsaredefined/implementedforallissuesidentified,LITE-ONcommodityteamapprovalisrequiredpriortoDVTphase.CorrectiveactionsthatareimplementedwillbeverifiedbyLite-OnSQE/JQEtore-initialorcontinuenextbuild.

在每一個(gè)生產(chǎn)階段中，一旦良率不符目標(biāo)，則本階段生產(chǎn)即停止。供應(yīng)商對(duì)每一件確認(rèn)的品質(zhì)問題都須提供改善措施的定義與執(zhí)行，光寶commodityteam必須在DVT階段完成前核準(zhǔn)供應(yīng)商所有的品質(zhì)狀況與改善績效。改善行動(dòng)的執(zhí)行的情形，必須在經(jīng)由光寶SQE/JQE確認(rèn)後決議再次生產(chǎn)或是逕行進(jìn)入下階段。42SafeLaunchGateRulesandCorThepilotphasewillberepeateduntilallofthephasegatesareachievedorexceeded.Thecontrolledrampmayalsobeextendedifgatesarenotmet(atthediscretionoftheLITE-ONcommodityteam).

在生產(chǎn)良率目標(biāo)達(dá)成前，Pilotbuild階段將會(huì)重複進(jìn)行與延長。須由光寶commodityteam審慎考量後決定之。

Correctiveactionsthatarelongertermandcannotbeimplementedintheappropriatetimeperiodmaybeleftopen.Thenextbuildmayproceedaslongacontainmentplanisdefined/validatedandapprovedbytheLITE-ONSQE.

有關(guān)長期的改善措施，在短期間可留下未結(jié)案事項(xiàng)。在下生產(chǎn)階段時(shí)SQE仍需持續(xù)監(jiān)控、結(jié)案。

GateviolationwillbecodedREDontheSafeLaunchreport/datacollectiontemplate.

未達(dá)目標(biāo)的生產(chǎn)階段將會(huì)在工作表中標(biāo)註為「紅色」，以為警示。GatesthatareachievedorexceedthewillbecodedasGREENontheSafeLaunchreport.

每一階段達(dá)成或是超越目標(biāo)時(shí)，工作表上就會(huì)以「綠色」顯示良好狀態(tài)。4ThepilotphasewillbGreen/RedcodeofGatesreviewGreencodeRedcodeGreencodeGreencode44Green/RedcodeofGatesreviewMRBforfailedGate特採AccordingtotheRTSmanagement,iftheproductionbuilddoesn’tmeetFPYrequirement,CommodityteamcouldholdaMRBreview.theMRBdispositionmakingwouldbedonebycommoditymembersandcustomerJQE.

產(chǎn)品小組可依照產(chǎn)品開發(fā)上市時(shí)程，對(duì)於未達(dá)目標(biāo)的生產(chǎn)階段，進(jìn)行特採管理，需經(jīng)過產(chǎn)品小組與客戶JQE共同決議之。MRBreviewshalladoptworksheetofthisprocedure.

特採作業(yè)需保留書面審查紀(jì)錄，依照附表格核準(zhǔn)之。WaiverecordshallberecordedinPilotControlledbuildsPlan.

特採作業(yè)需在PilotControlledbuildsPlan中註記特採紀(jì)錄，與核準(zhǔn)人員。Afterwaivedecisionmaking,TheSuppliershallfollowchapter5.4.2ensureroot-causeandcorrectiveactionsaredefined/implemented,LITE-ONcommodityteamapprovalisrequiredpriortoDVTMVTphase,andCorrectiveactionsthatareimplementedwillbeverifiedbyLite-OnSQE/JQEtore-initialorcontinuenextbuild.

特採作業(yè)決定後，仍需要依照5.4.2章節(jié)要求，進(jìn)行改善措施的執(zhí)行，在DVT階段完成前核準(zhǔn)供應(yīng)商所有的品質(zhì)狀況與改善績效，改善行動(dòng)的執(zhí)行的情形，必須在經(jīng)由光寶SQE/JQE確認(rèn)後決議再次生產(chǎn)或是逕行進(jìn)入下階段。45MRBforfailedGate特採AccordinDataCollection/Reporting資訊蒐集與報(bào)告

5.7.1Thesupplierisrequiredtomonitoreachoftheprocessesidentifiedduringeachofthebuildsperthegatesestablished.Thiscanbecompletedthroughautomatedshopfloorcontrolsystemsormanualcollection/reporting.Thesupplierwillstopbuildingimmediatelywhenthegateisviolated.Thesuppliershallcapturethedata/resultsasrealtimeaspossible.

供應(yīng)商必須在生產(chǎn)階段定義後，監(jiān)督每一個(gè)生產(chǎn)步驟；可以SFIS系統(tǒng)、或是人力進(jìn)行蒐集生產(chǎn)資訊與報(bào)告。供應(yīng)商必須在無法達(dá)成良率目標(biāo)時(shí)，立即停止生產(chǎn)，此時(shí)供應(yīng)商無法完成生產(chǎn)作業(yè)，進(jìn)而獲得生產(chǎn)資訊，供應(yīng)商必須儘可能的即時(shí)的進(jìn)行生產(chǎn)資訊蒐集。5.7.2SafeLaunchPilotandControlledRampDataCollectionTemplateandActionPlanRegister–worksheet（C-SQM-023-01）willbeusedforallbuilds.

供應(yīng)商必須以附表進(jìn)行生產(chǎn)結(jié)果記錄。5.7.3ThesupplierJQEwillprovideadailysummaryreportforeachbuild/phaseimmediatelyafteritiscompletedthroughthesafelaunchperiod.Itwillcontainalloftheappropriateyieldsvs.gates,allissuesidentifiedandcorrectiveactionplans.Seetemplatenotedinsection5.8.2forcompletedatacollectiondetails.

供應(yīng)商JQE即時(shí)提供的每日生產(chǎn)總結(jié)報(bào)告，並應(yīng)包含良率資訊、問題與改善計(jì)畫，參照5.8.2節(jié)進(jìn)行。46DataCollection/Reporting資訊蒐集PostBuildmeetings&SQRCcompliancereview5.8生產(chǎn)後會(huì)議JQELite-Onshallorganizeadailypostbuildmeetingaftereverybuild/phase.LI