???????? ????? Advanced Product Quality Planning and Control Plan)

1
???????? ????? Advanced Product Quality
Planning and Control Plan)

• ?? ?????
• ????????(?)????
• ?? 91 ? 1 ? 15 ?

2
?? ????????????
1???????
?? QS9000 ??????
??????? ??????? ?????
??????? ?????
APQP?FMEA?QFD
3
?? ????????????
?? QS9000 ??????
1???????
????????????
??????? ???
123
??????? ?????????
?
??????? Information Technology Innovation
??
??
4
?? ????????????
?? QS9000 ??????
1???????
e ?????
???????
e ?????
??????? ???????? ??????? ???? ??????? ???????????
?????? ?????? ???????? e ???? ???? ????????
???
???
???
??????
?? 1
?? 2
?????
??????
???
????
?????
??????
????????????
???
????
????
?????????? ??????????? ???????????
????
????
???
5
?? QS9000 ??????
2??????????
Quality System 9000??????????????,????????,


? QS-9000???????????,??,????,??????,????????,?????
??,?????,????????????????????
?? ????,??????,????????????
?? Q -101 ????????
???? NAO Targets for Excellence
???? ?????????
6
?? QS9000 ??????
2??????????
A?1994?8?????, 1995?2??????, 1998?3??????? B?QS90
00??????????????? ??????ISO9000????????????
??????????????? ?????? ????????????????????
?1998??????????????????,??????,??????24
???20?,ISO9000???????? C?QS9000?????
QSR Quality System Requirements ??????
APQP Advanced Product Quality Planning and
Control Plan ????????????? PPAP
Production Part Approval Process?????????
FMEA Potential Failure Mode and Effects
Analysis????????? MSA Measurement
Systems Analysis?????? SPC Statistical
Process Control ?????? QSA Quality
System Assessment??????
7
?? QS9000 ??????
2??????????
ISO 9000 ????
????????? ???????? ??QS9000?? ?????

• ??????
• ??????
• ???????????
• ??????????
• QS??
• ??????????

???? QS 9000 IASG ???????? ??????
???? ?? ????? ????
?????? APQPCP FMEA MSA SPC
8
?? QS9000 ??????
3?QS-9000 ?????
4.1???? ????????????????????,????????,??????????,?
???????????????????????????,????????????,???????
  4.2 ???? ?????????????????????????,?????????????
??,???????,???????,??????????,???????????,???????,
??????????,???????????????,?????????????,?????????
?????????????,??????,?????????,????????
9
?? QS9000 ??????
3?QS-9000 ?????
4.3 ???? ?????????????,???DM????????????????   4.4
???? ??????OEM??????,??????????,??????????,??????
???
4.5??????? ???????????????,?????????????,???????,?
?????????   4.6 ???? ?????????????????????????????
????,?????,???,????????,????????????
10
?? QS9000 ??????
3?QS-9000 ?????

• 4.8?????????
• ??????,??????????,???????????? ?????????
•  
• 4.9 ????
• ???????????????????????????,?????????????,????????
  ???,?????????????????
•  
• 4.11 ????????????
• ???????????
• ?????????,????????,????????
• ???????????????,????????
• ?????????,??????,???????????,
• ???????????????????????????

11
?? QS9000 ??????
3?QS-9000 ?????
4.14 ??????? ????8D????,?????????????????   4.15
?????????????? ?????????????????????????????????,?
????????,?????   4.17 ???? ?????,????????????,????
??,??????????????????,???????,??????????????    4.
20?? ????SPC??????????????????????
12
ISO 9000/2000? ????
Process Approach Model
Continual Improvement of the Quality Management
System
Satisfaction
MANAGEMENT RESPONSIBILITY
CUSTOMER
CUSTOMER
Requirement
Measurement, Analysis, improvement
RESOURCE MANAGEMENT
Input
Output
PRODUCT REALIZATION
PROCESS
Product
13
?? APQP?CP???
1?????APQP????
4.2.3.1 ???????
???????????????????,?????? ????????,?????????????,
??? ?????????????????????????? ???????,??,????????
??????? ??,?????????

• ?????????/??
• ?????????????????
• ????????,?????????,?????????
• ????????????

14
?? APQP?CP???
1?????APQP????
?????????? 

• ???????????????
• ???????????????

???????? 
????????,??????????(??)? ????????,????????????(
??)? ????????,??????????????(????)?
???????????????,????? ???????
TEAM WORK ???????????
15
?? APQP?CP???
1?????APQP????

• ???????(????????????)?
• ????(????????????????????)?
• ?????(???????) ????
• ?????????
• ?????? ( ?????? )
• ??????
• ?????????(????????)
• ??????????????????
• ???????????????????
• ????????????
• ???????????

? ? ? ? ? ? ? ?
16
?? APQP?CP???
1?????APQP????

• ????????????????,???????
• ???????
• ???????,??????????????????????????
• ????
• ????????,?????
• ????(QC???)
• ???????????????,???????????
• ??? ??????,????????
• ????(??)? ???????????????
• ??? ????????????,????,????????

17
?? APQP?CP???
1?????APQP????
? ??APQP???????
????????? (1)??????,???????????,???
????,?????????????? (2)??????????,????????
(3)?????????? (4)????,???????????
(5)??????????? (6)????????
(7)?????????,????????????? (8)????????????
(9)????,????????
18
?? APQP?CP???
1?????APQP????
(?) APQP???? 7W3H?????
Why
What
When
Where
Who
Whom
Which
?? ???? ??/?? ??/?? ??/??
?? ?? ???? ?? QCD ??
?? ?? ?? ?? ?? ??
?? ?? ?? ??
?? ?? ?? ?? ??
??? ??? ?? ?? ???
??? ??? ???
How Much
How Many
How to
??/?? ??/?? ??/?? ??? ?? ????
???? ??? ??? ??? ?? ??/??
????? ????? ??? ?? ?? ??
19
?? APQP?CP???
1?????APQP????
? ???? ?? APQP ??????? (1)???????
(2)????????? (3)??????
(4)???????? (5)????????? (6)??????
(7)?????????? (8)???????
? ?
20
?? APQP?CP???
1?????APQP????
1. PLAN
4. ACT
Act on the information from completion process
Defining the Project and the Planning
2. DO
3. CHECK
(STUDY)
Successful completion
Implementation process
21
?? APQP?CP???
1?????APQP????
PDCA CYCLE
Procrastinate
Do nothing
Argue
Complain
22
?? APQP?CP???
1?????APQP????
(?) ??????
????
10 11 12 1 2 3 4 5 6 7 8 9
?.???? .???? .???? ?.????? .????
.??????? .???? .???? ?.????? .??????
.?????? ?.???? .???? .?????? ?.????
?????(?????????)
23
?? APQP?CP???
2????????TTM??Road Map

• ??????
• ????????????
• ????????
• ????????
• ??????????
• ?????

24
?? APQP?CP???
2????????TTM??Road Map
Q??? C???D?? ?? Balance
25
?? APQP?CP???
2????????TTM??Road Map

• Lack of market/customer orientation - causing
  delays and changes
• further down the development cycle
  (?????????)
• Poor quality of execution - causing wasted time
  and resources (????)
• Not enough up-front homework - causing lost
  time in rework and making changes
• 
  (??????)
• Lack of focus, too many projects being done
  simultaneously - causing delays of
• high priority projects while scarce resources
  are being applied on lower priority,
• less desirable projects. (????,??????)
• An ineffective NPD process, leading to program
  delays, increased costs and
• increased use of resources.. (????????)

26
?? APQP?CP???
2????????TTM??Road Map

• On the other hand, some of the attributes common
  to companies that have achieved fast times to
  market are
• Strong market orientation and customer focus
  (?????????)
• Up-front homework (????,????)
• Sharp product definition (???????)
• An empowered, dedicated, well represented,
  cross-functional team (??????)
• Senior management support for the team and the
  NPD process (????)
• A systematic design process (???????)
• Early prototyping and testing (??????)

27
?? APQP?CP???
2????????TTM??Road Map
???????,?????????????,???????!

• ??? Negative VOC
• ??????????
• ????????????
• ?????,?????
• ?????
• ????????????
• ??????
• ?????????
• ?????
• ??????

??? VOC
CD-ROM?CD-RW?DVD-ROM?Combo 4???,????????????????
Combo?DVD-Multi ?????????????
28
???DVD?????
????PIDA?????
29
???????CTQ?? ??Pugh??
????
???????? ?????????
??pugh?????? ????????
??????
?????????? (??)
? ? ? ? ? ? ?
??????BOM
??????? ?????
???????
?????? ??CTQ???
???????
?????????? KPIV?KPOV(???) (??)
??????????? , ????????? (??)
30
??CE?
??DOE??
?CE?????,?? KPIV?KPOV
??DOE?????? ????
? ? ? ? ? ? ? DOE
??FMEA???? KPIV???
?????? ????
??DOE??????
??????,???? ?????
?????????? ?????????
??DOE????? ?????
????30????
31
?????????? ????
??Cpk??1.5?
???????? DMAIC
?? ?????????
??????
32
?? APQP?CP???
3???????Critical To Quality

• Is tolerancing correct as per manufacturing
  capability?

• Have all CTQs been identified on the drawing?

• Is a bill of material complete and a part of the
  drawing?

• Are reference dimensions identified to reduce
  inspection?

• Are there any specifications specified that
  cannot be evaluated using
• known inspection techniques?

• Are all material characteristics identified and
  specified on the drawing?

• Are all dimensions that affect fit, function and
  durability identified
• and tolerance specified?

33
?? APQP?CP???
3???????Critical To Quality

• Is selected process feasible for manufacture? a.
  Technically b. Cost wise

• What inputs will the supplier need?

• Are needed inputs provided?

• What is supplier's feedback on achieving critical
  to quality for process?

• Is there any process capability study done on the
  process?

??

• What tolerance the supplier will be comfortably
  achieving?

• Is supplier capable of measuring Critical to
  Quality?

• Does supplier possess sufficient capacity to
  handle forecasted production?

34
?? APQP?CP???
3???????Critical To Quality

• Does flow chart illustrate sequence of production
  and inspection?

• Does flow chart identify all the KPIV and the
  KPOV of the process?

• Have provisions been made to identify and inspect
  reworked products
• before use?

• Is costing derived from the flow chart?

• Is there a separate flow chart for manufacture of
  tooling?

??

• Are drawings available for tooling?

35
?? APQP?CP???
3???????Critical To Quality

• Is control plan derived from flow chart, FMEA,
  DOE critical to quality
• requirements?

• Have all customer concerns been identified on
  control plan?

• Are all critical Xs identified?

• Is contribution of X with respect to Y
  identified?

• Is appropriate statistical control method
  identified for the critical Xs?

??

• Are material specifications requiring inspection
  identified?

• Does control plan address incoming through
  processing and assembly,
• including packing?

• Are functional testing requirements identified?

36
?????????????
1??????????
???????????(???????)
1. ?????? ??????????????,???????
2. ?????? ???????,??????????????,????
?????????????,????????
3. ?????? ???????????????,????????????
?????????,??????
4. ?????? ??????,??????????QM/QP???????
????,???????????????
QT
DVT
AT
? ?
??
37
?????????????
1??????????
QS9000 APQP ???????? ???????,??????
?????????
?? ??/??
????
???
???
???
? ?
???????
???????
????? ??
??
?? ????
????
?????
???? ?????
???? ?????
????? ??
?????? ????
38
?????????????
2????????????

• ??????????
• ?????????
• ??????????????
• ??????
• ?????/??
• ??,????
• ??????
• ??????

• ????????????
• (1)??? ???????
• (2)??????
• (3)???????

SIPOC SUPPLY, INPUT, PROCESS, OUTPUT, CUSTOMER
39
?????????????
APQP?????????

• ???????
• (1)???????
• A.?????? B.?????????
• ( ????)
  
• (2)???????
• A.??????????? B.??????
• C.????????? D.??????
• (3)??????
• A.????????
• B.???????????
• C.??????????? ?

40
?????????????
????????????

• ??????
• 1.?????
• 2.????????
• 3.???????????
• 4.??????
• 5.??????

• ???????
• 1.??/?????
• 2.????????????
• 3.??????
• 4.????????
• 5.???????????

41
?????????????
????? SIPOC

• ???????
• 1.?????????????????
• 2.??????????????????
• 3.????????????????????,???????
• 4 ??????????
• 5.??????
• 6.????????????

42
?????????????
??????
? ?
? ?
? ?
? ?
????? ?????
???
??
? ?
? ?
??
? ?
? ?
????
?? ??
?? ??
?? ??
??
??
?? ??
?? ??
??
43
??????????
1?????????
44
??????????
1?????????
??????
?????(Tacit Knowledge)? ??????????????????????
????? ?????(Explicit Knowledge)?
????????????????????????????
?????,??????????,?????????
?????????????????????,???????
???????? ??(Knowledge)???(Intelligence)???? ????
???????,?????????????????,???????????????,????????
????
45
??????????
1?????????
46
??????????
2?????
????? ?????????????????,???????????????? ?
????????????? ???????? ??????????????,?????????
????????????,??????????,???????????????,??????????
??????????????,?????????,?????????????????????
????? ?????????,??????,???????????????????????
????? ????????????????????????????,?????????????
? ????? ?????????,???????????????,????????????,?
???????????
47
Toyota ???????

• F1??????
• ?????????proposals

???? ? ????
???? ? ????
????????????,??John Koenig???????

• ????????
• ????????????????
• ??

• ??????????????
• ????

• A3???
• Design standard
• Standard work processes
• Checklist

Chief engineer?????????????,????????????????

• ?????????????,????????????????????????????
• 450???????

??????????supervision ?????????
48
1????????
49
?? ????????????????
1????????
50
?? ????????????????
1????????
????????

• ?PDCA?

51
?? ????????????????
1????????

• ?????APQP??????
• ???????
• ??????????Needs?Expectation???
• ?????????
• ????????
• ?????????????

52
?? ????????????????
1????????

• APQP??????
• ????? (Control Plan) ????????????
• ????? (PPAP) ???????????
• ?????
• ?????
• ?????

• ????
• ?????????????????
• ??????????????????
• ????????????????
• ?????,?FMEA?????????????
• ?????????????

53
?? ????????????????
1????????
?????
???????
???????
???????
????? ????
?? ?? ?? ??
?? ?? ?? ?? ??
??

• ????
• ????????
• ?????
• ?????
• ?????? /
• ???????
• ?????
• ??????

• ??FMEA
• ???????
• ??
• ????
• ????
• ????(???
• ??)
• ????
• ????
• ???????
• ???????
• ????
• ????????
• ????????
• ??????
• ???????

• ????
• ??/?????
• ???
• ???
• ???????
• ????
• ??FMEA
• ?????
• ????????
• ????????
• ????
• ??????
• ???????

• ????
• ??????
• ????????
• ??/????
• ??????
• ????
• ???????
• ??????
• ???????

• ????
• ????
• ?????

• ????
• ????
• ???????
• ??????
• ???????
• ????
• ??/????
• ??/????
• ???????
• ???????

54
?? ????????????????
1????????
55
?? ????????????????
1????????
56
?? ????????????????
57
?? ????????????????
1????????
??????????

• ??????
• ???????
• ??????????????
• ??????,????????????
• ????????????????
• ????????????
• ????????????
• ?????,?????????????
• ???????????????

• ????
• ?????????????
• ??????,?????
• ??????,?????????
• ???????????,???????

• ????
• ??????????
• ????????????
• ?????????????,????
• ????
• ???????,???????????
• ??????
• ?????
• ????(?????????)?????

• ????
• ???????????
• ?????????,?????????
• ?????
• ???????????,???????
• ??????,???????
• ???????
• ????????????????

58
?? ????????????????
APQP????????
????????,????????????,????????,???????????????????
????????,?????????????????,????????????????,?????
???????????????,?????????
?????,??????
59
?? ????????????????
PHASE 1 ???????
?????????

• ????????
• ??
• ??
• ??
• ??????
• ??
• ?????
• ????
• ?????
• ????????----
• ???
• ????
• ??
• ??

?? ??/??
????
? ?
???????
60
Links Between the Tools
????????
Phase I
Determine Customer Expectations and Plan for
Quality
DFMEA
Phase II
Identify Key Characteristics
????/??? ???????
Phase II
????????
???????
Phase III
????????????????????
?? PFMEA
Phase III
?????????????
??Control Plan
Phase III
????????????????
??WI
Phase III
?? Control Plan ??????
????(?)???
Phase IV
????????
??CI
Phase V
??????
61
Link Between the Documents
62
(No Transcript)
63
?? ????????????????
PHASE 1 ???????

• ?????????????,????????????,????????????????
• ??????????????????
• ??????????,????????????????????
• ?????????????????,???????????????????

????????
64
?? ????????????????
ISO-9001??????
?????????
?????
????? ????
??/?????
?????
?------ ??????
?????????
65
?? ????????????????
ISO-9001??????
??????? ??? ?
66
?????????IC???????????
67

• ?????
• IDE??????
• ISO 9660 / UDF ????
• DVD-RAM Drive
• DVD-R/RW/RAM Testing Software
• DVD-R/RW/RAM Application Software
• DVD-VIDEO player
• CD-R/CD-RW system
• MP3 CD player
• Multi-Beams DVD????
• SD?????
• CPRM??????
• ??????????

68
?? ????????????????
PHASE 1 ???????
PHASE 1 ????

• ??????????????????
• ????? ??
  ??????
• ??????? ??? ???
  ??? ???
• ??????
• ??????????????
• ????(???????????????????)
• ??????????????????????????
• ?????????????
• ???????????
• 1. ????(??????,???????????(??,??---?))
• 2. ????????(???????????????)
• 3. ??????(BOM)
• 4. ???????
• 5. ????????????
• 6. ????????(????,????---?)
• 8. ???????

69
?? ????????????????
PHASE 1 ???????
PHASE 1 ???????
??
??
??
???
------





????





????????





??????





???????





??????/???????





??????





??????
70
?? ????????????????
PHASE 2 ???????
PHASE 2????
?????????????????? ????? ??
??????
??????? ??? ???
??? ??? 1.?????DFMEA
2.??DFM/DFA??????????
3.?????? (Design Verification) 4.?????? 5.??????
6. ??????????,???????? 7. ???????? 8. ?????
9. ????????
10.????????????????????
11.?????????? 12.???????
13.????????? 14.????????
15.??????? 16. ????? 17.
?????
71
?? ????????????????
PHASE 3 ???????
PHASE 3 ????
?????????????????? ????? ??
??????
??????? ??? ???
??? ??? 1.
??????,????????????????? 2. ??????/??????(check
list)?? 3. ????????,????????????? 4.
???????? 5. ??????????? 6.
??PFMEA 7. ?????????(Pre-launch Control
Plan) 8. ??????? 9. ??????????
10. ???????????? 11. ??????
72
?? ????????????????
PHASE 4 ???????
PHASE 4 ????
?????????????????? ????? ??
??????
??????? ??? ???
??? ??? 1.???? 2.
?????????? 3. ???????????? 4. ??PPAP 5.
????????????? 6. ?????????? 7. ???????? 8.
?????? 9. ??????
73
?? ????????????????
PHASE 5?????????
PHASE 5 ????
?????????????????? ????? ??
??????
??????? ??? ???
??? ??? 1.????????????(RATP)
2. ??????,???????????????????? 3. ????????
74
??????? PHASE 1 ???????

• ???????? ?????????????????????
• ??,???????,????????????
• ?????????????,??????????????????
• ?????????????????

???? ??
?????? ?????
??????? ??---??
????(product brief)???????????? idea ????
????????????????????????
75
??????? PHASE 1 ???????

• ?????
• ???????????????
• ??????????/??????????
• ?????????????
• ?????????,?????????????????

?? ????
76
??????? PHASE 1 ???????
2.1. ?????????? ???Designer???????????????,
????????
RD?? ??????
???????????????
77
?? ????????????????
??????
VOC COM VOE VOC
78
?? ????????????????
?????????
??????
D
????
B
? ? ?
? ? ? ?
? ? ? ? ?
? ? ? ? ? ?
????? ????? ?????
? ? ? ?
F
A
C
??????
E
????
79
?? ????????????????
??????????

• A????????,????????????????????????,
• ???????????????????
• B????????????????,????????????
• C??????????????????????,??????????
• ???,???????????? 9 ?,?????? 3 ?,????
• ???? 1 ?,???????????
• D???????,??????????????????????
• E???????,???C?????????????????? F??
• ?????????????????????????????????
• ???????
• F????????????,????????????????????
• ???

80
? ??????
????????/???????? ????? 5 / 3 1.67
?????? 3 1.67 1.5 7.5 ??? ????? ????
???????????????????????????,??????,???????????????
????
81
?? ????????????????
??????
???10????

• ???
• ??????
• ???????
• ???????
• ?????

82
????
????

• ?????????????

???? ????
????? ?????
?????
?? ????
????

? KJ ???????
???????
????????
????

• ??????
• ????
• ????????

• ???????
• ????????
• ???????

83
????
????????

• ?????
• ???
• ??
• ????????????
• ????
• ???

?KJ ???????
????
????
??

• ????
• ??
• ??
• ??

• ????
• ????
• ????

84
QFD??????
85
??????????
???? ????
????
? ? ? ? ? ?
? ? ? ? ? ?
????
? ? ? ? ? ?
? ? ? ?
????
??????
? ? ? ? ? ?
? ? ? ?
??????
????
????
??????
???? ????
????
???? ????
???? ????
86
?? ????????????????
FMEA ?????
1.??????????????, ??? / ??????
?,?????????,????????????? ??????? 2.??? /
??????????,?????????? ??????????,???????????,
?? ????? 3.??????????,?????????????
87
?? ????????????????
FMEA ?????
?????????????????,?????????????????????,????????,?
????????????????????
FMEA ??
1.??????(failure mode analysis)
? FM

• ??????,??????????,?????????
• ?????????????

2.??????(failure effect analysis)
? EA

• ????????,???????????????????
• ???,????????????,??????????

3.?????(critical analysis)
? CA

• ????????,?????????????????
• ???,????????????????????

88
?? ????????????????
QS 9000 ??/?? FMEA ?
??
??/??
??
??
????
????
???
???
89
APQP Links to PFMEA
90
?? ????????????????
???

• ???????????
• ??????????????????
• ?????????????????
• ???????????????
• ????????????
• ????????????
• ???????????????????,????????????
• ?????????????????? , ??????????????
• ??????????????????????
• ???????????????????????????
• ?????????????????
• ??????????????????
• ????
• ????(??????)

• ???????
• ???

91
?? ????????????????
?????? ????? ?????
?????
1. ????? ?????????,?????????,??????,
??????????
? ????
????
????
????
????
?????? ?????
??????? ??????? ????
15?
?????????? ???????? ?????
92
?? ????????????????
?????? ( bath-tub curve )
??? ??????????????????? ???
????????,???????,??????? ??? ??????????????
??????? ???????
93
?? ????????????????
?????
?????
??????
? ? ? ? ?
???
??C
?? A
?? B
?????????
94
?? ????????????????
?????
1. ????? a b c
d e f
g
?????
??????
???
???
??A
??B
??C
RS Ra Rb Rc Rd Re Rf Rg
f
2. ????? a b
c d e
??B
?????
??????
???
???
??A
g
??C
RS Ra RbRcRd 1-(1- Re)(1- Rf)(1- Rg)
??????????
95
(No Transcript)
96
?? ????????????????
????????
(?)????????? ???????(?????????????)?????? ????????
????????( ???? Time to failure ti
) ???????????????,????????? (Mean time to
failure)???????(Mean time between
failure)?????? ??n ??????t0??????,??????????
????ti ,???n??????ti????n ,?? ??????(T/n) ????????
???,????(??)???????? ??,????????????????????
97
?? ????????????????
????????
(?)??????????? ??????????? m ???????????????,?????
???? Maximum likelihood estimate ???100????????
???,?????,??5 ???????95????,?100???????? ????
T t1t2t3t4t595t5 ?
mT/5 ???5?????????? ??n???????????,?tr?????,?r?
??,(n-r)??????,? m T/r t1t2t3t4
tr (n-r)tr/r
98
?? ????????????????
??????
1. ???DR?? ? ?????????78?????? ?
??FMEA 2. ??????? ? ??QC?Redundancy??
3. ?????Margin ? ?????? 1.5 ?
?????? 2 ? ??? ? ?????? 1.25 ?
?????? 3 ? ??? ? ???? ???? ? 10?
NASA ???
99
?? ????????????????
????8D??

• ??????????????(???????)?
• ??????????
• ??????8D????????
• ?????????????????????

????
??????
????
????????????
???????
???????
???????
?????
????????
??????
?????????
?????
??????
100
Quality Problems
yes
no
no
no
yes
yes
no
yes
101
When to use 8-D

• When the cause is unknown
• When you need to get input from several parties
• When customers dictate use

Note We use voting techniques, X to Y variable
testing, and IS/IS Not to determine the root
cause. However, you still may not know what the
root cause is?
102
QS-9000 Semi-Conductor Supplement

• Conduct containment in 24 hours, electrical
  verification in 48 hours and root cause and
  corrective identification in ten days
• Complete returned product analysis
• Analyze the product in a qualified laboratory
• Make sure the corrective actions are effective
• Use the knowledge gained in similar processes and
  products

103
?? ????????????????
????8D??
?????????
??????????/??????
??????????
????
????/?????????
????????????
?????????????
?????????
????????
??????
????????
????????
?????????????
????????????? ???????
??????
104
When to use Designed Experiments or Regression

• After using 8-D, the cause is still unknown
• Designed experiments between cause and effect
  voted by team could identify the vital few root
  causes
• Semi-conductor companies collect product and
  process information that could be used to
  identify root cause using regression

105
Update the PFMEA Control Plans
After the 8-D is completed, the PMEA and the
control plan should be revised and updated as
applicable
106
PFMEAs/Control Plans and 8-Ds During APQP

• PFMEAs should be driven by real data, including
  8-Ds (internal and external), warranty and
  returned pat analysis
• PFMEAs should be completed by process experts and
  should be a driver of the control plans and work
  instructions
• Work instructions (Post control log, process
  parameter logs, preventive maintenance, etc.)
  implement the control plan in the process
• When there is a quality problem there is an
  opportunity to improve the control plan and the
  work instructions

107
??????

• ???????,???????????????????
• ?????????????????????
• ????????????????????SOP???????
• ????????????,????????????
• ?????phase?????????????????,????????????????,?????
  ????????????????????update????
• ?????????????,????????????
• ???
• system/design/process failure mode and effects
  analysis
• ??????
• ????????????????
• ????,QFD?DOE?

108
????????

• ???????
• ?????
• ????????????????????????
• ????????,????????????????????
• ???????
• ?????????????????????,??????????????????
• ?????
• ????????,???????????/??,????,???????????????????

109
APQP Links to Control Plan
110
?????????
111
?????????

• ??????????
• (1) ????
• (2) ????????????
• (3) ???????????????
• (4) ?????/????????
• (5) ????????????????????
• (6) ???????????
• (7) ???????????????
• (8) ??????????????????
• (9) ??????????????
• (10)???????????
• (11)???????????
• (12) ????????????????
• (13) ??????????????????

112
?????????

• ??????????
• (14) ???????????
• (15) ?????????
• (16) ???????????????????????
• (17) ??????????????????
• (18) ????,???????????????????
• (19) ???????????,?????????????????
• (20) ???????????????
• (21) ?????????????,???????????????
• ??????????
• (22) ??????????????????????????
• (23) ??????????
• (24) ???????
• (25) ???????????????(SPC??????????)
• (26) ???????????????????????

113
?????? FMEA ?QFD?QC???
??QFD??
????????
?DFMEA?RPN??????
?PFMEA?RPN??????
??control plan, WI, SOP??
114
?? ???????????????

• ??
• ?????????????????????????,???????,??????????,?????
  ????????????????????????? - ????(?????????????????
  ??),??????????????????????????????????????????????
  ????????????(Production Part Approval
  Process)?????????????????????????????????????????
  ?????????,???????????

?? ??????????????????????,???????? ???????????????
?
?? ???????????????????????????????? ?????(????????
??????)??????
115
?? ?????????????????
1. ?????? ?????? ?????????????????? ???????? ?????
???????? ?????????????? 2. ??????? 3. ???? 4.
???? 5. ?????????? 6. ??????
116
(No Transcript)
117
(No Transcript)
118
(No Transcript)
119
???????
?????????
??????
???????

• ???????
• ???????
• ??????
• ??????

?????? ?? ???? ??????
?????? ???????? ??/???????? ????????/????????? ???
? ????????? ??CC/SC LIST ??????(Ppk) QC??? ?????
??
??
???? ???? ?????? (???????8D??) KD?????????,??

• ?? CC / SC LIST
• ??????????(Ppk)
• ????