IEI Integration Corporation · TWSE:3022
IEI Integration — Computex 2007
40 slides from IEI Integration's conference presentation, Jun 2, 2007
Slide 1: Welcome
http://www.ieiworld.com Welcome June 2007
Slide 2: TEAM (Together Everybody Achieve More)
http://www.ieiworld.com TEAM (Together Everybody Achieve More) June 2007
Slide 3: Quality, Speed, Cost
http://www.ieiworld.com Quality Speed Cost June 2007
Slide 4: Do it Right the First Time: One-Piece Flow Lean Management
Do it Right the First Time One-Piece Flow Lean Management Jordan Jiang, Ph.D., CPIM General Manager, ICP June 2, 2007
Slide 5: Quality, Speed, and Cost
Quality, Speed, and Cost Do It Right the First Time (TQM – Total Quality Management) One-Piece Flow Lean Management (TPS – Toyota Production System)
Slide 6: To Do Things Right The First Time!
To Do Things Right The First Time! R&D, Engineering Production Field installation/ Operation 9 Deferral of critical issues supposed to be identified in house 9 When problems occur, unidentified errors coming from preceding stages will only make things worse 9 Extra efforts/ Costs of rectification on
Slide 7: Key Component Engineering
Key Component Engineering What does this mean to What we used to have New implementation customers RoHS XRF Spectrometer - DeskRoHs Compliance Top and Portable LCD Panel Characteristic Stable LCD Panel Quality Measurement PCB Impedance Measurement Stable Quality Power Management Stable Quality
Slide 8: RoHS Inspection – XRF Spectrometer
RoHS Inspection – XRF Spectrometer
Slide 9: Key Components Measurement - Panel
Key Components Measurement - Panel Brightness, View Angle, Uniformity, Response time, etc.
Slide 10: PCB Impedance Measurement
| PCB Impedance Measurement Fie [di View Sekp Ullties Agplcations Hely [6005 Waveloma Tedarvnis | XI &\2| 7 vlni’ PurvStos | doa Mode [v0 eS | | , A esha Li eabecokaP in| * Impedance Control > PCB quality control VEM>___.uf eee
Slide 11: Power measurement
www.icpems.com Power measurement One-Piece Flow Lean Management e Do It Right The First Time!
Slide 12: Design Stage – A Test
Design Stage – A Test What does this mean to What we used to have New implementation customers Assembly Thermal Simulation Robust Design and Time to (PCBA & System) Market Adding Test Pins/Pads on the Robust Design and Time to Board for Signal Integrity Market Measurement Outsource CNC, RP Mockup In
Slide 13: Thermal Analysis
Thermal Analysis • Thermal Analysis Æ To find out the critical parts
Slide 14: Thermal Simulation
Thermal Simulation Beet te Temperature (deg 0) 10.404 74323 sacl 62.882 34rt4 Baa WY <40 * Thermal Simulation > make a considered design immediately UEMS ___.uf eee
Slide 15: Thermal Measurement w/o Air Flow
Thermal Measurement w/o Air Flow
Slide 16: Signal Integrity Measurement
Signal Integrity Measurement
Slide 17: Improvement on Mechanical Capabilities
Improvement on Mechanical Capabilities
Slide 18: Dummy board for Examination
www.icpems.com ; Dummy board for Examination * To make a dummy board before gerber out > To examine the layout easier UVEMS__.uf One-Piece Flow Lean Management e Do It Right The First Time!
Slide 19: Verification Stage – B Test
Verification Stage – B Test What does this mean to What we used to have New implementation customers B Test B/C Test Plan Review and Compatibility and Reliability Implementation Verification Unclear Content, Confused User Project Management Kickoff User Manual Quality Meeting for User Manual, Diffic
Slide 20: Design Verification Lab
Design Verification Lab In-House Lab for Pre-Certification In-house lab for Agency Certification pre-testing: FCC, CE, CCC, VCCI, BSMI, UL (hosedown), TUV, CB, RF EMI (for wireless) Reduce customers’ engineering burden Lower total cost of ownership/ investments Shorten product development cy
Slide 21: ESD / EMI / EMC
www.icpems.com | ESD / EMI / EMC One-Piece Flow Lean Management e Do It Right The First Time!
Slide 22: Qualification Stage – C Test
Qualification Stage – C Test What does this mean to What we used to have New implementation customers R&D cooperate in SOP DFM – Design for Manufacturability Few sampling quantity Adding PPQV (Pre-Production Extend the quality verification Quality Verification) test prior to Mass Production
Slide 23: PPQV (Pre-Production Quality Verification)
PPQV (Pre-Production Quality Verification)
Slide 24: Mass Production Stage – D Test
Mass Production Stage – D Test What does this mean to What we used to have New implementation customers Implement ICT Quality Product Weekly Quality Meeting Real time Feedback System on Process Improvement defective products Batch Production Continuous Flow 1. Improves flexibility Manufacturing – On
Slide 25: ICT
ICT TR-518FR— Intel” Socket Test Technology * ICT > Digs out the defects early U ait eee
Slide 26: OQC High/Low Temperature Sampling Test
OQC High/Low Temperature Sampling Test
Slide 27: One-Piece Flow Lean Management
One-Piece Flow Lean Management Before – Batch Production SMT DIP&T/U Test After – One-Piece Flow SMT DIP & T/U Test
Slide 28: Old Layout
Old Layout: SMT DIP Testing Area
Slide 29: New Layout
New Layout: To Logistic OQC Inspection completed B SMTBOT Production O 目檢站 T Appearance AOI 送板機 REFLOW YV88 YV100 YV100 YV100 SPIPRITER OQC TEST DIP 翻 inspection 轉向機 面 Conveyer 放 入 Soltec 送板機 PRITER SPI YV100 YV100 YV100 YV88 REFLOW AOI AppearanceConveyer DIP 6D22C inspection SMT TOP Production
Slide 30: One Piece Flow Layout (13F)
One Piece Flow Layout TP Production Site 13F: 線修區 切 Maintenance area 小錫爐區 S LINE on assembling 片 目檢站 產出 投入 測試流線 修補流線 檢 X- RAY Appearance AOI REFLOW YV88 YV100 YV100 YV100 SPI PRITER 送板機 INPUT OUT Testing workflow Repairing workflow inspection 輸 驗 PUT X-RF 送 前置作業區 室 轉板機 ONE PIECES FLOW 專線 機 Conv 目檢站
Slide 31: One Piece Flow Layout (3F)
One Piece Flow Layout TP Production Site 3F: 廠長室 Power Module SMT架料區 組裝線 Test Area Factory Burn In Burn In Director＇s Assembly Line 會議室 Office SMT Material Loading Room 1 Room 2 Meeting Area Room 投入 Input 輸送機 貨梯 VI AOI REFLOW YV88 YV100 YV100 YV100 SPI Printer Loader 產出 測試流線 修補流線 貨梯 Testing workflow
Slide 32: Quality Feedback and Improvement Process
Quality Feedback and Improvement Process Before: Daily / Weekly SMT Queue DIP&T/U Queue Test Problem solving After: Real Time Management Problem Record problem solving Line suspension results, resume production Confirmation Solving 3 defects in a DIP&T/U MES SMT Test row Database
Slide 33: MES Management System
MES Management System Input Output MES MES MES MES MES PASS PASS PASS TO T1 T2 PCBA Voltage BEAR Function Windows Assembly Measure Test Card test NG NG NG REPAIR REPAIR REPAIR CENTER CENTER CENTER MES MES MES
Slide 34: MES Traceability Path
MES Traceability Path Product S/N Production Quality Components Shipping History Data Part No / IQC/LQC/OQC Production Line Shipment No Revision /BIOS Ver. Data Shipment Date Process RoHS Validation Defects Stat. And Warranty Work Order / S/N or Date code Reason Analysis Original Order # Revision Ti
Slide 35: Real Time Management
Real Time Management • Brief real-time quality status to all employees • Managers to understand yield rate of each station and take care of any abnormal conditions right away • Auto suspension of production lines to prevent from producing more defective items
Slide 36: Real Time feedback System on Defective Products
Real Time feedback System on Defective Products
Slide 37: How does MES manage One-Piece Flow control?
How does MES manage One-Piece Flow control? SPC SPC Software Software Deviation Deviation Detect Detect System System Detect Deviation Shutdown Shutdown Event Event Deviation Deviation MES MES Equipment Equipment Database Database Leader to Cancel E-mail Page LED Board
Slide 38: Kaizen Case
www.icpems.com GN Kaizen Case: = TEST Stee ie aT Before After One-Piece Flow Lean Management e Do It Right The First Time!
Slide 39: Kaizen Case
www.icpems.com Kaizen Case: Testing Screen (w/RGB > DVI and Audio output) MES Screen eee connection Testing Panel (MES & 10/100 (Different tooling & Giga net for different products) | ATX PSU Keyboard / Mouse One-Piece Flow Lean Management e Do It Right The First Time!
Slide 40: Add Value to the Product Continuously
$ Value $ $ $ $ $ $ $ $ Finished Goods $ Add Value to the Product Continuously Through the Product Development and Mfg. Process Copyright C Shingijutsu Co., Ltd.