NPI工程师培训资料

1、 Foxconn Confidential整理课件 Foxconn Confidential整理课件 工作職掌介紹工作職掌介紹 新產品導入流程新產品導入流程 新產品量試流程圖新產品量試流程圖 大大 綱綱 Foxconn Confidential整理课件工工 作作 職職 掌掌 介介 紹紹NPI工作職責分為以下幾點: 1.負責新產品導入進程的掌控以及物料準備狀況的跟催. 2.Readiness check list的製作及維護. 3.L6L10測試程式及治具版本的管控. 4.量試生產及人力排配,相關單位的組織協調. 5.Compass網站管理,各部門準備狀況跟催. 6.整理每次量試的DPHU/is

2、sue list. Foxconn Confidential整理课件工工 作作 職職 掌掌 介介 紹紹並與客戶溝通. 7.追蹤每次量試的不良改善情況. 8.量試作業的檢討及不良改善追蹤. 9.量試費用統計及檢討. 10.專案負責人需掌控所有文件的版次包括SMT及TSE程式,并記錄制作產品履歷. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points1治具費用評估NPI根據PM提供之產品相關信息,由前後段ME比照現有機種進行治具預估報價單,NPI確認匯總.1Estimate Fixture C

3、ostNPIME has to do the quotat-ion referring to new pro-ject data and existing project.2新產品信息發布/新產品信息發布會NPI1.確定仁義時間,地點,出席人員.2.準備相關2New product informationIssue/New product intro-duce meetingNPI1.Meeting time,address &Attendee notice2.Datas prepare by PPT,Including detailed project information &am

4、p;build Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points3工程可行性評估NPI密切聯系制造和制工1.特別是新技朮新制程的可行性評估,研究和准備工作3Engineering feasibility evaluationNPIKeep the contact close with manufa- cture and manufac- ture engineer .1.The evaluation and preparation of new technology and proce

5、ss4工程資料獲得与移轉相關部門 工程資料括BOM,Overlay,Board file,Schematic,MPS,Cosmetic Inspection Criterion,Stencil Job Number,Fixture shipping tracking Number,Test Program release date.NPI量試說明會發布1.所有资料可以由Compass或MCMs網站下载或由客户的Email得到2.确認所有资料是否到位或有更新3.若有更新告知相关部门4Engineering documents acquire, including BOM,Overlay,Boar

6、d file,Schematic,MPS,Cosmetic Inspection Criterion,Stencil Job Number,Fixture shipping tracking Number,Test Program, and forward to related departmentNPIBuild preparation meeting1. Download all files from Compass/MCMS or by email2. To verify if all files are completed or updated3. Forward to all dep

7、artment if any update Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points5BOM 的区别PE1.PE在獲取BOM后與上一次量試BOM或相近BOM進行比對,找出不同點5BOM DifferencePE1.PE to show new BOM difference by comparing to previous one6BOM 的确认NPI1.NPI通過Moto 提供的信息對difference進行確認或將其傳給Moto確認6BOM ConfirmNPI1.NPI o

8、r Motorola confirm the difference base on Motorola provided information.7Missing ASL ListPE1.PE在獲取BOM后比照現有ASL將無Supplier Info的物料整理成Missing ASL List7Missing ASL ListPE1.If BOM available, PE make missing ASL list 8獲取 ASLMC1.MC/Neil將Missing ASL List 傳于Moto要求其提供8Acquire ASL MC1. MC/Neil forward the Missi

9、ng ASL list to Motorola and ask Morotola to provide the ASL. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points9原始BOM轉換發行PE1.PE由NPI處獲取原始BOM2.由PE申請新料Moto P/N對應之H.H P/N3.要求SCM對新料詢價,然后在SAP中建立物料主檔4.發行H.H BOM并將電子檔傳給各相關部門9The transform and issue of H.H BOMPE1.PE get the Moto B

10、OM from NPI.2.PE apply for new material H.H P/N3. Ask SCM to quote for new parts and setup materials datas in SAP. 4. H.H BOM issue and send E-BOM to all department10關務BOM製作PE10Custom BOM issuePE Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points11維護GTLMC1.Release PR 給采購

11、,并跟進PO及物料到廠狀況2.Daily update GTL11GTL updateMC1. Release PR to buyer, tracing PO and materials status2. Daily GTL update12Missing Spec ListCE1.根據BOM所列物料除去已有Spec物料在查找MCMs網站后確認沒有Spec的物料明細,傳于對應專案負責人12Missing Spec ListCE1. Make missing spec list and send to NPI leader13獲取物料Spec.NPI1.將Missing Spec List 傳給

12、Moto PM,要求其提供并跟進13Get material SpecNPI1. Ask Moto PM to supply materials spec per Missing sepc list Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points14整理Readiness Check listNPI1.将信息分類并將其进展状态列于Check list中2.依據Moto MEM要求Readiness Check List必須在量試一周前傳于Moto,實際要求從專案建立后每周都要將其發于

13、客戶進行及时沟通 14Readiness Check list udpateNPI1. Update Check list by project status2. Moto MEM requires to send Readiness check list to Moto one week before the build, in fact, we must send it for communication every week15FE SOP,Overlay,Board file,Schematic 發行FE-ME1.文件须發行或傳達到相關部門1.根據BOM對Overlay和Board f

14、ile進行確認并反饋NPI2.發行FE SOP,Schematics,Overlay15Issue of FE SOP,Overlay ,Board file,SchematicFE-ME1.Documents issue or forward to related department1. To verify Overlay & Boradfiles by BOM and feedback to NPI2. Issue FE SOP, Schematics & Overlay Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction i

15、temDRI unitRemarkCheck points16依據Board File 設計Nestplate ,H-tower,周轉箱(包裝規范)或托盤等SMT用具FE-ME1.在主板外形與現有主板差異太大無法共用時才需另行設計托盤2.在主板需裸板出貨時才需設計周轉外箱和發行包裝規范16Th design of SMT tools like Nestplate, H-tower, transfer box, POP&tray by Board filesFE-ME1. Design unique tray if couldnt share with others2. Make tra

16、nsfer carton & PCBA POP if PCBA shipment is needed17周轉箱設計圖樣確認NPI1.將周轉箱設計圖樣傳給Moto確認17Approval of transfer box drawingNPI1. Send drawing of transfer carton for Moto approval18依Stencil Job Number 向鋼板供應商請購FE-ME1.Check Nestplate与PCB相符18Order Stencils per Stencil job numberFE-ME1. Check the coherence

17、between Nestplate and PCB Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points19依據 設計圖紙請購SMT用具FE-ME19SMT tools purchasing by design drawingFE-ME20NestplateStencil到厂檢驗FE-ME1.NPI確保量試PCB到廠后告知FEME2.FEME協調SMT在Printer上用PCB實地驗証Stencil并反饋NPI20Check Nesplate&Stencils after arri

18、valFE-ME1. NPI to need to notice FE-ME after PCB arrival.2. FEME cooperate with SM to verify Stencils and feeback to NPI21BE SOP,流程卡,包裝規范發行BE-MEFixture list21Issue BE SOP, Flow chart&POPBE-MEFixture list22設計專用出貨紙箱BE-ME1.如產品不能共用現有紙箱則需設計22Design unique shipping cartonBE-ME1.To design Carton if can

19、t share with others Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points23出貨紙箱設計圖樣確認NPI1.將出貨紙箱設計圖樣傳給Moto確認23Drawing Approval of shipping cartonNPI1. Send Carton drawing to Moto for confirmaion24將包裝規范建進SAP系統中PE24Included POP into SAPPE25打印主板条码和整机条码IT25Print out kit number l

20、abel and tanapa labelIT26確認labelNPI將label拍照傳給Moto PM確認26Label approvalNPI1. Send label to Moto PM for confirming Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points27測試治具移轉(開發),包含Popple Pressing Fixture TEE1.一般所有的測試維修治軍具和部分SMT治具均由TEE負責移轉或開發27Transfer and develop of Testin

21、g fixture, inclduing Popple pressing fixture TEE1. All testing/analysis fixtures & SMT fixtures transfer and develop are charged by TEE 28治具發包給供應商制作并跟蹤到廠狀況TEE28Follow up with supplier regarding all fixtures statusTEE29專用機台移轉TEE1.如需使用專用機台則需移轉機台29Special equipment transferTEE1. To transfer if spec

22、ial equipment is needed. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points30治具維護及量產准備TEEPhoto build ,量試轉量產會議 review issue1.fixtures list30Maintenance of fixtures and preparation for mass productionTEEproto build transfer to mass production meeting reiview issue1.fixture

23、s list31物料到廠MC/NPI 倉31Materials arrivalMC/NPI warehouse32物料到廠后送IQC檢NPI 倉1.PE issue SWR 2. DQE issue inspection spec32Sent for IQC inspection after arrivalNPI housing1.PE issue SWR 3. DQE issue inspection spec33如有物料異常像無檢驗規范由CE 發行SWRCE33If any materials issue like missing SIP, CE has to issue SWR CE F

24、oxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points34制作Debug FileTest Profile ,用Golden Sample跑整個測試流程(BPCQA)TSETSE issue test iterm and spec to Analysis &TEE1.前提是機台治具ready2.收到Moto test profile 后制作Debug file并傳于客戶確認34Go through the whole test process with Golden Sample an

25、d make Debug FileTSETSE issue test iterm and spec to Analysis &TEE1.Confirm the test equipment and fixture is ready.2.Make the Debug File when Motorola test profile is available and sent it to Motorola for confirmation35制作上料表,Printer,SIEMENS,YAMAHA,Reflow Program.SMT按最新BOM/1st board reserve for

26、reflow profile/PE provide more board for test35Making Loading materialsheet, Printer, SIEMENS, YAMAHA, Reflow Program.SMTAccoring to latest BOM/1st board reserve for reflow profile/PE provide more board for testing. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points36開量試

27、執行單NPI36Issue proto build excutive sheetNPI37如客戶有特殊需求或release MEM則需發行相應SWRNPI1.从客户得到MEM2.交于工程支援組簽發37SWR(Special working request)NPI1.Get the MEM from customer side.2.Submit to Engineer Assistant team for signature. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points38召開量試

28、准備會NPI1.确定量试会议的时间,地点,参加人员,用Email提前半个工作日通知2.告知量试投入数量,生产线和注意事項3.會議紀錄及決議事項4.各部門反饋准備的情況和存在的問題38Holding Proto build preparation meeting NPI1.Confirm the time,address and attendees and notity related department at least half day before it.2.Hightlight the input qty,production line and the important thing

29、need to be noted.3.Meeting minitues and the agreement which has been reached.4.Each department feedback the issues.39開工單PE39Prepare the production order.PE40MC提供轉料明細表給NPI倉MC40MC provide detailed transfer material sheet to NPI warehouseMC Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitR

30、emarkCheck points41NPI倉由大倉轉料并開始前段物料備料NPI 倉緊缺料清單給SMT,A/R1.及時反饋少料明細給MC,NPI2.确认所缺物料何时入库41NPI warehouse transfer the materials from MP warehouse and start the FE material preparation.NPI warehouseProvide the risk material list to SMT and A/R1.Feedback the shorting material list to MC and NPI on time.2.C

31、onfirm when the short material can be put into stock.42FE物料出倉前品質確認DQE1.check 料盤Moto,H.H 和supplier P/N是否與BOM一致42SMT-IPQC/DQE check the quality of the material before they are loaded on line.DQE1.Check whether the P/N of H.H,Motorola and supplier is consistent or not.43SMT 確認量試線SMT1.要求SMT要核對領料數量43SMT

32、confirm the line# for proto buildSMT1.Request SMT to check the qty the materila that they get. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points44SMT從NPI倉領料SMT1.要求SMT要核對領料數量44SMT get the Material from NPI warehouseSMT1.Request SMT to check the qty the materila that they

33、 get.45SMT-IPQC/DQE對物料進行上線前確認DQE/FE IPQCASL極性發現共同解決1.物料上线时DQE,品管要在现场2.确认物料是否有极性,方向是否一致3.物料供应商,料号是否一致45SMT-IPQC/DQE check the quality of the material before they are loaded on line.DQE/FE IPQCCowork together to resolve the ASL and polarity issues.1.DQE and QC must be support on site when loading mate

34、rial.2.Confirm whether the material with polarity,if yes,need to check the polarity is correct or not.3.Check the supplier P/N is correct or not.46制作膠紙板SMT投入規範由FE-ME /SMT生技共同決定1.投入PCB板2PCS,檢查的程式是否准确46Make the tape panelSMTInput regulation depends on FE-ME/SMTs decision.1.Input 2 panel PCB and verify

35、 the programe is correct or not. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points47做LCR測試DQE訂時間5小時預約超時出報告1.將做好的膠紙板交前段工標47Do LCR testingDQELimit the time to be 5H,DQE need to make report if the time is over the limitation.1.Submit the finished tape panel to FE-DQE.48投初件

36、過回焊爐BP,BT,組成整機測RV,AC,F.F,CQAME/TSE 1.DQE做完LCR測試确認無問題后開始投初件2.在初件投入的過程中每個工站要按SOP 操作3.初件在過完BP,B測試后交后段制工組裝成整机做,測試4.做完RV,AC的整機送CQA檢測 Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points48Input the first panel and gothrough the post reflow.Test BP and BT.And then assemble the fu

37、nctional boards into radios for RV,AC,F.F and CQA verification.ME/TSE 1.Input the first panel if the LCR rest result which provided by DQE is OK.2.Each station need follow the SOP during the whole process for the first panel.3.Once the first panel passed BP,BT,submit the boards to BE-ME and do the R

38、V and AC testing.4.The radios which passed AC should sent to CQA for testing.49初件CQA pass後, SMT再投入5panelSMT49Input other 5 panels once the first panel is confirmed functional.SMT Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points505panel BP,BT pass 后成批投產SMT1.在DPHU不超過 8的情

39、況下成批投產否則由FEME決定2.在DPHU過高的情況下,NPI与生技,FEME.ARE共同商討,找出原因50input with batch once the first 5 panel passed BP,BT.SMT1.Continue the Build under the condition that the DPHU is lower than 8. Or else,FE-ME make the decision.2.If the DPHU is too high,NPI,PT,FE-ME and ARE should meet together and find the root

40、 cause before the build continue.51获得不良的板并提供分析报告ARE51Get the failure boards and provide the analysis resultARE Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points52BP,BT test pass 后,如需點膠則送點膠線然后送SMT 終檢SMT1.SMT送板要快,盡量不要積壓2.SMT及時反饋BP,BT測試結果52Do underfill first if the boards

41、which passed BP and BT need underfill.Or else sent the boards to SMT for final inspec-tion.SMT1.SMT must sent the boards immediately and the boards piled up is forbidded.2.SMT feedback the test result of BP,BT.53終檢后送FQC貼合格單SMT1.160 pcs as 1 batch 2.DQE keep a golden sample 3.batch(160pcs) inspection

42、1.DQE確認一檢驗樣品2.FQC依樣品和Overlay檢測3.FQC有疑問之處与DQE商討53Send the board to FQC for inspection and place the accept label once the final inspection finished.SMT1.160 pcs as 1 batch 2.DQE keep a golden sample 3.batch(161pcs) inspection1.DQE confirm a sample for inspection.2.FQC inspect according to sample and

43、overlay.3.FQC check wih DQE when encounter the issues. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points54良品板入NPI 倉SMT/NPI 倉/NPI54Put the good boards into NPI warehouseSMT/NPI Warehouse/NPI55不良品板由制工判斷如為外觀不良由SMT線內維修如為功能不良則移交ARE分析維修FE-ME55ME justify the defect boards.SMT

44、repair the Cosmetic defect boards on line and Non-functional boards will be sent to ARE team.FE-ME56外觀不良品板維修后功能測試Pass后按正常流程送檢SMT56The repaired cosmetic boards follw the normal process.SMT57功能不良品板則按ARE送檢流程走ARE57Non-functional boards follow the ARE process.ARE Foxconn Confidential整理课件新產品導入流程新產品導入流程Ite

45、mAction itemDRI unitRemarkCheck points58入庫單制作簽核NPI不良品板可分批入NPI 倉58Make and signate GR for product orderNPINon-functional boards can be put into warehouse seperately.59生產記錄報表SMT59Production record sheetSMT60前段生产报告FE-ME60FE Build ReportFE-ME61FE Build 功能不良PCBA分析報告ARE61FE build non-functional boards ana

46、lysis report.ARE Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points62前段DPHU报告和问题汇总FE-MEBryan 一個工作日1.FE DPHU Report& Issue List在前段量試結束8h 內由FE-ME提供2.DPHU Report & Issue List按指定標准格式制作62FE DPHU Report&Is-ssue ListFE-MEBryan one workday1.FE DPHU Report& Issue

47、List should be submitted within 8HR after the build completed.2.DPHU Report & Issue List should follow the standard format.63退料單NPI1.不良品入庫時要有標識与良品區分放置63Return material listNPI1.Marked the defect boards when put them in stock and quantine them from the good boards.64SMT剩余物料退NPI倉SMT/NPI倉入庫即刻盤點64Re

48、turn the rest material back bo NPI warehouse.SMT/NPI WarehouseClean the bill once the material are put into warehouse. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points65物料損耗明細表制作NPI1.重點highlight 損耗大于10%的異常情況2.SMT提供物料拋料原因65Make detailed loss material list NPI1.Emphassis

49、 the over 10% material loss issue.2.SMT provide the rootcause of the loss.66前段品質檢討會DQE1.DQE反饋生產中存在的品質問題66FE quality review meetingDQE1.DQE feedback the quality issue.67后段量試准備會NPI1.專案負責人提供BE量試投入數量2.量試注意事項及前次量試經驗3.BE各部門反饋准備狀況67BE readiness meetingNPI1.NPI leader provide the start Qty of BE.2.Highlight

50、 anything need to pay more attention to and summary the experience of previous build.3.All function departmentfeedback the readiness status. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points68后段物料備料NPI 倉緊缺料清單給Assy,BEME1.及時反饋少料明細給MC,NPI2.确认所缺物料何时入库68BE material preparati

51、onNPI stockprovide critical material list to ASSY,BEME.1.Feedback material shortage list to MC,NPI.2.Check when the short material will be ready.69后段物料出倉前品質確認DQE1. DQE提前半個工作日確認 1.check 料盤Moto,H.H 和supplier P/N是否與BOM一致69Check material quality before BE material be pulled out from NPI stock.DQEDQE nee

52、d to check half a working day before use the material.Check if the P/N of thematerial is according to BOM. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points70DQE參與LV Sub-assy檢驗過程DQE為避免發生LV與LX檢驗標准有偏差以及防止不良品流入LX1.在LX DQE在LV DQE貼合格單前要提出期望之檢驗標准70DQE join the inspection proc

53、edure of LV sub-assy.DQEAvoid the deviation between LV and LX inspection criteria, reject NG subassy.LX DQE provide the inspection criteria71LV 量試物料狀況NPI版次變更 入庫提前三個工作日1.确認LV前后蓋版次無誤,告知后段量試日期71LV subassy material statusNPIIf the revision is changed,put into stock three days early.Check LV material rev

54、ision status,inform BE build date. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points72安排線別進行生產/組裝物流領料Assy Plan1.NPI工程支援确認物料到量試倉,專案工程師再通知物流領料2.后段生管反饋安排的組裝線72Arrange line/drive material to the line.Assy Plan1.NPI engeering support check if every material is in NPI stock,N

55、PI leader inform logistic guy drive material.2.BE planner prove the arranged line.73物料上線前2小時確認DQE/BE QA1.品管,DQE确認物料料號,供應商,版次73Check material 2 hours before material drived on the line.DQE/BE QAQA,DQE check material P/N,Supplier ,revision74BE-ME用到線物料組裝2個整机直至CQA pass BE-ME由制工在線外組裝初件測試並反應問題74BE-ME use

56、the online material assy two radio test step by step to CQA pass.BE-MEME assy first article,test,feedback issues. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points75流程卡SOP到位,制程跟蹤BE-ME1.确認所有SOP發放到位2.TSE反饋測試程式有無更新,是否能用(特別是F.F)3.IT切換量試機種所需程式并反饋75Flowchart,SOP ready,process

57、 trackingBE-ME1.Make sure all SOPs are ready.2.TSE feedback the test software issue.3.IT change the software and feedback issues.76Training OperatorsAssy1.由后段制工指導組裝培訓Operator76Training OperatorsAssyBE-ME train the operator.77投入5pcs直至CQA passAssy77Input 5pcs first articles to CQA passAssy Foxconn Con

58、fidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points78正式投產Assy1.在生產的過程中有問題DQE与專案負責人共同商討78Start the build.AssyIf there is any issue,DQE and NPI leader discuss the strategy.79Get the failure radios and provide the analysis resultARE不良整機由制工管控79Get the failure radios and provide the anal

59、ysis resultAREME control the the NG radio.80CQA對量試產品進行全檢CQA80CQA inspect the products 100%.CQA Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction itemDRI unitRemarkCheck points81合格良品整機送FAB進行包裝CQA81Good radio go to FAB to be packed.CQA82對合格良品整機進行包裝Assy包裝規範提供及出貨時間1.包裝方式由PM提供在無要求的情況下由工標.專案負責人商定2.專用出貨紙箱由B

60、EME提供3.專案負責人將包裝方式告知FAB4.在封箱時DQE要在現場82Pack the good radioAssyPackage spec and shipmenttime.1.PM provide the package requirement,if no special requiremetn,DQE and NPI leader discuss the packing method.2.BE-ME provide the special used carton.3.NPI leader provide the packing spec to FAB.4.DQE should be present when seal the carton. Foxconn Confidential整理课件新產品導入流程新產品導入流程ItemAction item