Safe-Launch 必备之NPI培训课件

NewProductIntroduction

-SafeLaunchModelNPINewProductIntroduction

全过程各阶段定义,特性,要点包括以下：

BCAPDEVTDVTPVTMVTMPBCA(BusinessCaseApproval)阶段:项目立项可行性评审阶段项目商务事项认可过程,项目可行性评估,确定是否同意进行立项,确认立项后,项目启动,召开KickOffMeeting,组建项目小组.重点:确认项目是否立项(规划层经营层)PD(ProductDefinition)阶段:产品详细定义评审阶段产品系统框架确立完成并被评审,项目DevelopmentSchedule确立.重点:项目产品定义是否合理,DevelopmentSchedule确立.PS:一般情况下,满多公司不会对BCA和PD阶段做太明确的阶段区分,一般整合到一个阶段,即项目立项可行性评审阶段.EVT(EngineeringVerificationTest)阶段:工程样品验证测试评审阶段Identifydesignproblemsandsolvingthemasearlyinthedesigncycle,verifythedesignmeetspre-determinedspecificationsanddesigngoals.ConsistsofBasicFunctionalTests,ParametricMeasurements,SpecificationVerification.重点:Ensuresbasicunitperformancetodesigngoalsandspecifications.

PS:此阶段一般要完成如下资料/事项:Product/EngineeringSpecificationDesignVerificationTestPlan(BasicTest,CompatibilityTest,EMI)TestEquipmentandToolingTestProcess,TestGuidelineandTestProgramSoftwareCircuitSchematicPCBLayout3D&2D&ExplodedDrawingSurface&Artwork&PackagingPre-BoMCostReviewFailureAnalysisandCorrectiveActionsEVT评审会议DVT(DesignVerificationTest)阶段:设计样品验证测试评审阶段Designrefinement.Reviseandimprovethedesigntomeetperformanceanddesignrequirementsandspecifications.Deliverobjective,comprehensivetestingverifyallproductspecifications,interfacestandardsanddiagnosticcommands.ConsistsofFunctionalTesting(includingUsability),PerformanceTesting,ClimaticTesting,ReliabilityTesting,ComplianceTesting.重点:确认是否合符产品定义要求,可否批量生产.

PS:此阶段一般要完成如下资料/事项:DesignVerificationTestComplete(BasicTest,CompatibilityTest,EMI)BasicTest包括:a:FunctionTestb:SafetyTest(主要包括:Hit-Pot,绝缘电阻测试,CurrentLeakage,接地测试)c:EnvironmentTestd:MechanicalTest(主要包括:VibrationTest,DropTest)CompatibilityTest包括:a:

硬件与软件之兼容性b:

硬件与硬件之兼容性EMITest:

抗静电,电磁干扰SafetyCertificationDesignChange(accordingtothedesignchangeinformation,modifyallrelateddesignfiles/drawing/software/program...)ModifyBoM制程文件试用的制作AVL(ApprovedVendorList)FailureAnalysisandCorrectiveActionsDVT评审会议PVT(Production/Process/PilotRunVerificationTest)阶段:小批量过程/生产验证测试评审阶段Verifydesignhasbeencorrectlyimplementedintoproduction,consistsofCompatibilityVerificationTestingandReliabilityTesting.重点:能否量产

PS:此阶段一般要完成如下资料/事项:FailureAnalysisandCorrectiveActions各种制程文件修改并正式发行EngineeringChange针对变更(小变更)做相应测试ToolingVerificationApprovalSheet/FileCompatibilityVerificationTestReliabilityTest制程能力报告PPApprovalMeetingGoldenSample产品资料releaseMVT(MassProductionVerificationTest)阶段:量产验证测试阶段验证量产时产品的大批量一致性.MP(MassProduction)阶段:量产阶段

PS:一般情况下,满多公司不会对MVT和MP阶段做太明确的阶段区分,一般整合到一个阶段,即MP阶段,此阶段侧重制程能力,产品品质持续改善及成本costdown.SafeLaunchModel模式safelaunch模式

Asvolumeincreases…qualityincreases产品质量与产量同步提升管理模式。14Occasions时机DevelopmentCycleISO9001

(DesignInput)DesignOutputDesignVerificationDesignValidation

ODM’sNPIEVTDVTMVT(PhaseReviewProcess)SamplebuildPilotRunPre-MassproductionSupplierSafeLaunchProcessR&DSampleapprovalPilotBuild

ControlledRampPPAPcompliancePPAP:ProductionPartApprovalProcess15CompareS.L.withDellandODM戴尔vs.ODM模式ODMNPIEVTDVTMVTODM(PhaseReviewProcess)SampleRunPilotRunPre-MassproductionPPAPapprovalDell,totally

7gatesODM’sNPIphasesODMsupplier3gatesODM’ssupplieradopt3gates:ComponentlevelPilotInitiatives

SupplierNPIEVTDVTMVT

Supplier

SafeLaunchProcessSamplebuildPilotBuild

Gate1ControlledRampGate1+Gate2PPAPcompliance16Responsibility权责Commodityteam:whenpartcreated,PM,R&D,andSQMinvolvedtheNPIasonecommodityteam,defineyield/gates,RTSandMRBdecision.

产品小组：由PM,R&D与SQE共同组成，ODMRSQE与小组成员共同定义产品与制程的良率/阶段要求、时程管理、与阶段特采决议。PM：RTStimingmanagement,productionquantitydefinitionofDVTandMVTphases.

产品管理：产品开发至上市总时程管理、DVT,MVT生产数量定义。

ODMJQE:InvolvetheMRBdecisionmakingwithcommodityteam.

客户JQE：与commodityteam共同参与试产特采决定。ODMSQE：Processreviewforeachgate;ismanagingtheproduct/programisresponsibleforimplementationandadherencetothisprocess.

本程序之制程审查;管理本程序之供货商试产（Pilotbuild,Controlramp）、纪录审查、与供货商制程改善活动。R&D：Productreviewforeachgate;definetheCTQofindividualpartdiagram,solvethecriticaldesignissuewhenitbefoundinsafelaunchprocess.

本程序之产品审查;定义产品重要功能特性（CTQ）、并描述于零件承认书图面中；解决本程序中供货商生产所发现之设计面重大问题。RTS:ReadytoshipmentCTQ:Criticaltoquality17Yields/Gates良率/阶段的定义Processyield-gateswillbedefinedanddocumentedforboththepilotandcontrolledramppriortothefirstpilotbuild.ODMcommodityteamdefinesthesegatesandtargets.Gatesaresetwithriskmanagementinmindthatisbasedonquality.Seetablebelowasanexample.Goalswillnotbechangedwithouttheagreementofthecommodityteam.

本程序的各个阶段良率由ODMcommodityteam共同定义之，基本上是由质量风险的角度来设定，如下表案例。一旦各个阶段良率目标定义后，就不再变更。目标变更，须经由产品小组同意。CommodityTypeDVTMVTPilotBuild

Gate1ControlledRamp

Gate1ControlledRamp

Gate2QuantityFPYQuantityFPYQuantityFPYPCB3280%30085%50090%Plasticsmolding5085%10090%30095%Metalstamping12080%30%DM85%60%DM90%QuantityandFPYtargetsarerecommendation.DM:DemandofMarket18SafeLaunchFlowChart流程图ControlledRampGate1+

Gate2PilotbuildGate1MVTSafeLaunchProcessDVTFlowChartSampleverificationEVTNPIPhaseR&D新零件开发:P1(G1,G2)供货商,R&Dnewpartdevelopment:P(G1,G2)supplier样品核准Sampletest&verification供货商试产Supplierpilot-runProductreviewbyLiteOnR&DProcessreviewbyODMSQM发行零件承认书Issueanapprovalsheet供货商试产SupplierControlledRampCorrectiveActionCorrectiveActionMRBMRBFailFailPassPass供货商样品SuppliersamplebuildProductreviewbyLiteOnR&DProcessreviewbyODMSQM*MRBmember:PM,R&D,JQEandSQE*Productreview:ByODMR&D

Processreview:byODMSQE19ContentofSafeLaunchprocess内容5.1. SafeLaunchModelODM供货商safelaunch模式 5.2. Occasions应用时机 5.3. Yields/Gates良率/阶段的定义 5.4. SafeLaunchGateRulesandCorrectiveActions

规则与改善行动要求 5.5.MRBforfailedGate特采5.6. ProcessestobeMonitored,Guidelines制程监督与指引5.7. DataCollection/Reporting信息搜集与报告 5.8. PostBuildmeetings生产后会议5.9. SupplierNPRRcompliancereview 5.10. ControlofQualityRecords质量纪录管制 5.11. 「SupplierSafelaunch程序」更新P1ofG1,G2supplierlist,22Nov2006SOPandworksheetSafeLaunchprojectcalendar20Purpose目的Thisproceduretoestablishacommoditysafelaunchprocessthatwillprovideaphasedapproachtowardsprocessvalidation,ameansoffine-tuningaprocessbeforevolumeramp,processforbuildinginqualityanddevelopmentofsupplierprocessesthatwillhelptheSuppliertomeetODM’squalityexpectations.

对ODM重点供货商，制定一「供货商safelaunch程序」要求；本程序展现了ODM科技对供货商生产个别产品制程的阶段性核可要求，也是在量产前的制程能力提升要求，以达成本公司良好进料质量的期望。21Scope范围ThisprocedurewillbeappliedforP1(ODMDesignParts:PlasticInjection,MetalStamping,PCB)ofG1(highrisk,highspend)andG2(highrisk,lowspend)levelkeysuppliers’SafeLaunchrequirement,thekeysuppliersdefinitioncombinedwithspendandqualityriskelements,thekeysupplierlistintegratedboth2factorsbySQMdepartment.

本程序适用本公司供货商管理部所定义的P1(ODMDesignParts:PlasticInjection,MetalStamping,PCB)供货商之G1(highrisk,highspend)与G2(highrisk,lowspend)类型厂商之管理要求，重点供货商名册会依照营业额与质量风险综合评比后定义。22Thesuppliersafelaunchshouldbeusedinthefollowingsituations.下述情形供货商应导入本程序Newproduct新产品NewManufacturingfacility,existingsupplier

新生产设备导入NewSupplier新供货商Significantform/functionchangestoexistingproduct现有产品重要功能变更MultipleLinequalificationwithexistingproduct.

现有产品之衍生生产线核可Occasions-223Safelaunchtimeline导入时间表导入时间表ThepilotstartsintheDVTphase.Thisphasewillbecompletedandgatesmet/exceededpriortotheControlledRampstartoftheMVTphase.

Pilotbuild起自DVT阶段，达成/超过既定目标后，才能进行MVT的ControlledRamp阶段。IntheMVTphase,RTSatthesuppliersitestartsthecontrolledrampprocess.ControlledRampwillcontinueuntilallgatesaremetfor2consecutivegates.

在MVT的ControlledRamp阶段，产品出货质量要求，仍须符合controlledramp的量产管制的目标定义。24ApplyingGatestosafelaunch生产阶段定义本程序之生产阶段定义TheODMcommodityteamwilldeterminethegatesbaseduponexperience,supplierinputs,qualityhistoryandthequalityrequirementsforthenexthigherassembly.ODMR&Dimplementsproductreview,ODMSQEimplementsprocessreview.

ODMcommodityteam会依据经验、供货商建议、质量履历、与下阶段组配质量要求、、等，来定义生产阶段与质量目标。产品面审查由ODMR&D执行，制程面审查由ODMSQE执行。Pilotgateswillbesetforatleast1pilotphase.MeanwhilesuppliershallcomplywithODM’sPPAPprocedurerequirements（C-SQM-015）.

Pilotbuild阶段，至少进行一次生产评估。除了FPY良率要求外，本阶段供货商也必须符合ODMPPAP程序（C-SQM-015）相关要求。Controlledrampbuildsgateswillbeset(by2times)andwillincreaseinincrementsasdefinedbytheODMcommodityteam.MeanwhilesuppliershallcomplywithODM’sPPAPprocedurerequirements（C-SQM-015）.

Controlledramp阶段，至少进行连续两次的生产评估。除了FPY良率要求外，本阶段供货商也必须符合ODMPPAP程序（C-SQM-015）相关要求。25SafeLaunchGateRulesandCorrectiveActions规则与改善行动要求5.4.1In-processandaftereachPilotPhaseorControlledRampbuildphases(typicallyproductiondays),therequiredyieldsandPPAPareevaluatedvs.theestablishedgates.Aformaldailyreviewofresultswillbecompletedafterallbuilds.TheODMJQEshallhostthismeeting,SQEmayattenditasrequired.

不论在Pilotbuild或是ControlledRamp阶段进行中、或是在完成后，都须进行良率与目标，以ODM相关要求（PPAP）的评估。ODMJQE必须主导每日的正式检讨会议，SQE适时参加。

5.4.2ViolationofaGate阶段未达目标时

Duringanybuild,ifagateisviolatedthebuildmuststop.TheSupplierwillensurethatroot-causeandcorrectiveactionsaredefined/implementedforallissuesidentified,ODMcommodityteamapprovalisrequiredpriortoDVTphase.CorrectiveactionsthatareimplementedwillbeverifiedbyODMSQE/JQEtore-initialorcontinuenextbuild.

在每一个生产阶段中，一旦良率不符目标，则本阶段生产即停止。供货商对每一件确认的质量问题都须提供改善措施的定义与执行，ODMcommodityteam必须在DVT阶段完成前核准供货商所有的质量状况与改善绩效。改善行动的执行的情形，必须在经由ODMSQE/JQE确认后决议再次生产或是径行进入下阶段。2Thepilotphasewillberepeateduntilallofthephasegatesareachievedorexceeded.Thecontrolledrampmayalsobeextendedifgatesarenotmet(atthediscretionoftheODMcommodityteam).

在生产良率目标达成前，Pilotbuild阶段将会重复进行与延长。须由ODMcommodityteam审慎考虑后决定之。

Correctiveactionsthatarelongertermandcannotbeimplementedintheappropriatetimeperiodmaybeleftopen.Thenextbuildmayproceedaslongacontainmentplanisdefined/validatedandapprovedbytheODMSQE.

有关长期的改善措施，在短期间可留下未结案事项。在下生产阶段时SQE仍需持续监控、结案。

GateviolationwillbecodedREDontheSafeLaunchreport/datacollectiontemplate.

未达目标的生产阶段将会在工作表中标注为「红色」，以为警示。GatesthatareachievedorexceedthewillbecodedasGREENontheSafeLaunchreport.

每一阶段达成或是超越目标时，工作表上就会以「绿色」显示良好状态。27Green/RedcodeofGatesreviewGreencodeRedcodeGreencodeGreencode28MRBforfailedGate特采AccordingtotheRTSmanagement,iftheproductionbuilddoesn’tmeetFPYrequirement,CommodityteamcouldholdaMRBreview.theMRBdispositionmakingwouldbedonebycommoditymembersandcustomerJQE.

产品小组可依照产品开发上市时程，对于未达目标的生产阶段，进行特采管理，需经过产品小组与客户JQE共同决议之。MRBreviewshalladoptworksheetofthisprocedure.

特采作业需保留书面审查纪录，依照附表格核准之。WaiverecordshallberecordedinPilotControlledbuildsPlan.

特采作业需在PilotControlledbuildsPlan中注记特采纪录，与核准人员。Afterwaivedecisionmaking,TheSuppliershallfollowchapter5.4.2ensureroot-causeandcorrectiveactionsaredefined/implemented,ODMcommodityteamapprovalisrequiredpriortoDVTMVTphase,andCorrectiveactionsthatareimplementedwillbeverifiedbyODMSQE/JQEtore-initialorcontinuenextbuild.

特采作业决定后，仍需要依照5.4.2章节要求，进行改善措施的执行，在DVT阶段完成前核准供货商所有的质量状况与改善绩效，改善行动的执行的情形，必须在经由ODMSQE/JQE

确认后决议再次生产或是径行进入下阶段。29DataCollection/Reporting信息搜集与报告

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

供货商必须在生产阶段定义后，监督每一个生产步骤；可以SFIS系统、或是人力进行搜集生产信息与报告。供货商必须在无法达成良率目标时，立即停止生产，此时供货商无法完成生产作业，进而获得生产信息，供货商必须尽可能的实时的进行生产信息搜集。5.7.2SafeLaunchPilotandControlledRampDataCollectionTemplateandActionPlanRegister–worksheet（C-SQM-023-01）willbeusedforallbuilds.

供货商必须以附表进行生产结果记录。5.7.3ThesupplierJQEwillprovideadailysummaryreportforeachbuild/phaseimmediatelyafteritiscompletedthroughthesafelaunchperiod.Itwillcontainalloftheappropriateyieldsvs.gates,allissuesidentifiedandcorrectiveactionplans.Seetemplatenotedinsection5.8.2forcompletedatacollectiondetails.

供货商JQE实时提供的每日生产总结报告，并应包含良率信息、问题与改善计划，参照5.8.2节进行。30PostBuildmeetings&SQRCcompliancereview5.8生产后会议JQEODMshallorganizeadailypostbuildmeetingaftereverybuild/phase.ODMSQEmayattendthisasrequired.

ODMJQE必须主导在每生产阶段期间召开每日生产后会议，ODMSQE适时参加。5.9SQRC审查ODMSQEwillimplementSQRC(supplierqualityreportcard)reviewasaproductreadinesscompliancereviewbeforemassproductionwhichbasedonODMPPAPrequirement.

ODMSQE将进行SQRC审查,以为产品量产前查核,此审查以ODM供货商的PPAP要求为基础.31SupplierNPRRPerformanceReviewNPRR:Newproductreadinessreview32SafeLaunchprojectcalendaritemProjectstep2007TargetMarAprMayJunJulAug1DevelopdraftversionSOP40Suppliers

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

V

2SOPcrossfunctionapproval

VV

3Internaltraining:PM,R&DandSQE

V

4SupplierKickOffmeeting:ODMSQEvs.supplierlist

V

5ProjectmonthlyreviewRSQMassistvisit

V

V

V

V

33supplierlistApr200742SuppliersadoptODMsafelaunchprocess.SupplierselectionprinciplesP1suppliers(ODMdesignparts)G1,G2,G3suppliersRelatedwithBUserveKeycustomer

重点客户的供货商,如:Dell,HP,此标准则不局限供货商G1,G2类别,G3也可以.There’renewproductsdevelopmentatcoming3~6months

wouldliketoco-workwithODM

有配合意愿,ODM能主动要求的供货商.(低配合度供货商,请协助删除.)

34PPAPkeysupplierdefinitionThisprocedureshallbeappliedforP1typesuppliers(ODMDesignParts:PlasticInjection,MetalStamping,andPCB).andsuitedforG1,G2levelsuppliers.HighHighLowLowSPENDRISKGroupII(34Suppliers)PerformanceisimportanttoproductperformanceOneormorerestrictedsourcesFewOptionsTemporaryorinherentriskHighRiskLowSpendGroupI(49Suppliers)GroupIII(255Suppliers)ManyOptionsManySourcesLittlebrandpreferenceLowRiskLowSpendCriticaltoproductperformancetechnicallyirreplaceableLossordelayhasmajorimpactFewalternativesorcosttochangesuppliersishighHighriskHighspendCommondesignsLossordelayhaslessimpactManyalternativesourcesManysourcesLargemarketcapacityLowRiskHighspendSurvei