Model Defect Defect cause Corrective actionTCJ1900 LABEL - Dented Mark NG During remove of label hole excess material , i) Improve existing stopper to guide and stop for

existing stopper can't proper stop for label moving during remove excess material at label

label moving with cause for punching pin hole surface.

not in-center punched for label hole.

Supplier : Sanko Sangyo

TAS9700 Lower Case Wrong judgement for part surface sink mark i) Tooling down re-matching & servicing to improve the part

( Sink Mark NG ) after improved the moulding condition to parting line.

improve the part parting line.

ii) Educate the operators and inspector to aware :-

a) Part defect rootcaused & action taken.

b) Moulding process flow.

for better understanding.

Supplier : Luster

TAS9700 PWB On line V-Cut PIC not proper set up V-Cut i) Educate PIC V-Cut regarding V-Cut setting arrangement

( V - Cut NG ) machine by using PWB thickness 1.00mm with must using PWB thickness 1.60mm during V-Cut testing.

V-Cut testing before mass production.

( Not follow machine specification standard ii) Improve V-Cut Inspection Method such as.

must use PWB thickness : 1.60mm ) Before : Using Range 7X scale Scope.

After : Using Range 10X scale Scope.

Supplier : AE Corp.

Supplier : Bumicircuit

Sink Mark NG

No Sink Mark OK

Defect : Dented Mark ( NG Condition )

Before Improvement After Improvement

Existing Stopper

V-Cut Spec :-

T1 & T3 = 0.20 ~ 0.25mm.

T2 =0.40~0.60mm

Avearge Measurement data

for Rejected sets.

V-Cut T1 = 0.50mm

T2 = 0.20mm

T3 = 0.30mm

No. Model Part Name Defect Detected Rejected Ratio Defect (Rootcaused)

1 TCJ1900 LABEL Dented Mark 241/12000 During remove of label hole excess material ,

existing stopper can't proper stop for

label moving with cause for punching pin

not in-center punched for label hole.

Worst Defect 1 ( AUG 2013 )

Defect : Dented Mark ( NG Condition )

OLD JIG - EXISTING STOPPER, Label has movement and pin not in-center punch

at label center hole area during remove the excess material.

Existing

Stopper ( NG )

Before Improvement

Attention Note

Existing Stopper

Training Record

Training Record

Supplier Improvement activties

i) Improve existing stopper to guide and stop for

label moving during remove excess material at label

hole surface.

iii) Update work instruction for future monitoring.

iv) Provide training to related PIC regarding defect

rootcaused and action taken.

After Improvement

Work Instruction

Work Instruction

No. Model Part Name Defect DetectedRejected

RatioDefect (Rootcaused) Supplier Improvement activties

1 TAS9700 Lower Case Sink Mark 42/2000 Wrong judgement for part surface sink mark i) Tooling down re-matching & servicing to improve the part

( Cav.4-2 ) after improved the moulding condition to parting line.

improve the part parting line.

ii) Educate the operators and inspector to aware :-

a) Part defect rootcaused & action taken.

b) Moulding process flow.

for better understanding.

Worst Defect 2 ( AUG 2013 )

Defect : Sink Mark ( NG Condition )

Attention Note

Repairing Sheet Moulding Process Flow

Training Record

１．IQC Failure Frequency

KGM IQC不良率 4月 5月 6月 7月

Lot inspectioned 382 323 318 335

不良Lot数 10 11 12 12

不良率(%) 2.6 3.4 3.8 3.6

Target 6.0% MAX

IQC failure all list ( JULY 2013 )

Product Name

TKC0800-T

TKC0600-T-0-T0T

TAS9700-T-0-NIK

Others

２．SMT Pick-Up rate and Working rate

4月 5月 6月 7月

Working days/Month 17 21 20 22

Working Time/day 22 16 16.25 17

Working Time/Month (h) 4114 3696 3575 4114

Total time (s) 14,810,400 13,305,600 12,870,000 14,810,400

Mounting point 39,461,861 48,305,731 34,223,467 41,243,219

Mounting theoretical value /Qty 205,245,900 183,322,000 158,262,100 191,973,000

Total Mounting Time (s) 2,796,711 3,506,025 2,782,494 3,181,273

Working rate (Target 50% Min)(%) 19.23 26.35 21.62 21.48

STD Pick-Up rate (Target 99.950% Min)(%) 99.955 99.951 99.950 99.940

ODD Pick-Up rate (Target 99.950% Min)(%) 99.945 99.946 99.945 99.945

Pick-Up rate (Target 99.950% Min)(%) 99.952 99.952 99.950 99.949

Lead Dirty Contamination

Upper Case Moisture

T1

Location No. Defect Contents

-,+ Mould Soft Feeling NG

0

50

100

150

200

250

300

350

400

450

500

4月 5月 6月 7月 8月 9月

Lot inspectioned KGM

SMT pick up rate

Date Model Qty Qty/sheet Feeder No

3．Production Failure Frequency

By Production section 4月 5月 6月 7月

PCBA Inspection 394 220 231 68

ICT 1019 472 407 326

FCT 103 54 51 33

Final FCT 0 0 0 0

FINAL Inspection 0 0 0 0

Total 1516 746 689 427

Inspection Qty 436,790 242,096 246,690 140,220

By Production DPPM 4月 5月 6月 7月

PCBA Inspection 902 909 936 485

ICT 2333 1950 1650 2325

FCT 236 223 207 235

Final FCT 0 0 0 0

FINAL Inspection 0 0 0 0

Dppm (overall ) 3471 3081 2793 3045

単位：ppm

2500

DPPM 不良率(ppm)

Month 99.900

99.910

99.920

99.930

99.940

99.950

99.960

99.970

99.980

99.990

100.000

4月 5月 6月 7月 8月 9月 10

pick up rate SMT pick up rate

Month

吸着率(%)

4．OQC Failure Frequency

KGM OQC不良率 4月 5月 6月 7月

Lot inspectioned 4086 903 1910 1153

不良数 0 1 0 2

不良率(%) 0.0 0.1 0.0 0.2

Target 3.0% MAX

発生場所 4月

市場 6 速報件数

Defect

0

500

1000

1500

2000

2500

4月 5月 6月 7月 8月 9月

0

500

1000

1500

2000

2500

3000

3500

4000

4500

4月 5月 6月 7月 8月 9月

Lot inspectioned KGM OQC

6 6

8

[5] 市場クレーム発生推移

6

1 1 2

0 0

2

4

6

4月 5月 6月 7月 8月 9月 10月 11月

個

8月 9月 10月 11月 12月 1月

329

13

4.0

Qty Lot Qty Frequency

15 3000 1

13 6000 1

11 5000 1

57

96

8月 9月 10月 11月 12月 1月

Lead Dirty Contamination

Moisture

Defect Contents

Mould Soft Feeling NG

月 10月 11月 12月 1月 2月 3月

KGM IQC不良率

Month

working rate

Pickup Error Mount Error

8月 9月 10月 11月 12月 1月

8月 9月 10月 11月 12月 1月

Action TakenContent

Production LDR KGM 工程不良率

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

10月 11月 12月 1月 2月 3月

working rate

Pick-Up rate (Target 99.950% Min)(%)

STD Pick-Up rate (Target 99.950% Min)(%)

ODD Pick-Up rate (Target 99.950% Min)(%)

Working rate (Target 50% Min)(%)

稼働率(%)

8月 9月 10月 11月 12月 1月

2

#DIV/0!

5月 6月 7月 8月 9月 10月

1 1 2 0

9月 10月 11月 12月 1月 2月 3月

Month

9月 10月 11月 12月 1月 2月

KGM OQC不良率

Month

12月 1月 2月 3月 速報件数

2月 3月 合計

1687

58

3.4

2月 3月 合計

80

15499

55,796,400

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

Lot inspectioned

不良率(%)

不良率

working rate

Result

2月 3月 合計

913

2224

241

0

0

3378

1,065,796

2月 3月 合計

3232.11585

8257.330599

900.9449311

0

0

Action Taken

working rate

Pick-Up rate (Target 99.950% Min)(%)

STD Pick-Up rate (Target 99.950% Min)(%)

ODD Pick-Up rate (Target 99.950% Min)(%)

Working rate (Target 50% Min)(%)

2月 3月 合計

8052

5

0.1

11月 12月 1月 2月 3月 合計

10

3月

PCBA Inspection

ICT

FCT

Final FCT

FINAL Inspection

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3月 Lot inspectioned

不良率(%)

不良率(%)