Model Defect Defect cause Corrective action

TCJ1900 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 Detected
Rejected
Ratio
Defect (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
IQC Failure Frequency
KGM IQC 4 5 6 7
Lot inspectioned 382 323 318 335
Lot 10 11 12 12
(%) 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
SMT Pick-Up rate and Working rate
4 5 6 7
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 5 6 7 8 9
Lot inspectioned
KGM
SMT pick up rate
Date Model Qty Qty/sheet Feeder No
3Production Failure Frequency
By Production section 4 5 6 7
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 5 6 7
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
ppm
2500
DPPM
(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 5 6 7 8 9 10
pick up rate
SMT pick up rate
Month
(%)
4OQC Failure Frequency
KGM OQC 4 5 6 7
Lot inspectioned 4086 903 1910 1153
0 1 0 2
(%) 0.0 0.1 0.0 0.2
Target 3.0% MAX
4
6
Defect
0
500
1000
1500
2000
2500
4 5 6 7 8 9
0
500
1000
1500
2000
2500
3000
3500
4000
4500
4 5 6 7 8 9
Lot inspectioned
KGM OQC
6 6
8
[5]
6
1 1
2
0 0
2
4
6
4 5 6 7 8 9 10 11

8 9 10 11 12 1
329
13
4.0
Qty Lot Qty Frequency
15 3000 1
13 6000 1
11 5000 1
57
96
8 9 10 11 12 1
Lead Dirty Contamination
Moisture
Defect Contents
Mould Soft Feeling NG
10 11 12 1 2 3
KGM IQC
Month
working rate
Pickup Error Mount Error
8 9 10 11 12 1
8 9 10 11 12 1
Action Taken Content
Production LDR
KGM
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
10 11 12 1 2 3
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)(%)
(%)
8 9 10 11 12 1
2
#DIV/0!
5 6 7 8 9 10
1 1 2 0
9 10 11 12 1 2 3
Month
9 10 11 12 1 2
KGM OQC
Month
12 1 2 3

2 3
1687
58
3.4
2 3
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
(%)

working rate
Result
2 3
913
2224
241
0
0
3378
1,065,796
2 3
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 3
8052
5
0.1
11 12 1 2 3
10
3
PCBA Inspection
ICT
FCT
Final FCT
FINAL Inspection
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3
Lot inspectioned
(%)
(%)