精英集团质量管理系统（IT英文版）.pptx

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1、Level 2 MaterialElitegroup Computer SystemsQuality System introduction, November 2002ECS Quality Policy#1 Customers set the requirement#2 PreventionEach employee takes responsibility for their own workFocus on anticipating potential problems and preventing themPrevention improves ECSs ability to get

2、 things right first time, - every time#3 Continuous improvementFocus on asking “why?”Tracing root cause of problemEstablishing method to prevent recurrence#4 RevolutionContinuous improvement = evolutionChange, new processes & reengineering = revolutionECS Total Quality AssuranceQuality policy:Preven

3、tion and continuous improvementDesign QASupplier QAA-systemDFM/DFTNPIEMI/Safety testVendor surveyQA system auditVendor performance assessmentCustomer complaint operation reviewProcess QACS QAThe pursuit of excellence and the trust in quality at affordable pricesIQCIPQCOQCCQC (reliability & compatibi

4、lity test)Customer complaintsDOA/RMAFA/CAREscalation processTechnical supportMaterial buffer managementECS and Conglomerates 2003 Quality TargetsDesign QAEstablish NPI Rule- A-System- Component approval- NPI CriteriaSupplier QAProductivity & Quality Improvement- Vender Survey/ Audit- QVL(60 vendors,

5、 75 Fa.)- Vender performance monthly rating- Process improvementProcess QAImprove quality & create added value- QS 9000 Certification- SFCS- ECN 150/Month- Cost 300/Manpower- MB scrap 1.5- IQC 91%- OQC 1,600 DPPMCustomer satisfaction - Customer satisfaction 100% Quality Policy: Prevention and Contin

6、uous ImprovementReduce customer dissatisfaction- Customer complaint procession time 3 days- FA/CAR Operation 5 days- DOA 4,000 DPPM- RMA 2.0% (include NDF)- RMA 1.5% (Verified)- RMA early warning systemCS QAQuality Strategy Pillars Advanced Quality Planning Factory Prevention Optimization & Continuo

7、us Improvement Reaction & RecoveryThe first 2 portions are undertaken primarily with the factory production department as an internal customer in mind.The last 2 portions are undertaken with the end customers in mind.Strategies (Product Life Cycle view )Strategy #2Minimize Intro Failure RateIntroR&D

8、,PurchasingProduction RampAQPActivitiesStrategy #1FMEA NPIControl gatesTimePresentCompetitionFutureStrategy #3Early Process Optimization during MPDOE, SPC, CLCA, & other CIPsStrategy #4Quality Escalation (external failures)Detect, contain & recoveryInherent Quality & DFM/DFT; Vendor QA Customer Perc

9、eived Failure RateDevelopment of Quality StrategyDecreasing Production CostIncreasing ProfitabilityIncreasing CompetitivenessQuality Prevention PlanPrevention and Continuous ImprovementQC QA TQM Re-Engineering TOCDevelopment of Quality StrategyCost of Quality Failure(1) Appraisal:(1) Appraisal: Prod

10、uction testing & Inspection, IQC, IPQC, OQC(2) Internal Failures(2) Internal Failures: Trouble Shooting, Scrap & Lost), Rework(3) External Failures:(3) External Failures: FA/CAR, DOA/RMAHigh Quality, Best Price, Good Service, More Flexible!Cost of Quality Prevention (1) NPI(1) NPI(2) QVL Management

11、(2) QVL Management (3) Vendor Rating System(3) Vendor Rating System(4) SFIS(4) SFIS(5) Subcontractor Supporting System(5) Subcontractor Supporting System(6) Field Analysis Engineering(6) Field Analysis Engineering(7) Employee Training(7) Employee Training1.還沒有制度，建立制度2.已經有制度，落實制度Standardization Simpl

12、ification Computerization2003 ECS M/B Quality Strategy1. Advanced Design Quality Management for NPI2. Supplier JIT Delivery3. Optimization of Shop floor control system/Sub-Con. Integration 4. Reduce the Noise of Customer dissatisfactionObjectiveControl MethodActivityDevelopmentParts & SupplierManufa

13、cturingShipping & SVCProtoAssyRun-InInspectionShippingSVCPilotPre-ProSourcingApprovalInspectionE/SDesign VerificationSupplier Quality ManagementProcess QualificationCustomer Satisfaction Verification at each design stage Design Review Parts Qualification SPC Supplier Qualification Continuous Supplie

14、r Improvement On Going Reliability Continuous Quality Improvement Safety & Regulatory Audit Service Parts Plan Local Service Support Field Data Analysis Quality Planning Reliability TestEVTDVTPVT (ELP) Compatibility Test Parts/Commodity Qualification Test DFM/DFT Cpk Verification EMI Verification Pr

15、oduction & Ship-Hold Program Analysis of Field Quality Field Trouble Shooting Provide Service Parts Parts & Product RMA Local SVC Support (US, Europe, Asia, South America) ECN Control & Follow-up Periodic Process Audit Weekly Quality Management Meeting Safety & Regulation F-up Monitoring & Analysis

16、of Manufacturing Date FAI Outgoing Quality Audit Out of Box Audit Cpk Implementation Supplier/Sub Contractor Approval Periodic Supplier Audit Quality Contract with Supplier Supplier Control by QMS member Incoming InspectionQuality PolicyTo produce our products first time right and consistently meeti

17、ng and exceeding our customer requirements. In our company, quality means not only just satisfying our customer requirements, but constantly improving our product quality. Our commitment to product quality improvement extends from the management to all employees in the company. Customer Satisfaction

18、 Survey Customer Visit Rush Order Line Site Stock RMA Reliability Test Design Evaluation Product Management Technology Breakthrough IQC Supplier Partnership Program Supplier Audit Supplier Performance Evaluations QA System Refine FMEA Application D.O.E. Application SPC Manufacturing Audit Incoming I

19、nspection Vendor Support/Audit Vendor Rating System Dock to Stock Control Semi F/G IQC Subcontractor Support/Audit SKD Subcontractor Training Roving ESD ECN Control Process, Parts Abnormal Control Purge/Rework Control MVT Meeting New Model/Version Transfer Non-conforming control Shop Floor System OQ

20、C Inspection Pallet Reject Follow-up Out of Box Audit Shipping Inspection Customer Complaint Feedback CKDProduct DesignECSs QA SYSTEMManufacturing Customer Complaint CustomerCustomerNew Product IntroductionSupplier Quality ManagementProduction Engineering CenterECS Quality Management Systems- Design

21、 Quality Support - Supplier Quality Management Support - Manufacturing Quality Support - CLCA for Customer Complaint ECS Support Systems- Customer Data Reporting - Training - Quality Assessment & Audit - Change Management - Product Regulations & Safety - Documentation Control - Customer Complaint Ha

22、ndling - DOA/RMA Operation (Advanced Design Quality Management)NPI (New Product Introduction)Component Engineering & QualificationVerification & PreventionPrevent Recurrence of Customer ComplaintBuild up Test Plan & Procedure Review A3A4 Product Pilot Run EngineeringReview & Reduce ECN Release Quant

23、ityBuild up Parts Specification and Check ListReview Parts Specification & Vendor TestingQuality Engineering Dept.(Supplier JIT Delivery)Audit the qualified suppliers/subcontractors so as to approve their quality system and product quality matching ECS requirementsDevelop Supplier Quality Management

24、 System so as to achieve the target of JIT deliveryRating the suppliers and subcontractors quality and support them to improve process yield rateImprove qualified suppliers and subcontractors product quality by periodic audit and consultationSupplier Quality Management Dept.JIT DeliveryFramework of

25、Manufacturing Quality Assurance SystemNative Suppliers SQAIQCManufacturingOngoing Reliability/Compatibility Test IPQCOQCOEM SitesEnd-users DistributorsXXXCustomer Service(RMA)SFCSCross-enterprise Operation (2003/Q3)BLACKCONTINUOUS IMPROVEMENT Quality Escalation Quality Improvement Programs Regular C

26、ustomer Review ForumsQUALIY SUPPORTS Quality Audit Corrective/preventive action Doc Con system Calibration system TrainingFACTORY QUALITY SYSTEM START- UP & NPI NPI Checklist DFM/DFT Product Training Post Mortem Analysis Production Release CriteriaPROCESS CONTROLS SPC PVS PCS QAN ESD SFCS Yield trig

27、gerINCOMING AQL MRB VFAR VCAROQM AQL VOQA FOQAINPUTOUTPUTCustomer Complaint Operation-Response in 24hrs, Preliminary FA/CAR in 3 workdays, Finalized FA/CAR in 5 workdays- Quality Issues Escalation- Close Loop Corrective ActionTechnical Support - In-country Repair Training- Duplicate the Failure Mode

28、- Find out the Root Cause- E-SupportL.A./USAMiami/USATaipei/TaiwanShenZhen/ChinaWijchen/The NetherlandsCSDDistributorsOEM/ Branch/ SI CustomersCustomer Service ECS TaipeiOrganizationFunctionQDPart ApprovalNew Product VerificationFailure Analysis & VerificationSupplier managementInternal AuditCustome

29、r Issue Tracing and ManagementCustomer WindowCustomer SatisfactionRelease FA &Eight D Report零件承認New Product Verification不良分析及驗證Customer SatisfactionCustomer WindowCustomer Issue Tracing and ManagementInternal AuditSupplier managementPart ApprovalFailure Analysis & VerificationRelease FA &Eight D Rep

30、ortPECQuality Related Department of ECSM ( ECS China )PECQDQDTSDTMDTMDTMDTMDNote : Quality policy and planning are established by ECS Taipei. The customer service affairs of OEM/Global are in charge of ECS Taipei. The customer service affairs of China SI are in charge of ECSM.The “red color arrowhea

31、d” stands for the affairs which commanded by ECS Taipei. The “blue color arrowhead” stands for the affairs which are correlated the ECS Taipei with ECSM.China SIOEM&GlobalQAOrganizational Chart Quality DivisionRMAQECSDOrganizationTypes of TrainingSkills trainingTouch-up soldering, BGA repair/rework,

32、 machine operation/alignment, etc.Supervisory trainingProductivity, CTR, Train the Operators, 5S, QCC facilitator, etcTeamwork trainingQCC, Team Problem Solving, Cross functional projects, etcSpecial knowledge trainingDFM, SMT, Wave Soldering, PCB, FMEA, D.O.E., Solder Failure Analysis, etcManagemen

33、t trainingQuality direction, staff strategy, managing breakthrough, etcLanguage trainingEnglish, Japanese, etc.Others - Presentation training, OJT, TPM, TQM, etc.Education / Training SystemCertification ProgramPurpose: Improve operators skill and guarantee qualityRange: All MFG. direct operatorsResp

34、: MFG. - major responser and cooperate with HR, ENG and PEMFlow:Function SelectedCertificationRegistrationNext Skill TrainingSkill TrainingNO ScientialLevelTraining ItemsDurationType ManagerQLP3 hoursLecturePSP(QC7&NQC7)6 hoursLectureTeam Working6 hoursLectureLearning Organization3 hoursLecture Supe

35、rvisorTQM3 hoursLecture PSP(QC7&NQC7)12 hoursLecture/OJTTeam Building6 hoursLectureSystems thinking6 hoursLecture EngineerPSP(QC7&NQC7)12 hoursLecture/OJT Team Consciousness6 hoursLectureCreativity thinking6 hoursLecture OperatorBasic Quality Consciousness3 hoursOJTPSP(QC7&NQC7)12 hoursLecture Level

36、Training ItemsDurationType ManagerFMEA12 hoursLectureDOE18 hoursLectureQFD12 hoursLecture SupervisorFMEA12 hoursLecture DOE18 hoursLectureSPC12 hoursLectureTPM6 hoursLecture EngineerFMEA12 hoursLecture DOE18 hoursLectureSPC12 hoursLecture 5S6 hoursOJT OperatorBasic SPC12 hoursLecture/OJT5S6 hoursOJT

37、SFCS-Architecture Data Tracking Method.SFCS-Report type ECR/ECN Flowchart RD Correlative RD Production Production Initiator Data Center PM Department Engineer PEC QA Control Dept.ECRReview bycorrelative dept.ECNTo modify BOMECN ReleaseECNdispose sheet / or advice sheetECR NO.CheckedOKOKCloseNGReleas

38、eDocumentM/OReworkInspectionNGTo turn towarehouseNGOKECR ConclusionOKNG Engineering Change Flow ChartExternal RequestInternal RequestCustomerSupplierSales/AMPurchasingFactoryPEPMR&D DepartmentSolution Submitted as ECRPMPESales/AMCRBCustomerECNDCCOKPMRMAFactoryPESales/AMProduct Manager PurchasingNOAl

39、ert PhaseECR ReleasedInvestigative PhaseECR Approval PhaseEC Implementation PhaseECN ReleasedECN Distribution PhaseLegend:1ECR: Engineering Change Request2ECN: Engineering Change Notice 3CRB: Change Review Board4DCC: Document Control Center5PE: Production EngineeringQA* 5S* ISO 9000 * QC 7 Tools * C

40、ontrol Chart * Process Control Improvement * Continuous Improvement* Vendor Survey * NPI * KPI * Vendor Performance Assessment* ISO 14001* TQM* QS 9000/3C* FMEA Implement * SPC forerunner program* Solderability Improvement project* Inspection & analyzing equipment enhancementDPM150001000050002500019

41、98 19992000200120022003Yearly12000 ppm 8000 ppm 5000 ppm 2500 ppm 1600 ppm16003000 DPPM * Solderability Improvement project* FMEA Implement * Quality Training : QS 9000/3C, Solder tech. I, TQM, NPI* Conduct Oracle system to supply chain * Quality engineering for system product 2500 DPPM * QS 9000/3C

42、 Implement* FMEA Implement* Inspection & analyzing equipment enhancement* SPC forerunner program* Quality Training : FMEA, Solder tech. II, TQM, NPI, SPC* SQE function enhancement1900 DPPM * QS 9000/3C certification* SPC forerunner program* Quality Training : SPC, PFP2200 DPPM * QS 9000/3C Implement

43、* FMEA Implement * SPC forerunner program* Quality Training : Quality Cost, SPCDPM3000250010000Year2002 4Q2003 1Q2Q3Q4QYearly20001600 DPPM * QS 9000/3C certification* SPC forerunner program* Quality Training : SPC, PFP IQC Batch Defect Rate2%IQC Quality Level2000DPPMOQC Batch Defect Rate9%OQC Qualit

44、y Level (M/B)1600DPPMOQC Quality Level (Barebone)1600DPPMOQC Quality Level (DeskNote)5000DPPMOQC Quality Level (System)5000DPPMCQC Defect Rate1.5%Customer Complain7 pcs/M Quality GoalQuality Record - Example1. Model:Axxx project (L4S5MGL)2. Period:From: 1-06-2001 2002/11/313. Target Status(ECS site)

45、Current PPMMB26000600FDD48000PSU7800630Total3860012314. Current System Failure Rate Analysis(ECS site)Output DOARMAField Site Return RatePPMMB333169200.06%600FDD33316000.00%0PSU333169210.06%630* MB NDF : DOA/2; RMA/3; ECN/22(reoworked failed by Acer)Est. Return Rate(Year)2600048007800386006000630123

46、1050001000015000200002500030000350004000045000MBFDDPSUTotalEst. ReturnRateCurrent PPMQuality Contact Window Strategy of ECS QualitySupplierProcessCQCQISProcedure EstablishmentAudit & AnalysisTrainingCustomer ExperienceQuality ManagementQM AssistantManagementQuality EngineeringQuality AssuranceQualit

47、y SystemConsultingTestingTechnical SupportCustomer ServiceKPI ( key performance indices for quality )QIT ( quality improvement team )QIS ( quality information system )QTS ( quality tracking system )EvaluationPeriod review / auditQVL / QPLESQER ( ECS supplier quality engineer representative ) Advance

48、d Quality PlanningFocus is to address manufacturing risks and work to eliminate/ contain ahead of factory productionActivitiesProduction Qualifications : EVT & DVT gatesDesign guidelines & checklistNew supplier/component qualifications & selectionDFX Forums (Design review participation)Product & Pro

49、cess Risk Assessment (FMEA)Production readiness reviews : DVT & MVT gatesDirection:View factory as a key internal customer. Factory PreventionFocus is to prepare production processes for factory pilot run stage in order to maximize production ramp readinessActivitiesConcurrent Engineering activities

50、NPI planning & preparation, checklists and “line-start” criteriaFMEA, Pilot Run post mortem analysisConfirm key process parameters for mass productionUtilize pilot run control gatesDirection:Factory works with upstream internal suppliers to do things right the first time. Optimization & Continuous I