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Dick van Hees
04-11-2015/D&E Event
Keep the Customer Satisfied
Customer Expectation
Translate Expectation Specification
Prediction Methodologies
Part Quality Prediction
Agenda
5 November 2015
Public
Slide 2
Customer Expectation
Translate Expectation Specification
Prediction Methodologies
Part Quality Prediction
5 November 2015
Public
Slide 3
Customer Expectation
Expose Wafers
• Resolution (..nm)
• Field size (..*..mm)
• Overlay (.nm)
• Throughput (…wph)
• Cost of Operation (. €/exposure)
Functional Breakdown
5 November 2015
Public
Slide 4
Expose Wafers: €/exposure
• System Availability
• System Cost of Operation
• System Delivery Time
Operational Breakdown
Customer Expectation
Translate Expectation Specification
Prediction Methodologies
Part Quality Prediction
5 November 2015
Public
Slide 5
Translate Expectation Specification
Operational Requirements
• Availability (SEMI)
• Reliability (MTBI, MTBF)
• Serviceability (MTTR)
• Cost
• System Cost
• Delivery Performance
• Cycle Time (CT)
• Part Quality (FPY, ZHDR)
5 November 2015
Public
Slide 6
Translate Expectation Specification
Availability (wpy)
• Up Time
• Down Time
• Non Scheduled Time
5 November 2015
Public
Slide 7
Translate Expectation Specification
€/exposure
• Cost Of operation
• Maintenance Cost
• Gas/fluids/electricity
• Repair cost
• System Cost
• Part Cost (Supplier Parts)
• Build Cost
Delivery Performance
• Time to Complete a system
• Cycle time (build and test)
• Disturbance Time (Part Quality/Part Availability/…)
5 November 2015
Public
Slide 8
Translate Expectation Specification
Functional Requirement/Part
Operational Requirement/Part
• Part Quality (FPY & Zero Hour Defect Rate)
• Part Cost (€)
• Cycle Time (h)
• Reliability (Hits/part/year)
• Serviceability (MTTR)
5 November 2015
Public
Slide 9
Customer Expectation
Translate Expectation Specification
Prediction Methodologies
Part Quality Prediction
5 November 2015
Public
Slide 10
Prediction Methodologies
Operational Requirement/Part
• Part Quality (Zero Hour Defect Rate)
• Part Cost (€)
• Cycle time (h)
• Reliability (Hits/part/year)
• Serviceability (MTTR)
5 November 2015
Public
Slide 11
Available Prediction Methodologies 5 November 2015
Public
Slide 12
PCB PCBAElectro
MechanicalMechanics Mechatronics
Part Quality
FPY %
ZHDR %/ppm
Reliability Hits/part/year
Servicability
Diagnostic h
Repair h
Recovery h
Part Cost €
Cycle Time h
Operational Requirements
Prediction Methodologies
Operational Requirement/Part
• Part Quality (Zero Hour Defect Rate)
• Reliability (Hits/part/year)
• Serviceability (MTTR)
• Part Cost (€)
• Cycle time (h)
5 November 2015
Public
Slide 13
Customer Expectation
Translate Expectation Specification
Prediction Methodologies
Part Quality Prediction
5 November 2015
Public
Slide 14
Zero Hour Defect Rate (ZHDR) Definition
Zero Hour Defect Rate (ZHDR) Definition
Definition:
Maximum accepted failure rate during system build (%) measured
over an agreed period of time.
5 November 2015
Public
Slide 15
# Accepted DEFECTS
# DELIVERED ZERO HOUR DEFECT RATE =
Text Min. Typ. Max. UnitFirst Pass Yield (FPY). Required ability to
manufacture part without rework or test.%
Zero Hour Defect Rate (ZHDR). Maximum
allowed part failure rate.
%
DPMO
Requirement
ID
Requirement Verification
method Status
Source
ID
Specification Text Min. Typ. Max. UnitFirst Pass Yield (FPY). Calculated ability
to manufacture part without rework or test.%
Zero Hour Defect Rate (ZHDR). Calculated
maximum allowed part failure rate.
%
DPMO
Zero Hour Defect Rate (ZHDR)
Manufacturing
%
DPMO Zero Hour Defect Rate (ZHDR) Design %
DPMO
Requirement
ID
Requirement Verification
method Status
Source
ID
Prediction
Part Quality (ZHDR) Prediction
5 November 2015
Public
Slide 16
Defect Part
Functional out of spec
Physical out of spec
Missing Part
Wrong Part
Misoriented Part
Misplaced Part
Fastening
Glueing
Soldering
Bonding
Connecting elec ,fluids
gas
Riveting
……
Cleaning
Adjusting
Excess parts
Testing
……
DO
i
iDPMOZHDR1
6 ]101[1
Parts Mounting Connect Assembly
Process
Part Defect Opportunities
Parts Quality (ZHDR) Prediction 5 November 2015
Public
Slide 19
Test Process Output
Rework
Test
Scrap
OK
False OK
NOK OK
False OK
Not Reworkable
NOK
Process ZHDR ZHDR
OK
False OK
ZHDR = False OK
False OK + OK
Reworked
Parts Quality (ZHDR) Methodology
New Product Introduction (NPI)
• Predict Supplier/Factory Part Quality in Design Phase
• Based on the Preliminary BOM (PBOM)
5 November 2015
Public
Slide 20
Risk
Calculator
Risk
Knowledge
base
0
500
1000
1500
DPMO
DPMO
Parts Quality (ZHDR) Prediction
Outcome is the Zero Hour Defect Rate
• Risk mitigation to bring the ZHDR at specified level
• Design Change
• Process change at Supplier/factory
• Test
5 November 2015
Public
Slide 21