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QUALITY ASSURANCE SYSTEM
"Contributing prosperity society with much pride through creation innovation unique products every sector", this goal strive fulfill. "We, Japan Radio Co., Ltd., continually creativity improve business thus produce adaptable products services high quality that meet satisfaction customers.", Quality policy. customers proffer product which high efficiency, high quality, high reliability, always consider earth environment. present circumstances, electronic equipment been upgraded with performance plays important role industry. Therefore default equipment might cause serious problem system. Year after year, electronic equipment requested higher quality higher reliability. acquired ISO9001 1994 acquired ISO14001 satisfy those severe demands 1997. addition, acquired ISO9001-2000. And, will enough consideration concerning environment mention quality, offer product high quality high reliability able have more than ease customer.
Quality Assurance System
Fig.1 shows NJRC's quality assurance system from planning shipping customer services.
Production Planning
Before make plan products, research into customer needs trend market extensively based business. Finally, decide planning production Products Development Meeting.
Design, Pre-production(Design Review) 2.2.1 Design
design product meet customer's requirement close communications. design makes using system based design rules justified reliability. quality design check production technologies, development data quality information Design Review (DR).
2.2.2 Test Production
test products assessed characteristic reliability. reliability evaluation method condition shall performed EIAJ ED-4701(JEITA) specification.(Except STEPPER MOTOR CONTROLLER/DRIVER) mass production able started after consideration process capability, yield result, reliability test result customer's evaluation ES(Engineering Sample).
Mass Production 2.3.1 Quality control Materials
make effort improve quality material quality approval materials, purchasing specification, incoming inspection close communication with vendors.
2.3.2 Process Control
addition materials, process control effects importantly quality. make effort avoid scattering products standardization automatic system. check performance quality inspection. Fig.2 shows example process control.
2.3.3 Environment Control
environment during production effect importantly quality reliability. control properly temperature, humidity dust fabrication. Especially high quality high reliable production, make utmost effort improve cleanliness dust control most important factor.
2.3.4 Production equipment facility control
Production equipment facility control very important maintain quality, characteristics reliability. keep production, prescribe rule maintenance inspection production equipment facility. Therefore maintain stable productivity.
2.3.5 Measuring instrument control
Measuring instrument control basis quality assurance. Therefore quality products greatly influenced control measuring instruments production line. maintain high precision measuring instruments accordance with rule national standards. Periodically, entrust maintenance measurement instruments traders public institution.
2.3.6 Change control corrective action
Certainly, change condition design, process, material facility accordance with change control system. maintain this change control system prevent occurrence nonconformance. this system, changing specification characteristics performed after customer's approval. Finally failure analysis data production process notified related sections, prevent recurrence accident.
2.3.7 Sub-contractors control
sub-contractor when entrust production, customer when parts materials, investigate quality assurance system. investigation carried when entrust production first time. investigation quality assurance system continued regularly temporary. hold regularly meeting process patrol, maintain quality control system incoming products.
QUALITY ASSURANCE SYSTEM
2.3.8 Education training
educational policy educate employee individual growing, NJRC's development" educate employee sections, classes. educational course consisted three items, training, training individual education". education according educational program enough satisfy public circumstances.
2.3.9 circle
activity circle trigger individual mutual education. promoting activity this circle part activity. Employee's consciousness essential power development. accordance with their independent management, employees skills improve quality products, services working circle.
2.3.10 Internal quality audit
internal quality audit performed team consisted qualified auditors. this internal audit, periodically, auditors confirm whether activity quality assurance conformed planning.
2.3.11 Quality Records Control
quality system, provide data obtain production, process, quality audit customer audit quality records. provides rules make quality records effectively.
2.3.12 Document System
document system which composes quality management system company shown right picture. quality manual made based demand with ISO9001, sections which compose each system, various documents made operated. Quality Manual Quality rules whole company Manuals/Standards/ Designs
QUALITY ASSURANCE SYSTEM
Section Step
Customer Management
Sales Dept.
Production Production Control Planning Dept. Dept.
Design Dept.
Manufacturing Line Quality
Sub-
Sub-
Engineering Production Assurance contractors contractors Dept. Sec. Sec. (WP) (Ass'y)
Standardization Documents
Policy
Market Research products Development Meeting Product Development Provision
Production Planning Design, Pre-Production Mass-Production
Order
Appro Design Review Design Test Production Feature Reliability Test Overall Evaluation
Design/Development Control Manual
Design Review Provision
Process Parameter Specification
Mass Production Approval
Mass Production Meeting
Marketing Action
Sales Planning
Mass Production Transfer
Production Planning
Wafer Process Receiving Inspection Wafer Process Receiving Inspection Assembly Inspection Receiving Inspection
Operation Procedure Inspection Standard
Modification Instruction
Order Acceptance Warehouse
Quality Assurance Inspection
Handling Storage Standard
Shipping Directions
Shipping Preparation
Sales
Delivery Quality Claim
Claim Investigation Request
Shipping Packing
Shipping Inspection
Packing/Shipping Standard
Claim Investigation Acceptance
Claim Treatment Rule
Services, Quality Improvement
Claim Cause Investigation Report
Claim Investigation Report
Quality Audit
Quality Improvement
Quality Audit Provision
Fig.1 Quality Assurance System
QUALITY ASSURANCE SYSTEM
Process
Wafer Wafer Process Wafer Test (100%) External Visual paste Read flame Dicing test Electrical characteristics External visual(wafer) Depth dicing, Electrical Resistivity pure water External visual (chip)
Check Item
bonding wire test Wire bonding Mold resin test Molding test Marking Electrical characteristics test sampling inspection Storage Outgoing inspection Shipping
Temperature External visual, Adhesive strength (Die) Temperature, power External visual, Bonding strength (Wire) Temperature, Pressure, Time External visual
Electrical characteristics Electrical characteristics, External visual
Product's name, Quantity
Fig.2 Example flow
QUALITY ASSURANCE SYSTEM
3.Reliabirity Tests
apply reliability tests products, modified products (design, production equipment, process materials) reliability monitor test. Reliability tests verify that products attain reliability target. Table1 (BIPOLAR, C-MOS, GaAs), Table2 (Precondition BIPOLAR, C-MOS, GaAs), Table3 (OPTOELECTRONIC DEVICE), Table4, 5(STEPPER MOTOR CONTROLLER/DRIVER) following. Table1.Example reliability tests(BIPOLAR, C-MOS, GaAs) Test Item Precondition Test Condition Steady State Life voltage applied High Temperature Storage Temperature Humidity-Bias 85%, voltage applied Humidity Soldering Heat Thermal Shock Liquid Phase Temperature Cycling Atmospheric Phase BIPOLAR, C-MOS 100%, Pressure Cooker GaAs 100%, Flux used [Sn-37%Pb] Solderability (Wetting balance method)[Sn-3%Bi] BIPOLAR, C-MOS C=100pF, R=1.5k, V=1kV Electrostatic Discharge GaAs C=200pF, R=0, V=40V
1000h 1000h 1000h 1000h 10cycles 100cycles 100h
Table2, Precondition (BIPOLAR,C-MOS, GaAs) Moisture Soldering
times
Table3.Example reliability tests(OPTOELECTRONIC DEVICE) Test Item Test Condition Steady State Life IF=Absolute Maximum Rating, VCE=Absolute Maximum Rating High Temperature Storage Ta=Tstg Humidity Soldering Heat 10s, dipping depth should 1.5mm from body specimen. Temperature Cycling Tstg min(30min) Tstg max(30min), Atmospheric Phase Solderability Flux used, dipping depth should 1.5mm from body specimen. Electrostatic Discharge C=200pF, R=0, V=1kv Terminal Tensile Strength each lead
1000h 1000h 1000h
20cycles
Table4.Example reliability tests(STEPPER MOTOR CONTROLLER/DRIVER) Test Item Test Condition Steady State Life Tstgmax., Voltage Maximum Operating Voltage High Temperature Storage Tstgmax. Temperature Humidity-Bias Voltage Maximum Operating Voltage Soldering Heat Reflow(Convection) Reference Table Temperature Cycling Tstgmin.(30 min) min) Tstgmax.(30 min), Atmospheric Phase Pressure Cooker 2.03 Solderability Solder Electrostatic Discharge ±500
1000 1000 1000 cycles
Table5.Package Reflow Conditions(STEPPER MOTOR CONTROLLER/DRIVER) Package Thickness Package Thickness Package Thickness Package Volume Package Volume +5/-0 +5/-0
QUALITY ASSURANCE SYSTEM
4.Customer Returning Failure Analysis
case device trouble customer's operation, request that customers should send back With troubled products, cause troubles founded salesmen returned factory. Generally, quality assurance section responsible failure analysis. design section engineer section responsible application troubles. Failure analysis data returned quality assurance section. After totally reevaluate these failure analysis data, report failure analysis data customer salesman. These data returned design section, engineer section manufacturing section, useful preventing troubles progressing product's quality. Customer Returning Customer Trouble Claim Quality request Sales dept. Failure investigation request Failure analysis Report Visual Inspection Electrical Characteristics Test Good Testing under Failure Condition Electrical Characteristics Test Defective Good Package Open Inside Check Feedback (Prevention re-occurrence Progress Quality) Chip Analysis Investigating damage cause Measures, Recurrence Prevention Final Report Writing Good Testing when need Occurrence Investigation Market, Process
Operating Condition Environment, Reject Ratio
Quality Assurance Dept. Failure analysis Discuss prevention re-occurrence Failure investigation request necessary) Report Production dept. Technical dept. Design dept.
Fig.3 Customer Returning Failure Analysis Route
Fig.4 Failure Analysis Procedure

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