Post on 26-Nov-2015
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Rules of Engagement for Proto / Pilot PCAs
The following are requirements that are needed in order to be successful to support proto / pilot PCAs. This is in order to improve the accuracy of Foxconn product schedule, time to market and quality with respect to assembly and test of PCAs as well as fabrication of PCBs. This will set the level of expectation up front for internal functional groups as well as NPI PCB/PCA vendors.
Assumptions:
Time line assumes business days Complexity is defined as
o Low – No logic involved i.e. PCI switch boardso Medium – some logic involved i.e. Memory, Backplane, Peripheral boardso High – High level logic involved, parts count 2200+ and test nodes 3500+ i.e. I/O, Processor, Host boards
Add additional time for materials when build is scheduled at international sites e.g. Mexico, Scotland etc
Expectation Deliverables Action Item Owner
CONCEPT
1.
Assess design requirements vs. EMS manufacturing capabilities; identify design requirements that are outside of stable /reliable EMS capabilities
EMS capability matrix ISS SC
2. Develop processes partnering with EMS resources to support new component / design requirements.
Align development of new processes to HPQ program
requirementsNew processes validated prior to
1st HPQ proto board
ISS SC
3. EMS provides DFx Feedback as and when HPQ (ISS SC) provides the data
DFx issues list to be provided back to ISS SC within 1 business
day
EMS
4. EMS to coordinate with HPQ Process / Design / PCB procurement engineering to optimize PCB panelization to minimize PCB costs during the mechanical design phase
Optimized PCB dimension within 1 business day from dxf file is
available.
ISS SC
MATERIALS1. Materials list to be provided to EMS via soft
copy at least 1 business day in advanced prior to actual receipt of materials at EMS site. Hard copy to come with shipment.
Materials list of the items shipped in an attached format
HPQ Program teams
2. 80% of the consigned materials to be made available at the EMS site at least 5 days in
advanced of scheduled PCA build start (except for PCBs and unique chip set).
(Materials to be shipped as early as possible as there could be multiple builds
scheduled at the EMS site)
Materials kitting and shipment
See Appendix A for attrition values
HPQ Program teams
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 3
Expectation Deliverables Action Item Owner
3. Remaining 20% of the materials to be made available at EMS site at least 1
business day in advanced of scheduled PCA build start (including PCBs and unique
chipset)
Shipment tracking info to EMS HPQ Program teams
4. HP be notified of any materials issues within 2 business days after receipt of initial
material kit
Detailed list of material issues to HP – attached format
EMS
5. HP p/n labels on the reels should not be covered up by other labels when EMS
applies their labels
Apply labels in a clear area EMS
6. EMS to provide the excess material list (Qty shipped – qty used) to HP after
completion of the scheduled PCA quantity. This report should be provided within 10 business days of start of the PCA build
Attached format EMS
7. COMMON MATERIALEMS will provide common material upon Hp’s request.
8. If material kits include more than one skid and/or 100+ part numbers, materials to be
made available to EMS site at least 7 business days in advanced of scheduled
PCA start.(Materials to be shipped as early as
possible as there could be multiple builds scheduled at the EMS site)
Materials kitting and shipment HPQ Program teams
9. EMS to provide material process plan for HPQ consigned material and EMS provided
materials
EMS NPI Materials Team.
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 4
Expectation Deliverables Action Item Owner
10. EMS to provide process plan to transition materials from site to site
EMS NPI Materials Team.
11. SMT parts are required to be in Tape/Reel and/or Trays per supplier specification. No
loose SMT parts in ESD bags or tubes allowed (except SMT parts for 2nd
assembly)
SMT parts in T/R HPQ Program teams
12. If SMT parts required to be Tape/Reel by EMS, parts are to be made available at least 3 business days in advanced of
scheduled PCA start date.
SMT materials highlighted in material list that Tape / Reel is
required
EMS T & R capability HPQ Program teams
13. If the materials are made available to EMS within 1 business day window, all the SMT
materials need to be in Tape/Reel packages (except QFP/BGA where applicable). No loose parts, parts in
tube/trays allowed
SMT parts in T/RException to be handled on a
case by case basis
HPQ Program teams
14. HP to identify the moisture sensitive devices with labels
MSD parts to be provided in a sealed bags
HPQ Program teams
15. EMS to comply with J-STD-033 for MSD Bake the parts as necessary and reseal after build completion. EMS to keep the log of open
parts and baked parts
EMS
16. SMT materials shipped in a T/R should have at least 14” leading and 18” trailing
empty tape.
Tape & Reel with sufficient length HPQ Program teams
17. Untested PCAs to be shipped to HP with following schedule(business days) after the
start of the PCAs (typically low qty)
Complexity is defined as: Low – No logic involved
i.e. PCI switch boards Medium – some logic
EMS NPI Production
Team.
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 5
Expectation Deliverables Action Item Owner
50% 75% 100%Low 3 days 6 days 7 daysMed 4 days 7days 8 daysHigh 5 days 8 days 10days
involved i.e. Memory, Backplane, Peripheral boards
High – High level logic involved, parts count 2200+
and test nodes 3500+ i.e. I/O, Processor, Host boards
18. Tested PCAs to be shipped to HP with following schedule after the receipt of
“working” test fixture/programs from HP (see item 51 for definition of working ICT
fixture and program)50% within 2 days75% within 5 days
100% within 7 days
EMS NPI Production
Team.
BOM / CAD19.CAD, Gerber, BOM locked and released at
least 5 business days prior to scheduled start (for all PCAs except Highly complex PCAs) Known formats. As much advance notice (1-2 days) as possible is needed for
new formats so that a parser can be created.
Data files to be encrypted and released to EMS
HPQ Program teams
20. CAD, Gerber, BOM locked and released at least 7 business days prior to scheduled
start for Highly complex PCAs,
Data files to be encrypted and released to EMS
HPQ Program teams
21. EMS should use EDB format for BOM ONLY when there is an upper level
assembly (mechanical parts) involved.
EMS PM, PE and Records Department
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 6
Expectation Deliverables Action Item Owner
22. HPQ to provide mechanical drawings for the 2nd assembly operation to EMS at least 3 business days prior to start of PCA build
Mechanical drawings HPQ Program teams
23. HPQ to communicate 6-8 weeks in advance the process requirement for
unique component to EMS (e.g. VHDM, BGAs)
Provide component spec or process requirements
HPQ NPI Engineering
24. All the part numbers on the BOM should have associated reference designators.
HPQ Program teams
25. No bogus part numbers on the BOM allowed. If HPQ part numbers are not
available (including off-line programmed parts), use the PCA # with dash number as
5xx (eg 010391-501)
Only valid HPQ part numbers on the BOM
HPQ Program teams
26. EMS to provide a parser for duplicate part numbers or a process to combine them on
the BOM before parsing
EMS will process EM’s on an internal Special
Instruction Process.
EMS Records Dept
27. Exception memo for the purpose of making changes to an NPI build to have a standard
HP format
Attached format HPQ Program teams
28. Exception memo to be provided to EMS at least 24 hrs prior to schedule start of the
PCAs
EM to be released EMS will process EM’s on an internal Special
Instruction Process.
HPQ Program teams
29. Exception Memo to be provided to HP internal teams (Test, NPI & Procurement
engineering) at the same time it is provided to EMS
EM to be distributed to “ISSG EM Distribution” list
HPQ Program teams
30. Identify the programmed parts (ICT), socketed parts, off-line programmed parts
on Exception memo
Edited EM for ICT / offline programmed parts
HPQ Program teams
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 7
Expectation Deliverables Action Item Owner
31. For off-line programmed parts, HPQ to release Hex code, AVL info for the blank and checksum at least 5 business days prior to the start of the PCA build so as to complete first articles and get HPQ approval of the programmed device(s).
EMS will deliver 1st article to HPQ for approval within 3 business
days provided the supplier being used for programming can obtain
the blanks.
HPQ to provide 1st article approval/reject within the
same day of receipt.
HPQ program teams/
EMS NPI Materials Team
32. EMS to provide real time support for CAD layout and checking prior to ordering tools – i.e., stencils, etc.
Timely / regular reviews of PCAs. All DFx input prior to 3 business days before final check during
database release process
EMS
33. PCB suppliers to provide DFm review at each gerber release
Timely / regular documented reviews of PCBs by production supplier within 5 business days
Corp PCB Procurement
34. HP to provide PCA New Product Introduction readiness checklist to EMS at least 5 business days prior to scheduled
start of the PCA build
HPQ NPI Process
Engineering
35. PCB order checklist complete prior to release of PCB artwork
Checklist signed off HP teams
36. HPQ to provide a central repository/server with FTP link for EMS to access data /
documentation
HPQ to investigate the feasibility On Going – iSDP HPQ / EMS
37. EMS should provide build reports within 5 business days from the completion of 75%
of the scheduled PCA quantities
Build report should include but not limited to process issues, DFx issues, process yields, test
yields, root cause analysis, program risk etc. See attached
sample report.
EMS NPI Engineering
Team
38. EMS should provide reports/feedback on logistics (i.e. material, schedule etc) issues to program teams within 5 business days of
PCA build start(Do not include in build reports)
An E-mail from EMS within 5 days of PCA build start
EMS NPI Materials Team
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 8
Expectation Deliverables Action Item Owner
Test (FP – Flying Probe)39. Artwork will be approved to Test
Engineering resources before PCB check is complete and released to PCB vendor
Artwork HPQ Program teams
40. Schematics and BOM with correct Reference designators will be supplied to Test Engineering at PCB order 7 working
days prior to build for all PCAs except Highly Complex where this requirement is
10 days.
SchematicsBOM
PDF format . BOM format
HPQ Program teams
41. Quote and Purchase order placed & maintained for test services
Purchase Order HPQ Test Engineering
42. Flying Probe Program (debugged) delivered with following schedule after
Receipt of 1st PCA Low complexity – 1 Business day Medium Complexity – 2 Business days High Complexity – 3 Business days
Flying Probe Program EMS NPI Test Engineering
43. Flying Probe machine to be made available within the same area of NPI
Currently, no plan to have FP within NPI. Will be
available on site due to the lack of builds requiring FP.
44. EMS to provide Testability Design guidelines
Test (ICT)45. Artwork will be approved to Test
Engineering resources before PCB check is complete and release to PCB vendor
Artwork HPQ Program teams
46. Schematics & BOM with correct Reference designators will be supplied to Test
Engineering at PCB order 7 working days prior to build for all PCAs except Highly Complex where this requirement is 10
SchematicsBOM
PDF format. BOM format
HPQ Program teams
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 9
Expectation Deliverables Action Item Owner
days. 47. A mechanical sample of the PCA will be
supplied to Test Engineering at PCB order 7 working days prior to build for all PCAs
except Highly Complex where this Requirement is 10 days.
Previous rev / run fully populated PCAs
HPQ Program teams
48. Initial program complete and Test fixture ordered 5 working days prior to build for all PCAs except Highly Complex where this
requirement is 10 days
Initial ICT Code Fixture Ordered HPQ Test Engineering
49. At least 5 Golden PCAs to be made available to HP within 3 days (highly
complex within 5 days) of start of PCA build to support test development.
100 % of 5 PCAs to go thru visual, AOI, X-ray inspection.
Coverage should include but not limited to all PTH, BGAs etc
EMS Test Document: EMS NPI Production
Team
50. EMS to provide AXI/AOI guidelines51. Debugged ICT program 4 working days
after receipt of first “GOLDEN” PCA except Highly Complex where this requirement is
10 days
Working ICT is defined as a fixture that has successfully passed agreed
upon quantity of "golden boards." When fixture is returned or used at
the NPI site it is the expectation from HPQ to have ICT Engineering from the contract manufacturer to provide the first level of debug and maintenance. HPQ will also provide
the list of tested and untested components to the contract
manufacturer at commencement of each NEW BUILD. If and when there are issues that can not be
successfully resolved by the contract manufacturer due to
software/hardware issues, HPQ will get involved. The assumption is that
the contract manufacturer has eliminated ALL process issues.
HPQ/ EMS Test Engineering
52. 100% of remaining PCAs need to have PCAs to go thru visual, AOI, EMS to provide a proposal EMS
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 10
Expectation Deliverables Action Item Owner
Visual, AOI/Xray analysis done prior to final shipment.
X-ray inspection.Coverage should include but not
limited to all PTH, BGAs etc
to HPQ – see above EMS Test Document
Test (FBT – Functional Board Test)53. All the PCAs need to have passed either
the Flying Probe or the ICT requirement before FBT will be made available.
Completion of Flying Probe or Completion of ICT
EMS to perform Flying Probe or ICT before the
FBT station
EMS
54. All IUR (Internal User Orders) requirements fulfilled or a minimum of 3 functional sets of
PCAs with all necessary, cables, power supplies, processors, etc to be supplied to
Test Engineering a minimum of 6 weeks with a preference of 8 weeks before
expected date of service for Pilot
Necessary PCAs, Cables, processors, power supplies
HPQ Program teams
55. Appropriate System level specification, block diagram and theory of Operation Supplied, Schematics, and Access to
Design’s Shared File location 8 weeks prior to expected date of service. Access to
appropriate design resources.
Access to information HPQ Program Teams
56. Design, Build and Debug Prototype/Pilot test Equipment. Validate equipment
against Diagnostics before shipment of fixtures to site.
Competed Functioning Validated Test Equipment
Designs. ATEs/Hmus to supply to sites.
HPQ Test Engineering
Team
57. If HP is unable to validate test equipment before shipment. Supply adequate and
technically enable resources to handle this at supplier end. First level of responsibility
is HP’s
Validated Test EquipmentSupply adequate and technically
enabled resources.
EMS Test Engineering
Team
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 11
Expectation Deliverables Action Item Owner
58. Supply adequate resources to trouble shoot Test Equipment or PCA issues. Supply
adequate communication to HP Corporate Test Engineering for Problem resolution
Supply adequate and technically enabled resources.
EMS Test Engineering
Team
Test (Run-in)59. All the PCAs need to have passed all
previous test steps.Completion of all previous tests. EMS NPI
Production Team
60. Validate Run-IN Diagnostics at HP before placing Requirement for RUN-IN on
Supplier.
Validated Diags HPQ Test Engineering
61. If HP is unable to validate diags EMS to assist in Diag validation. Supply adequate
and technically enabled resources to handle this at supplier end. First level of
responsibility is HP’s
Supply adequate and technically enabled resources. Supply adequate communication to
resolve issues.
EMS Test Engineering
Team
Packaging
62. HP to provide packaging information highlighting the requirement.
HPQ to discuss internally with design engineering and
packaging group
HPQ Program teams
63. If EMS is to provide packaging solution, provide PCA samples to EMS at least 3
weeks prior to the start of the PCA
PCA Samples to EMS. EMS to provide packaging samples
HPQ / EMS
Shipping64. HP to identify the PCA shipment
information identifying contact, phone, address, carrier etc and provide this info to
EMS
HPQ Program teams
65. EMS to provide the shipping information with tracking number to HP by 10 AM EST
the following day.
EMS
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 12
Expectation Deliverables Action Item Owner
General66. At the time of scheduling PCA build with
EMS, communicate the PCA test (FP, ICT, FBT) requirements
# of boards and complexity will determine the type of test
HPQ Program teams
67. HPQ to provide the contact list of employees to EMS NPI 24 hrs in advance
of their visit to EMS with the function defined
HPQ
68. EMS to communicate on a daily basis the status of the build to HPQ teams, including but not limited to WIP, build, test, schedule
etc
Daily e-mail and/or WIP report
69.H
HPQ to provide report card to EMS for each build within 5 business days of the
completion of the build and receipt of build report from EMS
Report Card HPQ to provide sample report card to EMS for
review
HPQ NPI Team
70. EMS should submit final DFm / DFt /DFSC feedback to HPQ for approval and
incorporation into the NPIR as a step 3 gate
Final DFm / DFt reports to HPQ Process engineering /
Procurement engineering
EMS
Scheduling71. Any factory / line downtime, materials
issues, resources issues need to be communicated immediately to HP program
teams.
Contact HPQ Program Coordinator or Procurement
Engineering via phone, pager and follow-up with email.
EMS Program Management or
Engineering Team
72. HP to provide updated PCA build schedule once a week to EMS
PCA build schedule HPQ to provide upcoming 6 months schedule
HPQ Program teams
73. EMS to feedback to HPQ confirming the schedule within 1 business day for
immediate need and within 3 business days for subsequent PCA builds
PCA build schedule EMS Program Management
Team
Process
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 13
Expectation Deliverables Action Item Owner
74.EMS to provide the rework/repair capability for BGAs
Rework profiles and yield EMS NPI Production and
Engineering Team
75. HPQ to provide non-functional PCAs to EMS for thermal profile development.
Sample PCAs HPQ / EMS
Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 14
Appendix: A
General SMT material attrition guideline:
* Additional 100 pcs + 2% if description contains:Res ChpRes VarCap ChpFerrite beadPackaged: 0402, 0603, 0805, 1206, 1210
* Additional 30 pcs + 2% if description contains:Cap, TantPackages: 18182, 2010, 2512, 3216SOTSMT LED
* Additional 10 pcs if description contains:RADAXLPTHIcs
Note: BGAs and unique chipsets may be an exception
Appendix: BEMS = Environmental Management System