product realization flow chart - sahasra … flow chart_revb.pdf · customer product requirements...

Customer ProductRequirements

InputCustomerRFQ /PO

Contract Review

RepeatProducts

OrderAcceptance

ProductionControl

PurchasingDocument

ControlSales

AccountingEngineering

Scheduling Send Completed copy of OrderAcknowledgement to customer

New Product

Quoting

Pre-QuoteMeeting

Send Quote to Customer forReview

N0

5.2 Customer Focus5.4 Planning7.1 Planning of ProductRealization7.2 Customer Related Process

Quoting/OrderAcceptance and review of

PO Process

CONTRACT REVIEW

Approved and ScheduledProduction OUTPUT

Input(Approved BOM )

Turnkey

Parts ShortagesReport (MRP

Data Base)

Place Parts Order(AVL)

SupplierAcceptsOrder

AlternateComponents RequestRequired

Alternate ComponentsRequest to Customer

NO

YES

NO

YES

Completed MaterialOrders OUTPUT

CustomerSuppliedMaterials

5.2 Customer Focus5.4 Planning7.4 Purchasing

Purchasing Process

No

Yes

PURCHASING

INPUT( Received Raw

Material)

Preservation& DeliveryProduct ID &Trace ability

Moisture SensitiveDevices

ESD Procedure

VerifyQuantities& Verify

to AVL

IQC

Preservation

KitRelease

Control ofNon-Confor

mingProducts

5.2 Customer Focus5.4 Planning8.3 Control of Non-ConformingProducts

Receiving Process

No

Yes

No

Yes

Completed & VerifiedKit OUTPUT

MaterialReceiving

SMT WorkInstructions

SMT Build WorkInstructions

( Print & PlacementProgram )

First Article Run

FirstArticle

Validation

Production Release

Pre-reflowInspection/Tweaking

Re-flow Profile WorkInstructions

Post Re-flow workinstructions

PCBCleaningRequired

PCBCleaning

Post CleaningWork

instructions

SMT Rework

NonConfirming

Control of NonConfirming

Products

Completed Assemblies ready forPth,mounting or Shipping

OUTPUT

YES

NO YES

NO

NO

Yes

NO YES

NO

YES

5.2 Customer Focus7.2 Customer Related Process7.5 Production8.2 Monitoring & Measurement8.3 Control of Non ConfirmingProducts8.5 Improvement

Surface Mount ProductionProcess

VI AOI

AXI

Surface Mount Production

Preparation WorkInstructions

FirstPiece/Validation

ManualPthParts

PopulationPth mounting

WorkInstructionsProduct ID &Traceabilty

ESD Procedure

Board Masking

FirstArticle

WaveSoldering

Wave SolderingWork

InstructionsESD Procedure

FirstPiece/Validation

ProductionRelease

FinalTouch-up/PTH

Final Cleaning

Completed Assemblies ready for FinalVisual Inspection & testing

DevicesRequired Off-

Line CodesProgramming

Off-Line codesProgramming

WorkInstructions

Off-LineCodes

ProgrammingDevice ID &Traceabilty

Moisture SensitiveDevices

ESD Procedure

ChecksumVerifications

Completed KitOUTPUTControl of

Non-Conforming

5.2 Customer Focus5.4 Planning8.3 Control ofNon-Conforming Products

Off-Line CodesProgramming

Off-Line Codes Programming

5.2 Customer Focus7.2 Customer Related Process7.5 Production8.2 Monitoring &Measurement8.3 Control of Non ConfirmingProducts8.5 Improvement

Pth ProcessPth mounting WorkInstructions

Through Hole Preparation & Mounting

INPUT( Populated assemblies)

In circuit Testingwork

InstructionsRe-work

RejectControl of

Non-ConfirmingProducts

Sample Inspection Re-work

RejectControl of

Non-ConfirmingProducts

ICTRequired

5.2 Customer Focus7.2 Customer Related Process7.5 Production8.2 Monitoring &Measurement8.3 Control of Non ConfirmingProducts8.5 Improvement

ICT & Visual InspectionProcess

In-Circuit Testing

Completed & Inspected assemblies ready for FunctionalTesting/Conformal Coating/Epoxy Potting/Shipping

Test WorkInstructions

PassTest

FinalQC WorkInstructions

100% VisualInspection Work

Instructions

Non-Confirming

Control ofNon-Confirming

Products

PTH Rework/SMT Rework

Test ProcedureWork

InstructionsProduct ID &Trace ability

ESD ProcedureCalibration

Training

PCBA ready for Conformal Coating/EpoxyPotting/Shipping

5.2 Customer Focus7.2 Customer Related Process7.5 Production7.6 Control of monitoring &measurement systems8.2 Monitoring &Measurement8.3 Control of Non ConfirmingProducts8.5 Improvement

Functional Testing

Functional Testing

ConformalCoating

Required

ConformalCoating WorkInstructions

Procedure WorkInstructionsProduct ID &Traceability

ESD ProcedureTraining

IstPiece

EpoxyPotting

Epoxy PottingWork

Instructions

Procedure WorkInstructionsProduct ID &Traceability

ESD ProcedureTraining

IstPiece

Release Production Release Production

100% VisualInspection Work

Instructions

100% VisualInspection Work

Instructions

YES YES

YES YES

Rework Rework

NO NO

NO NO

5.2 Customer Focus7.2 Customer Related Process7.5 Production8.2 Monitoring &Measurement8.3 Control of Non ConfirmingProducts8.5 Improvement

Special Process

Completedassemblies for

Shipping

NO

Conformal Coating/Epoxy Potting

Customer SpecificInstructions

Packaging &Delivery

Packaging &Delivery WorkInstructions

Product ID & Traceability

ESD ProcedureTraining

Preservation &delivery WorkInstructions

ShippingProfile

Final Product is packaged& Ready for delivery

5.2 Customer Focus7.2 Customer Related Process

Shipping

Shipping

Customer Feedback

YES

YES

YES

YES

YES

YES

YESYES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

PRODUCT REALIZATION FLOW CHART

SEPL Product Realization ChartCreated Date: November,01,2009Rev: ACreated By: Parvez A. Khan

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