fusion improvement
DESCRIPTION
TRANSCRIPT
LTX
QR
M S
ep
.2002--
1
Fusion's status
CS.Tu
FUSION in PHILIPS 2
• Introduction of Fusion in Philips
• MTBBF V.S DOA/DUW
• Fault rates of PECHF and SMS
• Improvement Actions 2004 & 2005
• Bottle neck on Fusion.
Agenda
FUSION in PHILIPS 3
Introduction of Fusion in Philips
• Installed base :
Fusion HF x 41 , DH x 31 & DM x10.
• Configurations DH :
VX250(320ch), Baseline 1 , 2 &3, SMS_Hr (2), HS (2) ch,DPS(10) and AP(16).
• Configurations DM :
VX250(256), DPS(10).
FUSION in PHILIPS 4
MTBBF V.S DOA/DUWFusion MTBBF
0
200
400
600
800
1000
Q1'04 Q2'04 Q3'04 Q4'04 Q1'05
Q1'04 Q2'04 Q3'04 Q4'04 Q1'05
MTBBF 775 684 722 581 443
0
10
20
30
40
50
60
70
2003 2004 Q4'04 Q1'05
• Fusion HF is more sensitive then other plate forms to power cut. (Q4’04 response to Q1’05 + A great impact on LTX )
• 0185-01(PSCM) issue : Wrong action from LTX SG repair house.
• Take too much time to verify parts returned from LTX. (DOA)
DUW : fault before 90 days.DOA : fault before 13
days.2003 2004 Q4'04 Q1'05
DOA 45 22 3 25DUW 22 33 10 24
hrsea
FUSION in PHILIPS 5
0
50
100
150
200
250
300
350
400
450
500
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
Total 22 33 29 473
Rates% 3.95% 5.92% 5.21% 84.92%
DOA DUW PRE R&R
• 2005 Jan~May failures status.
• DOA 8.1%; DUW 12.0%
• High usage and failure rates come from application pcf5212/3 & om6384.
• 2004 ‘s failures status.
• 2004’s average planning ~94% < 2003’s
• DOA 3.95%; DUW 5.92%.
0
50
100
150
200
250
300
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
Total 29 43 12 265Rates% 8.1% 12.0% 3.4% 74.2%
DOA DUW PRE R&R
DOA/DUW Rates
2005 2004
FUSION in PHILIPS 6
TITL Fusion Board Usage Summary
Y05 MTBBF Goal=1400
Note: MTBBF including DOA parts.
Fusion Board Usage and MTBBF
1440
1275
812
744
0
3
6
9
12
15
18
Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
# of
boa
rds
600
900
1200
1500MTBBF
pwr sply pechf tsint farmnt dscm sms opt ctmu opt
others cooler MTBBF
Part Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Summary %
pechf 4 4 3 2 13 40.63
pwr sply 1 1 1 1 4 12.50
tsint 1 1 1 3 9.38
cooler 1 2 3 9.38
farmnt 2 2 6.25
dscm 2 1 3
sms opt 2 2
ctmu opt 1 1 others 1 0 1DOA 0 0 2 0 2 6.25Usage 11 12 3 3 29
Total 11 12 5 4 0 0 0 0 0 0 0 0 32MTBBF 812 744 1275 1440
FUSION in PHILIPS 7
Fault rates of PECHF and SMS
• SMS digital & SMS Hr become the top faults in PSK.
• 95% of SMS dig , SMS Hr fail are related to OM6384 & PCf5212/3.
0
10
20
30
40
50
60
2002 2003 2004 Q4'05 Q1'05
SMS Faults
Year 2002 2003 2004 Q4'05 Q1'05
SMS Faults 26 48 58 13 26
In Q1 we get 26 ea. DOA x 2DUW x 5
ea
Part NumberDOA DUW PRE R&RGrand Total
Failure Rates/installed base
865-7393-03 5 1 34 40 5.3%
865-2728-03 2 5 1 18 26 21.7%
865-7313-04 3 3 22 28 3.7%
865-1545-01 2 1 10 13 6.5%
865-2749-01 2 1 6 9 15.0%
FUSION in PHILIPS 8
0
10
20
30
40
50
60
0
20
40
60
80
100
120
140
160
180
board failures'03 49 43 40 48 48 56 31 29 43 37 35 29
board failures'04 37 26 33 29 36 40 45 45 48 30 30 43
Repair Price'03 170 134 141 138 148 143 101 105 121 134 113 95
Repair Price'04 121 74 97 91 110 110 154 141 149 70 107 109
Jan. '03Feb. '03Mar. '03Apr. '03 May '03 Jun. '03 Jul. '03 Aug '03Sep. '03Oct. '03 Nov '03Dec. '03
Failure & Repair Price(KUSD)
(EA)
FUSION in PHILIPS 9
Improvement Actions Related to Cost
• Evaluation of LTX new PECHF relay
• Looked for local service : Buying LCD instead of CRT, Snubbors, flower sensors. (CRT : Transportation + repair cost = nt 14xxxx + usd $800 )
• Heat-exchanger local solution.
• Look for consumable parts from local vendor.
• Repair PSCM, THBUF.
FUSION in PHILIPS 10
Evaluation of LTX new PECHF relay
newold
• 60% of PECHF fault causes are related to relay’s reliability.
• The results after the evaluation of LTX new PECHF relay.
Failure rate of PEC’s was slightly higher on the ZTR tester through 3 months.
Replacing all relays during repair does not improve reliability.
LTX have already implemented the above measures in repair.
FUSION in PHILIPS 11
Heat-exchanger local solution
• Purpose of request : To get stable temperature(17 centigrade ) + Cost saving.
• Real status in use : Same function as origin.
• Getting from LTX is (USD): $5900/ea
• Buying from local vendor is NT 5XXX/ 2ea
FUSION in PHILIPS 12
Bottle Necks On Fusion
• Hardware and software upgrade frozen.
• NPF (No Problem Found) control.
• DFCP control.
FUSION in PHILIPS 13
Items PSK TITL
Mix-Signal DH & Pure Dig DM (3:1) Pure Digital Tester.
Baseline3 VX250. Baseline 5 VX250 above.
TC and VME crate. 4 x pattern load.
AXMP + SunBlade 2500.
Solaris 7 Solaris 7
enVission++ R10.8.4.5.2enVission++ R12.x
Service Labor service Buy on site.
MTBBF 650 H/B (DOA 13days, DUW 90 days)1000 H/B (DOA = DUW = 90 days)
Parts 100% parts rent from Vendor. Partial parts rent from Vendor
Improvement Actions D.I.Y & Partial actions from Vendor. 90% control by Vendor.
H/W configuration
Software
PSK V.S.TI
(upgrade frozen)
(upgrade frozen)
(upgrade frozen)
(upgrade frozen)
FUSION in PHILIPS 14
DFCP in Q1’05
• DFCP: Device Fail Check Pass.
Order quantity (ea)
Failure status 05-01 05-02 05-03 05-04 Grand Total
CFDF 1 1
DFCF 64 38 37 58 197
DFCP 2 3 5 10
DPCF 27 23 12 13 75
DPCP 2 2
Recalibration 3 3
Grand Total 96 62 52 78 288
Month
FUSION in PHILIPS 15
FUSION in PHILIPS 16
5622
2633
946
14729
574473
0 100 200 300 400 500 600
DOA
DUW
ECO
PRE
R&R
2004
2003
Failures 2004 V.S 2003
FUSION in PHILIPS 17
765501
2721
5125
798648
0 100 200 300 400 500 600 700 800
DFCF
DFCP
DPCF
Grand Total
2004
2003
2004 501 21 125 648
2003 765 27 5 798
DFCF DFCP DPCF Grand Total
Failures Status in 2003 & 2004
FUSION in PHILIPS 18
High Failures Sorting in 2003 & 2004
Sum of Orderquantity
Part number DOA DUW ECO PRE R&R Grand Total865-7393-03 12 8 164 184865-7393-05 1 7 46 8 62865-7313-04 4 47 51865-2728-03 3 2 5 35 45865-2080-00 2 17 19865-2728-02 1 1 11 13
2004 Service CodeSum of Order
quantity
Part number DOA DUW ECO PRE R&R Grand Total
865-7393-03 17 5 19 152 193865-7313-04 6 1 60 67865-2080-00 5 4 57 66865-2728-03 2 2 16 19 39865-1533-01 27 27858-0213-01 2 2 10 9 23
2003 Service Code
FUSION in PHILIPS 19
Failure Status in 2003 & 2004
5622
2633
946
14729
574473
0 100 200 300 400 500 600
DOA
DUW
ECO
PRE
R&R
2004
2003
FUSION in PHILIPS 20
Vacuum Pump + Reservoir
• Purpose of request :
Prevent probe card from being damaged.
• Real status in use :
1. Charge the reservoir first. (it need 30 sec)
2. Keep –650 psi in reservoir.
3. It will hold 20 seconds when power cut or air lost.