kic 24/7 final report
DESCRIPTION
KIC 24-7 is a real-time monitoring system dedicated to assuring product quality. The system has been designed to watch the reflow process in real time, alarming when parameters fall outside of specification. The KIC 24-7 system is also designed to provide tracking and tracing all products that are produced on our reflow ovens whether for quality assurance or for customer satisfaction in determining what occurred for a given product at a specific time. Measure the KIC 24/7 accuracy as stated above. measure repeatability of the system This report summarizes the findings of a recently conducted acceptance testing performed by the technology group in Monterrey during March 2005. The purpose was to validate the accuracy of KIC 24-7 in tracking changes in the oven characteristics that could affect the quality of production.TRANSCRIPT
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
1 of 25
Table of Contents:
1. Introduction… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .… 2 2. Evaluation scop… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .… .2 3. Purpose of Evaluation… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … ...2 3.1. Evaluation procedure… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .… 2 4. R&R results using MINITAB… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .… .3 4.1 R&R study sumary report chart… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … ...20 5. Study R&R conclusions… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .25 6. Special issue… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 25 Version History… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … ..… .26
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
2 of 25
KIC 24-7 Evaluation
1. Introduction
KIC 24-7 is a real-time monitoring system dedicated to assuring product quality. The system has been designed to watch the reflow process in real time, alarming when parameters fall outside of specification. The KIC 24-7 system is also designed to provide tracking and tracing all products that are produced on our reflow ovens whether for quality assurance or for customer satisfaction in determining what occurred for a given product at a specific time.
2. Evaluation scope
? ? Evaluate Repeatability of the KIC 24/7 system ? ? Perform R & R studies of the KIC 24/7 system ? ? Evaluate the trace ability option. ? ? Ability to record profile, profile specs, and process CPK for each production board processed
3. Purpose of Evaluation Measure the KIC 24/7 accuracy as stated above. measure repeatability of the system This report summarizes the findings of a recently conducted acceptance testing performed by the technology group in Monterrey during March 2005. The purpose was to validate the accuracy of KIC 24-7 in tracking changes in the oven characteristics that could affect the quality of production.
3.1. Evaluation procedure
Once the KIC 24 /7 is installed and a profile for a given product is optimized (baseline profile or Virtual Profile), the idea is to load the Virtual Profile, then run several KIC 2000 profiles with the same PCB used to create the baseline profile through the oven.
•Soak Time •Preheat ramp rate •Reflow Time •Peak temperature •Cooling ramp rate
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
3 of 25
4 R&R results using MINITAB
REPORT FOR COMPONENT N700 (BGA) Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 0.485 0.0970000 58.2 0.000 Repeatability 12 0.020 0.0016667 Total 17 0.505 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0016667 4.98 Repeatability 0.0016667 4.98 Part-To-Part 0.0317778 95.02 Total Variation 0.0334444 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.040825 0.24495 22.32 Repeatability 0.040825 0.24495 22.32 Part-To-Part 0.178263 1.06958 97.48 Total Variation 0.182878 1.09727 100.00 Number of Distinct Categories = 6
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
2.4
2.2
2.0
Part
Sam
ple
Ran
ge
654321
0.12
0.08
0.04
0.00
_R=0.05
UCL=0.1287
LCL=0
Part
Sam
ple
Mea
n
654321
2.4
2.2
2.0
__X=2.35UCL=2.4012
LCL=2.2988
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Max. Raising Slope by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Max. Raising Slope
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
4 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 0.22 0.0440000 26.4 0.000 Repeatability 12 0.02 0.0016667 Total 17 0.24 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0016667 10.56 Repeatability 0.0016667 10.56 Part-To-Part 0.0141111 89.44 Total Variation 0.0157778 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.040825 0.244949 32.50 Repeatability 0.040825 0.244949 32.50 Part-To-Part 0.118790 0.712741 94.57 Total Variation 0.125610 0.753658 100.00 Number of Distinct Categories = 4
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
-3.2
-3.4
-3.6
Part
Sam
ple
Ran
ge
654321
0.12
0.08
0.04
0.00
_R=0.05
UCL=0.1287
LCL=0
Part
Sam
ple
Mea
n
654321
-3.3
-3.4
-3.5
-3.6
__X=-3.4667UCL=-3.4155
LCL=-3.5178
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Max. Falling Slope by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Max. Falling Slope
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
5 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1654.21 330.842 874.473 0.000 Repeatability 12 4.54 0.378 Total 17 1658.75 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.378 0.34 Repeatability 0.378 0.34 Part-To-Part 110.155 99.66 Total Variation 110.533 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.6151 3.6905 5.85 Repeatability 0.6151 3.6905 5.85 Part-To-Part 10.4955 62.9727 99.83 Total Variation 10.5135 63.0808 100.00 Number of Distinct Categories = 24
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
60
50
40
30
Part
Sam
ple
Ran
ge
654321
2
1
0
_R=0.983
UCL=2.531
LCL=0
Part
Sam
ple
Mea
n
654321
60
50
40
30
__X=37.42UCL=38.43LCL=36.42
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Soak Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Soak Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
6 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1929.75 385.950 5184.40 0.000 Repeatability 12 0.89 0.074 Total 17 1930.64 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.074 0.06 Repeatability 0.074 0.06 Part-To-Part 128.625 99.94 Total Variation 128.700 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.2728 1.6371 2.41 Repeatability 0.2728 1.6371 2.41 Part-To-Part 11.3413 68.0478 99.97 Total Variation 11.3446 68.0675 100.00 Number of Distinct Categories = 58
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
70
60
50
40
Part
Sam
ple
Ran
ge
654321
1.2
0.8
0.4
0.0
_R=0.467
UCL=1.201
LCL=0
Part
Sam
ple
Mea
n
654321
70
60
50
40
__X=54.64UCL=55.12LCL=54.16
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Reflow Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Reflow Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
7 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1010.38 202.077 2408.86 0.000 Repeatability 12 1.01 0.084 Total 17 1011.39 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0839 0.12 Repeatability 0.0839 0.12 Part-To-Part 67.3310 99.88 Total Variation 67.4149 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.28964 1.7378 3.53 Repeatability 0.28964 1.7378 3.53 Part-To-Part 8.20555 49.2333 99.94 Total Variation 8.21066 49.2639 100.00 Number of Distinct Categories = 39
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
256
248
240
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.517
UCL=1.330
LCL=0
Part
Sam
ple
Mea
n
654321
256
248
240
__X=245.62UCL=246.15LCL=245.09
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Peak Temp by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Peak Temp
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
8 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 3304.79 660.959 3801.04 0.000 Repeatability 12 2.09 0.174 Total 17 3306.88 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.174 0.08 Repeatability 0.174 0.08 Part-To-Part 220.262 99.92 Total Variation 220.435 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.4170 2.5020 2.81 Repeatability 0.4170 2.5020 2.81 Part-To-Part 14.8412 89.0473 99.96 Total Variation 14.8471 89.0824 100.00 Number of Distinct Categories = 50 Gage R&R for Tot Time above 230
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
60
40
20
Part
Sam
ple
Ran
ge
654321
2
1
0
_R=0.767
UCL=1.974
LCL=0
Part
Sam
ple
Mea
n
654321
60
50
40
30
__X=39.73UCL=40.52LCL=38.95
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Tot T ime above 230 by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Tot Time above 230
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
9 of 25
REPORT FOR SOT Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 0.926667 0.185333 166.8 0.000 Repeatability 12 0.013333 0.001111 Total 17 0.940000 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0011111 1.78 Repeatability 0.0011111 1.78 Part-To-Part 0.0614074 98.22 Total Variation 0.0625185 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.033333 0.20000 13.33 Repeatability 0.033333 0.20000 13.33 Part-To-Part 0.247805 1.48683 99.11 Total Variation 0.250037 1.50022 100.00 Number of Distinct Categories = 10
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
2.6
2.4
2.2
2.0
Part
Sam
ple
Ran
ge
654321
0.10
0.05
0.00
_R=0.0333
UCL=0.0858
LCL=0
Part
Sam
ple
Mea
n
654321
2.6
2.4
2.2
2.0
__X=2.4UCL=2.4341LCL=2.3659
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Max. Raising Slope by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Max. Raising Slope
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
10 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 0.591111 0.118222 53.2 0.000 Repeatability 12 0.026667 0.002222 Total 17 0.617778 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0022222 5.43 Repeatability 0.0022222 5.43 Part-To-Part 0.0386667 94.57 Total Variation 0.0408889 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.047140 0.28284 23.31 Repeatability 0.047140 0.28284 23.31 Part-To-Part 0.196638 1.17983 97.24 Total Variation 0.202210 1.21326 100.00 Number of Distinct Categories = 5
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
-4.0
-4.2
-4.4
-4.6
Part
Sam
ple
Ran
ge
654321
0.15
0.10
0.05
0.00
_R=0.0667
UCL=0.1716
LCL=0
Part
Sam
ple
Mea
n
654321
-4.0
-4.2
-4.4
-4.6
__X=-4.2889UCL=-4.2207
LCL=-4.3571
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Max. Falling Slope by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Max. Falling Slope
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
11 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 2443.03 488.606 1282.06 0.000 Repeatability 12 4.57 0.381 Total 17 2447.60 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.381 0.23 Repeatability 0.381 0.23 Part-To-Part 162.742 99.77 Total Variation 163.123 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.6173 3.7041 4.83 Repeatability 0.6173 3.7041 4.83 Part-To-Part 12.7570 76.5421 99.88 Total Variation 12.7719 76.6317 100.00 Number of Distinct Categories = 29
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
60
50
40
30
Part
Sam
ple
Ran
ge
654321
2
1
0
_R=0.983
UCL=2.531
LCL=0
Part
Sam
ple
Mea
n
654321
60
50
40
30
__X=40.06UCL=41.07LCL=39.06
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Soak Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Soak Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
12 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 2081.99 416.397 1972.41 0.000 Repeatability 12 2.53 0.211 Total 17 2084.52 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.211 0.15 Repeatability 0.211 0.15 Part-To-Part 138.729 99.85 Total Variation 138.940 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.4595 2.7568 3.90 Repeatability 0.4595 2.7568 3.90 Part-To-Part 11.7783 70.6699 99.92 Total Variation 11.7873 70.7236 100.00 Number of Distinct Categories = 36
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
80
70
60
50
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.7
UCL=1.802
LCL=0
Part
Sam
ple
Mea
n
654321
80
70
60
50
__X=63.23UCL=63.95LCL=62.52
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Reflow Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Reflow Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
13 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1029.72 205.945 2246.67 0.000 Repeatability 12 1.10 0.092 Total 17 1030.82 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0917 0.13 Repeatability 0.0917 0.13 Part-To-Part 68.6176 99.87 Total Variation 68.7093 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.30277 1.8166 3.65 Repeatability 0.30277 1.8166 3.65 Part-To-Part 8.28358 49.7015 99.93 Total Variation 8.28911 49.7346 100.00 Number of Distinct Categories = 38
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
260
250
240
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.517
UCL=1.330
LCL=0
Part
Sam
ple
Mea
n
654321
260
255
250
245
__X=252.16UCL=252.69LCL=251.63
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Peak Temp by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Peak Temp
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
14 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 3421.10 684.221 1792.72 0.000 Repeatability 12 4.58 0.382 Total 17 3425.68 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.382 0.17 Repeatability 0.382 0.17 Part-To-Part 227.946 99.83 Total Variation 228.328 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.6178 3.7068 4.09 Repeatability 0.6178 3.7068 4.09 Part-To-Part 15.0979 90.5873 99.92 Total Variation 15.1105 90.6631 100.00 Number of Distinct Categories = 34 Gage R&R for Tot Time above 230
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
80
60
40
Part
Sam
ple
Ran
ge
654321
2
1
0
_R=0.967
UCL=2.488
LCL=0
Part
Sam
ple
Mea
n
654321
70
60
50
40
__X=49.34UCL=50.33LCL=48.35
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Tot T ime above 230 by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Tot Time above 230
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
15 of 25
REPORT FOR CAPACITORS No variation was found in the measurement of Max. Raising Slope Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 0.829444 0.165889 99.5333 0.000 Repeatability 12 0.020000 0.001667 Total 17 0.849444 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0016667 2.95 Repeatability 0.0016667 2.95 Part-To-Part 0.0547407 97.05 Total Variation 0.0564074 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.040825 0.24495 17.19 Repeatability 0.040825 0.24495 17.19 Part-To-Part 0.233967 1.40380 98.51 Total Variation 0.237502 1.42501 100.00 Number of Distinct Categories = 8
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
-3.8
-4.0
-4.2
Part
Sam
ple
Ran
ge
654321
0.12
0.08
0.04
0.00
_R=0.05
UCL=0.1287
LCL=0
Part
Sam
ple
Mea
n
654321
-3.8
-4.0
-4.2
__X=-4.0944UCL=-4.0433
LCL=-4.1456
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Max. Falling Slope by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Max. Falling Slope
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
16 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1809.84 361.968 2246.70 0.000 Repeatability 12 1.93 0.161 Total 17 1811.77 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.161 0.13 Repeatability 0.161 0.13 Part-To-Part 120.602 99.87 Total Variation 120.763 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.4014 2.4083 3.65 Repeatability 0.4014 2.4083 3.65 Part-To-Part 10.9819 65.8914 99.93 Total Variation 10.9892 65.9354 100.00 Number of Distinct Categories = 38
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
60
50
40
30
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.567
UCL=1.459
LCL=0
Part
Sam
ple
Mea
n
654321
60
50
40
30
__X=37.52UCL=38.10LCL=36.94
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Soak Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Soak Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
17 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 2027.70 405.540 5886.87 0.000 Repeatability 12 0.83 0.069 Total 17 2028.53 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.069 0.05 Repeatability 0.069 0.05 Part-To-Part 135.157 99.95 Total Variation 135.226 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.2625 1.5748 2.26 Repeatability 0.2625 1.5748 2.26 Part-To-Part 11.6257 69.7542 99.97 Total Variation 11.6287 69.7720 100.00 Number of Distinct Categories = 62
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
80
70
60
50
Part
Sam
ple
Ran
ge
654321
1.2
0.8
0.4
0.0
_R=0.433
UCL=1.116
LCL=0
Part
Sam
ple
Mea
n
654321
80
70
60
50
__X=60.58UCL=61.03LCL=60.14
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Reflow Time by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Reflow Time
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
18 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 1172.44 234.487 2099.89 0.000 Repeatability 12 1.34 0.112 Total 17 1173.78 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.1117 0.14 Repeatability 0.1117 0.14 Part-To-Part 78.1252 99.86 Total Variation 78.2369 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.33417 2.0050 3.78 Repeatability 0.33417 2.0050 3.78 Part-To-Part 8.83885 53.0331 99.93 Total Variation 8.84516 53.0710 100.00 Number of Distinct Categories = 37
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
260
250
240
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.6
UCL=1.545
LCL=0
Part
Sam
ple
Mea
n
654321
255
250
245
240
__X=249.37UCL=249.99LCL=248.76
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Peak Temp by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Peak Temp
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
19 of 25
Gage R&R Study - ANOVA Method One-Way ANOVA Table Source DF SS MS F P Setup 5 3511.94 702.388 4919.45 0.000 Repeatability 12 1.71 0.143 Total 17 3513.65 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.143 0.06 Repeatability 0.143 0.06 Part-To-Part 234.082 99.94 Total Variation 234.224 100.00 Study Var %Study Var Source StdDev (SD) (6 * SD) (%SV) Total Gage R&R 0.3779 2.2672 2.47 Repeatability 0.3779 2.2672 2.47 Part-To-Part 15.2997 91.7984 99.97 Total Variation 15.3044 91.8263 100.00 Number of Distinct Categories = 57
Perc
ent
Part-to-PartGage R&R
100
50
0
% Contribution% Study Var
Setup875431
75
60
45
30
Part
Sam
ple
Ran
ge
654321
1.5
1.0
0.5
0.0
_R=0.667
UCL=1.716
LCL=0
Part
Sam
ple
Mea
n
654321
75
60
45
30
__X=45.58UCL=46.26LCL=44.90
Gage name:Date of study :
Reported by :Tolerance:Misc:
Components of Variation
Tot T ime above 230 by Setup
R Chart
XBar Chart
Gage R&R (ANOVA) for Tot Time above 230
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
20 of 25
4.1 R&R study sumary report chart
N700 % Cont. % Study Var Categories
Max. Raise Slope 4.98 22.32 6
Max. Falling Slope 10.56 32.5 4
Soak Time 0.34 5.85 24
Reflow Time 0.06 2.41 58
Peak Temp 0.12 3.53 39
Tot Time above 230 0.08 2.81 50
SOT % Cont. % Study Var Categories
Max. Raise Slope 1.78 13.33 10
Max. Falling Slope 5.43 23.31 5
Soak Time 0.23 4.83 29
Reflow Time 0.15 3.9 36
Peak Temp 0.13 3.65 38
Tot Time above 230 0.17 4.09 34
CAPACITOR % Cont. % Study Var Categories
Max. Raise Slope 0 0 8
Max. Falling Slope 2.95 17.19 8
Soak Time 0.13 3.65 38
Reflow Time 0.05 2.26 62
Peak Temp 0.14 3.78 37
Tot Time above 230 0.06 2.47 57
5. Study R&R conclusions
The Variable Gauge R&R Study was performed for three diferents components: BGA, SOT & Capacitor. The procedure was to create 6 differents profile for the oven, those were used as different parts in order to determine if change of differences can be detected by ZIC 24/7 and how much variation is contributing to measurements.
According with KIC 24/7 capabilities, it was selected 6 variables that this gage provide information: Maximun Raise Slope, Maximum Falling Slope, Soak Time, Reflow Time, Peak Temp, Total Time above 230?. Just to mention, traditionally the focus for Oven Reflow Process Control is Reflow Time & Peak Temp. It was not used any Process Window defined as a Tolerance, so, results are calculated based upon predicting 6 sigmas as is required in version 3.0 of MSA (Measure System Analysis).
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
21 of 25
Acceptance criteria table for Gage R&R Studys is:
% Contribution % Study Variation Distinct Categories
Measurement System is acceptable < 5 % < 10% > 10
May be accepted based upon importance of application, cost of
gage, cost of repairs 5 % to 15 % 10% to 30 % 4 to 9
Measurement System needs improvement
> 15 % > 30 % < 4
BGA results shows that there are not issues for Soak Time, Reflow Time, Peak Temp, and Total Time above 230?, all of them are under 10% of Study Variation. Nevertheles , for Max.Raise Slope is 22.32% and for 32.5% for Maximum Falling Slope. Reason for these is that that set-up provide to the oven don’t make too much differences between slopes: Max. Raise Slope range is 0.5 and Maximum Falling Slope is 0.4, so typacally Slopes are in range of 0 - 8 ?/sec. Based on the other variables results, we can make the inference that there is not issues with ZIC 24/7 and is acceptable to measure BGA’s Component profiles.
SOC Results shows that there are not issues for Maximun Raise Slope, Soak Time, Reflow Time, Peak Temp, and Total Time above 230?, all of them are under 10% of Study Variation. Nevertheles, for Maximum Falling Slope is 22.31. As in BGA, the reason for these is that that set-up provide to the oven don’t make too much differences between slopes: Maximum Falling Slope is 0.6, so as is mentioned above, typacally Slopes are in range of 0 - 8 ?/sec. Based on the other variables results, we can make the inference that there is not issues with KIC 24/7 and is acceptable to measure SOC Component profiles.
Capacitor results shows that there are not issues for Maximun Raise Slope, Soak Time, Reflow Time, Peak Temp, and Total Time above 230?, all of them are under 10% of Study Variation. Nevertheles, for Maximum Falling Slope is 17.19. As in BGA and SOC, the reason for these is that that set-up provide to the oven don’t make too much differences between slopes: Maximum Falling Slope is 0.5, so as is mentioned above, typacally Slopes are in range of 0 - 8 ?/sec. Based on the other variables results, we can make the inference that there is not issues with KIC 24/7 and is acceptable to measure Capacitors Component profiles, as well.
General conclusion: KIC 24/7 is capable enough to measure the most common variables for Process Control in Oven reflows: Reflow Time and Peak Temp. Other variables as Soak Time and Total Time above 230?, is capable enough as well. Variables as Maximun Raise Slope and Maximum Falling Slope, data shows issues to measure, however, we conclude that was due the short range of difference in the profiles that were used. so, KIC 24/7 is accepted.
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
22 of 25
5.1 Benefits derived from the KIC 24/7
? ? Zero defect production through early warning on CPK. ? ? Immediate shutdown on any “out of Spec.” situations. ? ? Process traceability: Provides ELCOTEQ a sales tool by accommodating or exceeding their customer’s
expectations for documentation, process trace ability etc. ? ? Eliminate the need for periodic profiling: Less downtime and higher productivity. ? ? Faster line troubleshooting when a yield issue occurs by ruling the thermal process in or out as the problem
cause: Less downtime and higher productivity. ? ? Managing the tighter process window associated with lead-free electronics. ? ? Faster oven changeover: The KIC 24/7 can immediately verify whether the oven is ready for production at the
new settings.
6. Special issue
During our evaluation, we notified to the production line 1 and maintenance group special problem was detected in the test oven omniflo 7 for more details see the special report below AS YOU CAN SEE IN THIS PICTURE THE REFLOW ZONE 6 AND 7 SHOWED VARIATION COMPARED WITH THE BASELINE PROFILE +/- 20 °c
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
23 of 25
THIS PICTURE SHOWED HIGH VARIATION IN THE PEAK TEMPERATURE WITH ALARM RESULTS IN THE CPK MONITOR.
THE ROOT CAUSE OF THE VARIATION IN THE KIC 24/7 AND BAD RESULTS IN THE PEAK TEMP CPK WAS :
? ? THERMAL SEAL BROKEN 2-799-133-00-0 Seal , triangul 3/4"*1/2". (PICTURE 1) ? ? THERMAL SEAL BROKEN (PICTURE 2 ) ? ? DUST IN HEATERS THERMOCOUPLE AREA (PICTURE 3)
PICTURE 1 PICTURE 3
¡ PWI= 153% !
¡ CPK=0.16% !
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
24 of 25
AFTER THIS PROBLEM THE MAINTENANCE GROUP FIX THE SEAL 2-799-133-00-0 Seal , triangul 3/4"*1/2".
Document code:
Manufacturing
Technology Development
KIC 24-7 EVALUATION Classification: Company confidential
Date:
May-4-2005
Prepared by: (Also subject responsible if other)
Alejandro Rodriguez
Reviewed by: (Also subject responsible if other)
Juan Ruiz
Approved by: (Also subject responsible if other)
Guadalupe Villarreal
Version:
Rev. 1
Page/pages:
25 of 25
Version History Version Date Prepared by Changes
1 May/06/05 Alex. Rdz New document