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