Integrated statistical process control and engineering process control for a manufacturing process with multiple tools and multiple products Shui-Pin Lee Department of Industrial Management, Chien Hsin University of Science and Technology, No. Using data collected while welding, the welding statistical process control (SPC) tool provides weld process quality control by implementing techniques of data trending analysis, tolerance analysis, and sequential analysis. SPC savvy users will likely argue that there are ways to reduce this by new and improved analytical methods. “There are Nelson Rules, we have AIAG, you should definitely use Juran Rules? SPC manufacturing comes in the form of gathering data on your products or processes in real-time using a graph with pre-determined control limits to measure its efficiency. These methods range from contamination control to the monitoring of continuous process parameters. He has evaluated another manufacturing process and made recommendations to a client for a totally integrated manufacturing information handling and product control system to meet the requirements of GMP and the FDA. View Profile, Thomas J. McLean. SPC can be applied to any process where the "conforming product" (product meeting specifications) output can be measured. The result is an estimated average of a “new process” every 10th unit or less. He has consulted on applications of dielectric heating and ultrasonic measurements and welding. By clicking “Accept”, you consent to the use of ALL the cookies. In this context, a process is said to be “in statistical control” if the probability distribution representing the quality characteristic is constant over time. As a next step, it is critical that you are able to quickly drill down to a Pareto view of your most occurring failures, across any of these dimensions. This makes traditional SPC worthless as a high-level approach to quality management, particularly in the light of the increasing amount of data … Mohd. We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. A cost-failure relationship known as the 10x rule says that for each step in the manufacturing process a failure is allowed to continue, the cost of fixing it increases by a factor of 10. 229, Jianxing Road, Zhongli District, Taoyuan 32097, Taiwan, ROC Manufacturing Process Control • Process Goals – Cost – Quality – Rate – Flexibility Manufacturing 8 10. It allows them to see if the production is moving forward, and if it is not, they will need to modify or even scrap the entire process. A failure found at system level can mean that technicians will need to pick apart the product, allowing for new problems to arise. Statistical Process Control (SPC) Software. It lets you quickly drill down to understand what the real origin of poor performance is, and make informed interventions. One problematic feature of WECO is that it on average will trigger a false alarm every 91,75 measurement. A few cases of manufacturing process waste are reworked, scrap and excessive inspection time. Authors Info & Affiliations ; Publication: Proceedings of the 12th annual conference on Computers and industrial engineering January 1990 Pages 234–238. Following this complexity, and combined with factors such as globalized markets driving up volume of manufacturing, the result is that the amount of output data today is incomprehensible by 1920 standards. Amongst other benefits, repair data supplies contextual data that improves root-cause analysis. There is no guarantee that Step 4 is included in monitored KPIs within an SPC system, but it is critical that the trend is brought to your attention. In modern electronics manufacturing, complexities involved do not comply with the fundamental assumption of process stability. Statistical process control Process capability is the ability of a process to produce output within specified limits. After their introduction, important concepts are illustrated with the help of application examples drawn from the area of yield control, photolithography and plasma etching. Every test after the first represents waste, resources the company could have spent better elsewhere. Statistical process control in semiconductor manufacturing Abstract: The author presents a brief survey of standard SPC (statistical process control) schemes, and illustrates them through examples taken from the semiconductor industry. We simply don’t have time to go looking for trouble. There are a range of statistical methods which can be used in manufacturing process improvement. Statistical Process Control was introduced in the 1920s, designed to address manufacturing of that era. This gives them a “new” product, or process ever 280th unit. To maintain stable operation of semiconductor fabrication lines, statistical process control (SPC) methods are recognized to be effective. For example, if we know that a process is only noticeably aff… View Profile. Knowing your FPY you can break this down in parallel across different products, product families, factories, stations, fixtures, operators, and test operation. There is a process called the statistical process control which is often used when manufacturing different electronic components. An approach following Manufacturing … In this post we will have a closer look at. It will experience many design modifications due to things such as component obsolescence. So what?? A recent example is Takata filing for bankruptcy after a massive recall of airbag components, that may exceed 100 million units. Before getting into the details of deep learning for manufacturing, it’s good to step back and view a brief history. Statistical process control application to weld process Abstract: A statistical weld process monitoring system is described. This is an obvious consequence of assuming stability in what in reality are highly dynamic factors, as mentioned earlier. In addition to manual key entry, NWA Quality Monitor can be set up for direct data collection from RS-232 serial devices and bar code systems. Before performing SPC or any new quality system, the manufacturing process ought to be evaluated to determine the main regions of waste. Wiper manufacturers should employ SPC programs to control the physical, chemical and contamination characteristics for each wiper lot that is manufactured. An obvious consequence of this is that problems are not detected where they happen, as they happen. This paper considers statistical process control (SPC) for the semiconductor manufacuturing industry, where automatic process adjustment and process maintenance are widely used. Authors: Kenneth W. Chapman. And even if you managed, how would you go about implementing the alarming system? Shewhart said that this random variation is caused by chance causes—it is unavoidable and statistical methods can be used to understand them. The parameters you need to worry about when they start to drift. What most does is to make assumptions on a limited set of important parameters to monitor, and carefully track these by plotting them in their Control Charts, X-mR Charts or whatever they use to try and separate the cliff from the wheat. This helps to ensure that the process operates efficiently, producing more specification-conforming products with less waste (rework or scrap). During SPC, not all dimensions are checked because of the cost, time and population delays that would incur. Control charts are used to check for process stability [15]. The presence of repair data in your system is also critical, it cannot be exclusively contained in an MES system. An example of this is Aidon, manufacturer of Smart Metering products. Or put in other words, 1.000 different processes in manufacturing a single batch. By True, it means that any kind of failure must be accounted for, even if it only came from the test operator forgetting to plug in a cable. Each gets tested through 5 different processes. who will have an active role in quality assurance. Preceding SPC imple… Share on. The Process Control Tool will be integrated as a part of the production line. A tool in Statistical Process Control, developed by Western Electric Company back in 1956, is known as Western Electrical Rules, or WECO. Unless you have a data management approach that is able to give you the full picture, across multiple operational dimensions you can never optimize your product and process quality or company profits. Let’s repeat that; assuming you, against all odds and reason, were able to remove common cause variations, you would still be receiving 62 alarms every day. You also have the option to opt-out of these cookies. By now it could very well be that tools from SPC become relevant in order to learn more details. One of the big inherent flaws of Statistical Process Control, according to standards of modern approaches such as Lean Six Sigma, is that it makes assumptions of where problems are coming from. What about this ground-breaking state-of-of-the-art chart developed in the early 2000s, given it a go yet?”. But now you know that you are applying it on something of high relevance, not based on educated guesses. In electronics manufacturing, this starts with an honest recognition and monitoring of your First Pass Yield (FPY). Control product quality at all stages of the cement manufacturing process by having a clear understanding of the targets and the levers that are used to control the targets along with the appropriate decision making process based on the impact of each lever. Statistical process control (SPC) is a method of quality control which employs statistical methods to monitor and control a process. The purpose was to get early detection of undesired behaviors, allowing for early intervention and improvements. Limitations of SPC were sat by available Information Technology, a landscape completely different from modern times. Combining these you will on average get 62 false alarms per day, assuming 220 working days per year. Statistical process control can be applied to individual components or end-products to ensure they perform within specified parameters. Legal   Privacy Policy   Cookie settings. These cookies do not store any personal information. Or if the product is in fact taken out of the standard manufacturing line and fixed, as intended. In fact, the measurements from manufacturing operations have no common measure with today’s situation. This makes traditional SPC worthless as a high-level approach to quality management, when combined with the increasing amount of data collected. In: 2nd International Conference on Mathematical Sciences 2007 (ICoMS 2007), Statistical Process Control appears to still hold an important position at Original Electronics Manufacturers (OEM). Concepts, original thinking, and physical inventions have been shaping the world economy and manufacturing industry since the beginning of modern era i.e. However, in semiconductor fabrication lines, there exist a huge number of process state signals to be monitored, and these signals contain both normally and non-normally distributed data. This data is then plotted on a … Statistical Process Control (SPC) has long been an important tactic for companies looking to ensure high product quality. Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. Trending and tracking a limited set of KPIs only enhance this flaw. From a human-resource point of view, it can also tell you if products are blindly retested, as sometimes normal process variations take the measurement within the pass-fail limits. In modern electronics manufacturing, the complexities involved don’t meet the fundamental rule of process stability. Statistical process control techniques and tools can be employed to monitor process behavior, discover issues in internal systems and develop solutions for production issues. Statistical process control (SPC) has long been an important technique for companies looking to ensure high product quality. OEMs: Automate data collection and data sorting from your test stations, The historical aspect of Statistical Process Control in manufacturing, and some fundamental limitations, Alarming capabilities, and the problems when applied to high-dynamic processes, How some use KPIs in attempts to compensate for the short-comings of SPC, A modern alternative to SPC based on First Pass Yield and optimized Test Coverage, How dashboards helps inform decision making, Why it is important that repair data can be analyzed in the context of test failures, has units containing over 350 electronics components each, experience more than 35 component changes throughout this build process. These cookies will be stored in your browser only with your consent. A fundamental assumption of SPC is that you have been able to remove the common cause variations from the process. Statistical Process Control (SPC) is a necessary part of modern chemical processing. In this presentation we cover the detailed development of a SPC program, from selecting the appropriate metrics for a manufacturing process to collecting data to analysing the data. Here is it apparent that Product B has a single failure contributing to around 50% of the waste. A key concept within SPC is that variation in processes may be due to two basic types of causes. Statistical Process Control (SPC) methods can be used to combat process variation by enabling companies to monitor real-time production processes and ensuring that they are operating at maximum potential while minimizing waste. How would you begin to eliminate common cause variations here? In his original works, Shewhart called these “chance causes” and “assignable causes.” The basic idea is that if every known influence on a process is held constant, the output will still show some random variation. If there is some change over time in this distribution, the process is said to be “out of control… Keywords: statistical process control, electronics manufacturing. ISBN 951-42-5870-3 University of Oulu SPC can also be applied to manufacturing tools and machines themselves to optimize machine output. Key tools used in SPC include run charts, control charts, a focus on continuous improvement, and All this is accounted for in modern methods for Quality Management and Manufacturing Intelligence. Ideas of economies-of–scaleby the likes of Adam Smith and John Stuart Mill, the first industrial revolution and steam-powered machines, electrification of factories and the second industrial revolution, and the introductio… SPC can be applied to any manufacturing or non-manufacturing process in which output that conforms to specifications can be measured. By using these tools companies have improved quality and given engineers a means to drive continuous process improvement in manufacturing as they build all levels of products. The SPC method is used to incorporate statistical computations that can monitor the quality control process. Adding actual process dynamics to the mix, can SPC give a system manufacturing managers relies on, and that keeps their concerns and ulcers at bay? Focus • Unit Operations • (1) Maximizing Quality – Conformance to Specifications • (2) Improving Throughput • (3) Improving Flexibility • (4) Reducing Cost Manufacturing 9 11. InfinityQS software automates SPC, eliminating human error and the need for paper records. Statistical process control (SPC) charts are used in quality-focused facilities to monitor process output on a continual basis and alert process operators, managers and the support staff in real-time when the process is shifting towards an undesirable condition. FPY represents your single most important KPI, still, most OEMs have no real clue what theirs is. According to their Head of Production, Petri Ounila, an average production batch. In theory such control limits help visualize if things are turning from good to worse. People receiving 62 emails per day from a single source would likely mute them, leaving important announcements unacknowledged, with no follow-up. An … There are multiple examples from modern times where firms had to declare bankruptcy or protection against such due to the prospect of massive recalls. An approach following Manufacturing Intelligence and Lean Six Sigma philosophy is superior in identifying and prioritizing relevant improvement initiatives. The examples used … True FPY to be more precise. In modern electronics manufacturing, the complexities involved cannot be easily mapped to the fundamental assumptions of process stability. Overview Objective Analysis of Variation. Statistical Process Control (SPC) is an industry-standard methodology for measuring and controlling quality during the manufacturing process. View Profile, W. Carroll Johnson. To help determine whether a manufacturing or business process is in a state of statistical control, process engineers use control charts, which help to predict the future performance of the process based on the current process. The need for Statistical Quality Control (SQC) in the manufacture of electronic components is well accepted. It would be most useful to apply the SPC tools to these areas first. We also use third-party cookies that help us analyze and understand how you use this website. It specifies certain rules where violation justifies investigation, depending on how far the observation are from ranges of standard deviations. He has designed sampled data controllers and digital controllers. Back-tracking Moore’s Law it is easy to accept that not only IT, but also product complexities and capabilities were different than today. Should the failure be allowed to reach the field the cost implications can be catastrophic. Yusof, Sha'ri and Mohamad, Ismail (2007) Application of statistical process control in manufacturing company to understand variability. Allocating this insight as live dashboards to all involved stakeholders also contributes to enhanced accountability of quality. But opting out of some of these cookies may have an effect on your browsing experience. Necessary cookies are absolutely essential for the website to function properly. These KPI’s are often captured and analyzed well downstream in the manufacturing process, often after multiple units are combined into a system. Statistical process control (SPC) is the application of statistical methods to the monitoring and control of a manufacturing process to ensure that it operates at its full potential to produce a conforming product. A high speed statistical process control application of machine vision to electronics manufacturing. Statistical process control has been successfully utilized for process monitoring and variation reduction in manufacturing applications. Direct SPC operation reduces error rates, provides access to SOPs and production information. In addition comes changes to test process, fixtures, test programs, instrumentation and more. Let’s say you have an annual production output of 10.000 units. However you may visit Cookie Settings to provide a controlled consent. This paper describes the application of NWA Quality Analyst to quality control in the assembly of electronic components. In short, quality influencing actions come from informed decisions. SPC must be practiced in 2 phases: The first phase is the initial establishment of the process, and the second phase is the regular production use of the process. You suddenly find yourself in a situation where you can prioritize initiatives based on a realistic cost-benefit ratio. Quality data in the form of Product or Process measurements are obtained in real-time during manufacturing. Meaning that all variations remaining are special cause ones. Combined with the increasing amount of data collected, this makes SPC worthless as a high-level approach to quality management. The origin could easily come from one of the components upstream, manufactured one month ago in a batch that by now has reached 50.000 units. The structure of the program makes different upgrades easy to implement. This paper summarizes the basic concepts and tools of Statistical Process Control as used today in semiconductor manufacturing. In modern electronics manufacturing, the complexities involved don’t meet the fundamental rule of process stability. Provides the operator with immediate feedback at the inspection station. You can’t fix what you don’t measure. This again kicks of improvement initiatives likely to fail at focusing on your most pressing or cost efficient issues. Statistical Process Control (SPC) has long been an important tactic for companies looking to ensure high product quality. Statistical process control (SPC) has long been an important tactic for companies looking to ensure high product quality. Statistical Process Control (SPC) is a statistical method to control and monitor the quality of a production line. This category only includes cookies that ensures basic functionalities and security features of the website. An electronics product today can contain hundreds of components. Rohani, Jafri and Mohd. Combined with the increasing amount of data collected, this makes SPC worthless as a high-level approach to quality management. Statistical Process Control (SPC) is an industry-standard methodology for measuring and controlling quality during the manufacturing process. SPC identifies when processes are out of control due to assignable cause variation (variation caused by special circumstances—not inherent to the process). Offering a complete toolset of data management and statistical evaluation methodologies to suit manufacturers of all sizes and setups, Hexagon Manufacturing Intelligence’s statistical process control (SPC) software solutions support quality assurance, capability evaluations and parameter-based process controls. Privacy Policy, Statistical Process Control in Electronics Manufacturing, Parameterized charting and reporting properties. Having this data available in real time as Dashboards gives you a powerful “Captains view”. Statistical Process Control (SPC) is the system of tools used by manufacturing operations worldwide to manage a high quality process with very little process variation. Even if we managed to reduce the amount of false alarms to 5 per day, could it represent a strategic alarming system? Statistical process control (SPC) ... An example of a process where SPC is applied is manufacturing lines. Not only does SQC allow firms to comply with vendor-certification programs, it is essential for maximizing yields, minimizing rework, and increasing profits. It will be tested in various stages during the assembly process; feature multiple firmware revision; test software versions; test operators; variance in environmental factors, and so forth. Each process has an average of 25 measurements. It is found in continuous manufacturing processes; calculating control limits and attempting to detect out-of-order process parameters. This website uses cookies to improve your experience while you navigate through the website. A good rule of thumb for dashboard is that unless the information is given to you it won’t be acted on. Real-Time Dashboards and drill down capabilities allows you to quickly identify the contributors to poor performance. Statistical process control quality (or SPC for short) is considered the industry standard when it comes to measuring and controlling quality during your production runs. early 18th century.

statistical process control in electronics manufacturing

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