Metric Monitor

Metrics Group: Metric Name: Corporate Owner: Related data Queries

Manufacturing ICT No Defect Found ICT User Group Champion, Manager, Mfg
Test Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Perio
Test & Inspection To understand and drive the reduction in false calls at ICT. Monthly
Tom Janckila with Site user support
Graph Analysis

Overall ICT NDF Rate ICT NDF rate by site

25.0% 60000

Total # of NDFs or boards

18.0% 50000
20.0%
16.0%

(current month)
NDF Rate (%)
14.0% 40000
15.0%

tested
12.0% 30000
NDF%

10.0% 10.0%
20000
8.0%
6.0% 5.0%
10000
4.0%
0.0% 0
2.0%
4 5 o n se eton arez side lside men
0.0% h-B ah-B hicag osto n Jo pl
na n B a Ap Ju Se
a Hil Xia
May-05

C
Feb-05

Mar-05

Apr-05

Jun-05

Jul-05

Oct-05

Nov-05

Dec-05
Aug-05

Sep-05

Jan-06
e e
Ne Ne S
ang nang
n Pe
Pe
Oct-05 Nov-05 Dec-05 Jan-06
Monthly NDF Rate NDF Goal 12 month Rolling Average
Boards Tested NDFs NDF Goal

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Database corrected 4x4 updated starting in
All Sites All Sites
Found error in database, Unique SNs were counted wrong March 2005 Tom Janckila Done
SFDM to STORM translator started in
Hillside Hillside
Added Hillside to NDF monitor starting from 7/1/2005 11/1/2005
Seaside Added Seaside to NDF monitor 3/1/2005
Serialation project re-focused and re-
started. Auto ICT data collection
Kelso Added Kelso to NDF monitor, no data/Data collection turned off Kelso Alan H
introduction re-targetted for Jan/Feb 06 -
not JDE dependant.
Failing tests have been debugged and
Had 4 new assemblies installed for the month of January plus operators have been told again to stop
Appleton 2nd time runs of previously installed fixtures contributed to the Appleton testing when failure trends are occurring. Tom Brandt on going
higher NDF rate for January. Supervisors and Group leaders also
informed.
Carlos
Telular Raptor board unstable readings on all by pass The main contributor is Elster, A2 Cisper
Juarez Juarez Pedroza./Jose 12/16/2005
capacitors, Elster A2 cisper. model R9 (Thermistor).Q1, R11,C25
Reyes.
 Top problems are:
Top 3 are:
Draeger MS15342: Shorts, J212, J207
Draeger MS15342
Chicago Chicago Airvana 750121: new fixture; Salvador to Conrad, Salvador 2/28/2006
Airvana 750121
monitor during next production build
Respironics 1009907
Respironics 1009907: U22, R19, R282
Data for everyone’s review. Overall, we
have seen a 6% improvement in the
number of average tests per board in April
compared to March (down to 1.41 tests per
Clint W.
board in April across all assemblies). The
Bldg5: Bldg5 Al Z.
39’s and 45’s are continuing to trend in a
Bryan T.
positive direction. 1 out of the kits for the
45’s had the retest preventer turned on in
NDF Reduction (see attached zip file for details on Juniper April.
assembly with a retest preventer)
We have had a large influx of new Honeywell ACS fixtures that
we are still working the kinks out on. So far this customer has
had a collective NDF rate of 14.88% which we are working on as Work to stablize all of the new Honeywell
Bldg 4: additional runs of these assemblies come through. We have Bldg 4 ACS fixtures as we continue to test more Dave Brunover on going
taken it down to 12% in December but have no forecast for product
January. February we will pick this back up as we have a large
forecast.
Sites using X7R caps are still debugging as assemblies arrive at
ALL
test

Minh is working these issues. He will be

Boston Boston monitoring the next build for these
assemblies.
We had a total of 394(12.54%) false calls.
Reported to quality and production
Many various contact issues occurring while probing on press fit
personnel in May. They have verified no
connector, not being entered as contamination issue. Press fit
Bldg5: Bldg 5 changes in with part or supplier. Again Al Z
connector on 710-010462 assembly has coating/contamination
seeing issue this month, having Quality
on tips of pins.
contact supplier about
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing ICT Test Acceptance http://bits.plexus.com/cgi-
bin/bits.pl/mfgtest/?View=Fixture_Accepta
Manager, Mfg Test Technology nce
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
Test & Inspection To understand and drive the timely utilization of test acceptance as Monthly
a standard ICT qualification process Tom Janckila with Site Support
Graph Analysis
Test Acceptance Status Test Acceptance Status
90% 40 (Rolling 4 months)

Days or Open Requests

120% 140

% closed on time
80%
100% 120
% closed on time

70%
30
100
60% 80%
80

Days
50% 60%
20 60
40%
40% 40
30%
10
20% 20
20%
0% 0
10%
0% 0

en
K
on

go

ee ise

Sa B5
ee B4

ng ose

Se e

on
e
ic

id

id
U

am
st

ca

et
ex

Bo

na Hills

as
h
h

J
Bo
5
05

05

05

pl
05

06
5

na
na
hi

M
-0
-0

r-0

-0
l-0

-0

n
-0

Xi

Ap
b-

g-

p-
n-

n-

C
ay
ar

ct

ec
ov
Ju
Ap

Au

Se
Fe

Ju

Ja
O
M

ng
D
N

na
Pe

Pe
% closed on time (Rolling 12 month Ave)
Ave days open on open request Oct-05 Nov-05
Dec-05 Jan-06
Average day's open goal (10 days) Ave days open on open request Current Open Requests
On time closed Goal (100%)

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Chicago Chicago
Mexico Acceptance has started in April Mexico
Boise BCOA - testjet instability Boise Fixture was sent back to TG and rebuilt Colby W. Complete
Penang
Penang Seaside WJ FOO has been trained
Seaside Fixture acceptance started as of 3/1/2005
WS Woon and CK Ong have beed
Penang Hillside Penang Hillside
Fixture acceptance started as of 3/1/2005 trained
Xiamen Alex has started fixture acceptance 3/1/2005 Xiamen
Appleton No issues Appleton
We have 4 new Harris fixtures from TG that have not been
Bldg4: Bldg 4:
installed due to 0 demand.
Bldg 5: Bldg 5:

Boston Boston
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing AOI Efficiency AOI User Group Champion,
Manager, Mfg Test
Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
Test & Inspection To understand and drive the reduction in false calls at MVP AOI. Brian Wesoloski & Site Test Monthly
Manager
Graph Analysis
AOI Efficiency by site
Overall AOI Efficiency (Rolling 3 months)
(All sites) 16000 800000
10,000 14000 700000

Total False Calls

9,000 12000 600000
8,000 10000 500000

fcpmi
7,000 8000 400000
6,000 6000 300000
fcpmi

5,000 4000 200000

4,000 2000 100000
3,000 0 0

Penang Hillside (390)

Xiamen (380)
Chicago (603)

Penang Seaside (370)

Appleton (400)

Boise (680)

Juarez (631)

Kelso (330)
Neenah-B4 (604)

Neenah-B5 (605)

Boston (402)
2,000
1,000
0
Feb-05

May-05

Dec-05
Mar-05

Apr-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Nov-05

Jan-06
Monthly fcpmi False Call Goal Rolling fcpmi
Nov-05 Dec-05 Jan-06 Total False Calls

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Top three are: All: removed program from
SJM 7050782 production, forcing operator to
Chicago Chicago Steve Estey Next Production Run.
UTS 2990193500 call STS for assistance during
Arris ARCT00587 next run.
Upgrade system crashes when non-serialised boards are
Kelso Kelso Engage MVP support Darryn Rutherford 1/9/2006
inspected

Boise November - Brought up new programs for Idirect.

 Working on dialing in our library for Honeywell ACS. This
Continue to work on the
customer is ramping up quickly and we need to get a handle on
Honeywell ACS Library and
it. One thing we are working on is getting a pallet for these
Bldg 4 Bldg 4 solidify the use of pallets - 0 Brian Klimpke 1/12/2005
assemblies to drop them down into the focus range of the
forecast in Jan, large forecast
cameras. We have one working proto that had an immediate
in Feb
impact of dropping the calls from 30 to 2 on side B

We have loaded 4.7 software on both of our AutoTrainers and

Bldg 4 have begun converting our Libraries. This is in preperation for Bldg 4 AOI STS
upgrading our equipment fully to 4.7.
The NDF Rate here is not correct. We had Penang opps
included but not the false calls. It should be 10403 in Nov and
Bldg 4
10556 in Dec. I have fixed the issue but the report here does
not reflect this.

Bldg 4

Bldg: 5 Focus on false calls by package. FF1 currently @10,000. Bldg: 5 Detailed AOI Metrics AOI STS

Cause is known but Kelso will

Kelso Focus Factory data pull thru - Kelso MAX useage suspected Kelso change JDE part numbers Darryn
again soon
Test metrics data shows a very large up swing in March for the
Appleton facility for false calls, escapes and defects.
Outsourcing trend from Boise to Neenah B5 in February with
actual build dates in March was very large. Note that Boise data
Forward outsourced program
collection for false calls or defects is not tied into our report,
schedule to factory AOI
Appleton SMT escapes would show up because of Appleton completes Appleton Randy W TBD
technicians for program
testing of the boards. All data collected from outsourced to
review and follow up.
Neenah builds show up in the Appleton report. AOI programs
developed on the Appleton MVP need additional debug for false
call reduction and defect detection to run in Neenah for optimum
results.
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing AOI Effectiveness AOI User Group Champion,
Manager, Mfg Test
Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
Test & Inspection To understand and drive the reduction of MVP AOI defect Brian Wesoloski & Site Test Monthly
escapes to downstream test and inspection steps. Managers
Graph Analysis
AOI Effectiveness by site
Overall AOI Effectiveness (Rolling 3 months)
(All sites, rolling 12 months)
100 5000

# of Escapes (current month)

100 90 4500
90 80 4000
80
Escapes (epmi)

Escapes (epmi)
70 3500
70
60 3000
60
50 2500
50
40 2000
40
30 1500
30
20 1000
20
10
10 500
0 0 0

Juarez (631)

Xiamen (380)
Neenah-B4

Neenah-B5

Appleton

Boston (402)
Chicago (603)

Boise (680)

Kelso (330)

Hillside (390)

Seaside (370)
Feb-05

May-05

Dec-05
Mar-05

Apr-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Nov-05

Jan-06

(400)

Penang
(604)

(605)

Penang
Escape Target Monthly epmi Rolling epmi
Nov-05 Dec-05 Jan-06 # of Escapes

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Arris ARCT00615: >340
incorrect value capacitors
placed that were not be
Top three escapes are: detected by AOI.
Arris ARCT00615 Draeger MS15342: J22 solder
Chicago Chicago Steve E 2/28/2006
Draeger MS15342 bridges; will monitor next
Medtronic 411781-005 production run.
Medtronic 411781-005:
insufficient solder on MP1
shield; not inspected at AOI.
 Trapeze was run without AOI in December. As a result, defects Do not expect this to continue
Bldg: 5 Bldg: 5 Clint W Complete
were charged to AOI even though it wasn't run. into January.

Bldg: 5 Evaluated daily Bldg: 5 Detailed AOI Metrics AOI STS

Await new data from data

Kelso No data in system Kelso Darryn 3/31/2005
entry system
It appears serial numbers are not being used at AOI or ICT,
Juarez
therefore escapes will be zero.
I have the complete list of the
After tracking down many escapes (780 for August), I found that escapes for August (780) and
Appleton around a 1/3 were due to true SMT AOI escapes. (Click to link to Appleton I'm revaluating programs as Randy 9/12/2005
detailed escape report) we run in September and
October.
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing XRAY Efficiency XRAY User Group Champion,
Manager, Mfg Test Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
Test & Inspection To understand and drive the reduction in false calls at 5DX Monthly
XRAY. Jim Eggleston with Site Test Managers
Graph Analysis
XRAY Efficiency by site
Overall XRAY Efficiency (Rolling 3 months)
(All sites, rolling 12 months)
10000 600000
7,000 9000

False Calls (fcmji)

Total False Calls

8000 500000
6,000
False Calls (fcmji)

7000 400000
6000
5,000
5000 300000
4,000 4000
3000 200000
3,000 2000 100000
1000
2,000 0 0

Penang Hillside (390)

Appleton (400)

Penang Seaside (370)

Chicago (603)
Neenah-B4(604)

Neenah-B5 (605)

Boise (680)

Boston(402)

San Jose (403)

1,000

0
May-05
Feb-05

Mar-05

Apr-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Jan-06
Dec-05
Nov-05

fcmji False Call Goal Rolling fcpmi

Nov-05 Dec-05 Jan-06 False calls Process Indicators

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Top three are: SJM 60002178-001/2: Much better Rene T 2/28/2006
SJM 60002178-001 than previous months, but need to look
SJM 60002178-002 further into Fpgullwing and connector
Draeger 7871309 algos.
Chicago Chicago
Draeger 7871309: Failing Gullwing and
Fpgullwing open, and PTH shorts;
need to review open and shorts algos.

Jan - False calls up due to tuning to prevent escapes. In Jan Idirect 6-2 board J13 connector with Patrick
started improving escape feed back and program adustment. shorts. Tuned to insure it would call all
Boise Boise shorts. Follow up to see if shorting
issue has been resolved.

There is some erroneous data in our metric this month in the Fix the data routing of Harris Rob Pfund
form of assemblies that we have transferred to Penang. The assmblies built in Penang
FCPMJI of this erroneous data was 7650. This has been
Bldg: 4 Bldg: 4
addressed and fixed but this data does not show it. We should
actually be at 3617.33 for Dec.
 Detailed Analysis \\neen-dsk- XRAY STS
Bldg: 5 Bldg: 5 002\data02\Db\Shared\TestEng\escap
es\XRAY Escape Report.xls
Real Time Reporting Working to empower xray operator XRAY STS
Bldg: 5 Bldg: 5 through the use of new real time
reporting tools.
San Jose San Jose
Boise Boise
43808 Process Indicators & 110405 False Calls in January. Continuine to monitor our false call Jonathan In process
and process indicator. Working on Jacobsen
Appleton Appleton feedback from PLR operators.

67101 false Calls & 54963 Process Indicators in January. We Chris and Vern have in contact with Vern Francis/ In process
are still experiencing problems with the machine.The machine Jim Eggleston and they will be sending Chris Tompkins
was down for about 2 to 3 days during the month of December. him some data in order to see what we
There were a lot issues with the solder qualities due to profile could to reduce the process indicators.
changes for numerous assemblies. In addition, some products In addition, we were not able to get
Boston were built at freemont and get tested in Boston. We are also, Boston any time on the machine to look at the
setting up additional training for the 5DX operators to notify the false calls due to the revenue push for
engineers once they high false call rate. the year. We will keep monitoring
those assemblies on the next build.

Require to configure 5DX system (automatic reporter and master Getting help from MTT to configure Vince Chan / Jim Closed
Hillside files). Hillside 5DX system. Eggleston / Brian
Wesoloski
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing XRAY Effectiveness XRAY User Group Champion, Manager,
Mfg Test Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
Test & Inspection To understand and drive the reduction of 5DX XRAY defect Monthly
escapes to downstream test and inspection steps. Jim Eggleston with Site Test Managers
Graph Analysis
XRAY Effectiveness by site
Overall XRAY Effectiveness (Rolling 3 months)
(All sites, 12 months rolling with trend)
40 500

# of Escapes (current month)

40 450
35
400
30

Escapes (emji)
Escapes (emji)

30 350
25 300
20 250
20
15 200
150
10
10 100
5 50
0 0
0

Boise (680)

Chicago

Appleton

Seaside
Neenah-

Boston(402)

San Jose
Neenah-B5

Penang
Penang

Hillside
B4(604)

(390)
(370)
(603)

(400)
May-05
Mar-05
Feb-05

Apr-05

Jun-05

Aug-05

Sep-05

Oct-05
Jul-05

Nov-05

Dec-05

Jan-06

(403)
(605)
Escape Target emji Rolling epmi
Nov-05 Dec-05 Jan-06 # of Escapes

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Top three are:
Top three are: Siemens AX 732537: ERSA-induced
Chicago Siemens AX 732537 Chicago shorts on bottom side test points.
SJM 60002178-001/2 Working with process techs to improve
Arris ARCT00638 ERSA process. Rene T 1/31/2006

Boston Boston This has been on going issue that

regularly get addressed with the product
143 escapes were recorded in January, engineers and quality engineers.Quality/ Vern Francis/ Chris
- 35% were on components that were not tested at 5DX. and Product engineers are working these Tompkins/Product
45% on components that we need to check on the next build. issues.. engineers/ Quality In Process

Bldg: 4 Bldg: 4
I'm sure there is some impact to the Harris assemblies showing
up in B4 data here too.
San Jose No Data San Jose
Need to detemine contribution toward
Bldg: 5 Bldg: 5
FF1 and Unisys BGA Only Programs metric and any possible fixes. Bill B and Adam J
 Avocent (leadfree) program has changed
Appleton Appleton from BGA Only to 100% SMT. Siemens
Avocent (leadfree) & Siemens BGA Only Programs. Avocent program may need to be re-tuned.
600-770-501 and Siemens 19T0036-002A have 38 and 78 Juniper's escapes for January is 63
escapes respectively. compared to 128 in last December. Jonathan Jacobsen In Process
 Metric Monitor
Metrics Group: Metric Name: Corporate Owner: Related data Queries
Manufacturing Test & Inspection User Group Attendance Manager, Mfg Test Technology <Insert hyperlinks here>
Metrics Category: Purpose Of Metric: Process/Data Owner: Report Frequency/Report Period:
To review at a high level, how engaged the manufacturing sites Monthly
are with corporate manufacturing test in the recognition, adoption,
and development of best practices. Dan Helein & Site Test Managers
Graph Analysis

Overall UG Attendance - Test & Inspection User Group Attendance - Test & Inspection
(Rolling 12 months)
100.00%
100%
90.00%
90%
80% 80.00%
Attendance [%]

70% 70.00%

Participation
60% 60.00%
50%
50.00%
40%
40.00%
30%
20% 30.00%
10% 20.00%
0% 10.00%
May-05
Feb-05

Mar-05

Apr-05

Jun-05

Jul-05

Oct-05

Nov-05

Dec-05
Aug-05

Sep-05

Jan-06
0.00%
Appleton Boston Chicago Mexico UK Boise Neenah Neenah San Jose Penang Penang Xiamen TDC
B4 B5 Seaside Hillside

Trend Goal Total User Group Participation

Issues/Causes Action Items/Dates

Scope Issue / Cause Scope Action Owner Due Date
Talked with Rene and stressed the
importance of attending all UG
meetings. Rene stated that there
Chicago Chicago On-Going
was a scheduling problem in January
that we'd like to receive participation
5DX UG attendance has been slipping. credit for. Rene T.
Bldg: 4 XRAY UG Attendance is inadequate
Attendance started the first week of
ICT and AOI Mexico Manuel Corona
Mexico August
Asia Test & Inspection User Groups were started in the
Penang Seaside January/February time frame. Penang Seaside
Asia Test & Inspection User Groups were started in the
Xiamen Xiamen
January/February time frame.
Asia Test & Inspection User Groups were started in the
Penang Hillside Penang Hillside
January/February time frame.