Guideline for. General Automotive Quality Agreement for Electronic Components

Transcription

1 Guideline for General Automotive Quality Agreement for Electronic Components Revision 2: Januar 2006

2 ZVEI-Guideline: General Automotive Quality Agreement for Electronic Components Impressum Guideline: Published by: General Automotive Quality Agreement for Electronic Components ZVEI German Electrical and Electronic Manufacturers` Association Electronic Components and Systems Division Stresemannallee Frankfurt am Main Editor: Editorial Team: Rainer Eckl Dr.F.-W. Wulfert Erwin Gehnen Roland Balkow Joachim Schwarz Dr.R.Arens-Fischer Rolf Münch Bernd Kapp Petr Hrassky Ad-hoc Arbeitskreis Halbleiter Lieferbedingungen Automotive with involvement of the Applikationsgruppe Automotive (APG) Analog Devices GmbH Freescale Halbleiter Deutschland GmbH Hella KG Hueck & Co Infineon Technologies AG Philips Semiconductors GmbH (Chairman) Robert BOSCH GmbH Siemens VDO AG Siemens VDO AG ST Microelectronics Application and Design GmbH Supported by: Stefan Reinkensmeier Fairchild Semiconductor GmbH Uwe Berger, Hella KG Hueck & Co Walter Huck Murata Elektronik GmbH Dr.Joachim Lux Robert BOSCH GmbH Contact at ZVEI: Dr.-Ing. Rolf Winter Telefon: +49 (0) Fax: +49 (0) Internet: Date of issue: January 2006 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means (print, Electronic, mechanical, photocopying) or otherwise without the prior permission of ZVEI. Every effort is made to ensure that the information given herein is accurate, but no legal responsibility is accepted for any errors, missions or misleading statements in this information. 2

3 Content Impressum...2 Preamble Introduction Non Conformance Costs & Liabilities Material Data Content / IMDS Audits Advanced Product Quality Planning / APQP Production Plan Approval Process / PPAP Process Control and Product Monitoring / Cpk-Values Failure Rates / ppm Levels Traceability FAR / CAR: Notifications and Terminations / PCN, PTN Archiving periods for quality relevant document and records...10

4 ZVEI-Guideline: General Automotive Quality Agreement for Electronic Components Preamble This document describes a basic framework and understands itself as a manual for treating automotive quality topics within the electronic market. It does not refer to the specifics of an individual quality agreement. The aim of this manual is to simplify and accelerate the mutual customer / supplier acceptance of general quality agreements. 4

5 1. Introduction 1.1 This automotive quality agreement describes general quality rules that the supplier and the customer have to apply for a successful partnership in order to achieve the goal of zero defect. 1.2 Quality agreements are used for common understanding of customers and suppliers regarding co-operation in the areas Technology, Quality and Responsiveness. 1.3 Therefore this framework document contains only quality relevant topics. The negotiation of any kind of cost claim requires a separate contractual treatment outside of the quality agreement. 1.4 Component specific quality agreements and targets (specifications, data sheets) are not part of this framework document. The order of precedence of related documents needs to be defined in advance. 1.5 The electronic component supplied and used shall be suitable for automotive applications in the worldwide market. To support the zero defect approach it is recommended to inform the supplier about the application. 1.6 The cooperation in automotive business often requires the exchange of confidential information. Therefore a Non-Disclosure-Agreement NDA is recommended between the involved parties. 2. Non Conformance Costs & Liabilities 2.1 Non-Conformance Costs & Liabilities are not part of this document (see Introduction). 2.2 The negotiation of any cost claim requires a separate contractual treatment outside of the quality agreement. 3. Material Data Content 3.1 The supplier must provide material data sheet in the agreed-upon format and medium. The material content must comply to legal requirements in the worldwide automotive market. 5

6 ZVEI-Guideline: General Automotive Quality Agreement for Electronic Components 4. Audits System Audits: 4.1 The quality system of the supplier has to be certified to ISO/TS The relevant version has to be agreed mutually. Usually TIER1 will accept quality system audits conducted by a certification body. Process Audits: 4.2 Generally customer audits should be mutually agreed after the following announcement times: minimum 4 weeks in advance on short notice for problem Audits (only for direct contract partner not for the related subcontractors or representatives) 4.3 Audit type (e.g. VDA6.3), participants and their functions will be announced in time before the Audit. 4.4 The number of Auditors in sensitive manufacturing areas like a clean room will be carefully chosen, a minimum of 2 Auditors should be accepted. Operation instructions will be respected. 4.5 The information exchanged during an audit is confidential. An Audit report shall not be shared or passed to third parties without mutual agreement from all parties involved. 4.6 Audits by customer at subcontractors need to be enabled by the supplier upon request (Para. 4.1 to 4.4 apply). Supplier is responsible to implement and follow up the corrective action plan. After the Audit: 4.7 A scoring and Audit report has to be provided at the end of an Audit during the common wrap-up discussion with the involved participants. A common agreement on the result is indicated by signature of both parties. Sharing of Audits: 4.8 In order to reduce the number of audits, a sharing of results by several customers is possible, if this is agreed in detail by the responsible parties and limited to the agreed upon processes and products. 6

7 5. Advanced Product Quality Planning / APQP 5.1 APQP is a key element for new part introduction at the customer. 5.2 The supplier shall cooperate with customer upon request to work on the System FMEA of the application. 5.3 The customer demands an APQP for all new component requests. The APQP is confidential information and may be reviewed by customer on regular basis. 5.4 Requested APQP details have to be defined prior to sourcing with the supplier. They shall consider the necessary qualification path respecting the application requirements. 6. Production Part Approval Process / PPAP 6.1 PPAP applies for automotive business. Requested level has to be agreed prior to design-in with the supplier. The default PPAP level is level3 (as defined in AIAG) if not otherwise mutually agreed. 6.2 The basis for PPAP is ISO-TS16949 and PPAP manual AIAG (Automotive International Action Group). The relevant version has to be agreed mutually. 7. Process Control and Product Monitoring / Process Capabilities 7.1 To control and monitor the quality level Statistical Process Control SPC, SBA-Statistical Bin Analysis, SBL-Statistical Bin Limit, PAT- Part Average Testing, etc. has to be used during manufacturing at electronic component manufacturer. 7.2 The supplier must ensure that the process capabilities will satisfy automotive quality requirements to meet the Zero Defect target. 8. Failure Rates 8.1 Defects can be measured in absolute or relative numbers (pieces or ppm). 8.2 The common goal of customer and supplier is to reach Zero Defect. PPM-rates in sense of upper limits are intermediate milestones to reach the Zero Defect target. 8.3 For the failure rate evaluation all returned parts shall be used. Returned defects not caused by the supplier will be taken out of the supplier statistics. 7

8 ZVEI-Guideline: General Automotive Quality Agreement for Electronic Components 9. Traceability The aim of a traceability is to minimize the impact and consequences of quality concerns. Suppliers and customers will maintain an appropriate traceability system. Forward Trace: Backward Trace: required information to identify already delivered suspect material. in order to minimize the quantity, which needs to be caught as early as possible. required information to identify suspect source material and origin at supplier. This requires an appropriate choice of following items: Part Number Customer Part Number Supplier Wafer Lot Number Assembly Lot Number Test Lot Number Reel / Tube Lot Number Date Code Trace Code : identifies customer part number and or Customer specification number : identifies supplier ordering code : identifies wafers which were processed as a single group through front-end manufacturing : identifies parts assembled in the same back-end lot : identifies a sub group from same test run : identifies single packaging unit : Year and Week of Assembly (typical format: yyww) : individual code which allows a trace of wafer, assembly and test lot If production requires to split lots for processing, those new sub-lot will be traced as separate lots and not be mixed again. 9.1 For packaged parts a maximum of 2 trace codes per packing unit (reel, tray, tube, etc.) is required. 9.2 For components without sufficient marking possibilities on the component itself (bare die, small package size, etc.) the data on the label are applicable. One lot per packing unit is required with one exception: in order to facilitate deliveries of full packing units, it is allowed to use the subsequent lot to complete the packing units (e.g. reel). 9.3 Traceability information is visible on the label of the packing (Box, Drypack). 9.4 Backward traceability requires as minimum information the part number and additional information like trace code, lot number or date code. 9.5 The maximum time period to provide the traceability information should be 2 working days for products which are not older than 2 years. Older information should be available within 5 working days. 8

9 10. FAR (Failure Analysis Request) / CAR (Corrective Action Request): 10.1 All following turn around times are to be understood starting from the point when the part is claimed at the supplier. Therefore the customer takes care that the parts will be returned immediately according to the upfront defined FAR process (location, condition, failure description, interfaces, ). Supplier and customer shall cooperate in minimizing the shipping time of the failed component at the customer until receipt at the supplier For the optimization of the processes and for the avoidance of additional damage which increases the difficulty or makes it impossible to perform an analysis it is necessary to define the return conditions (e.g. on PCB or desoldered or otherwise defined) upfront. It is recommended to provide the supplier with a detailed failure mode description on component level or with analysis results already performed Standard analysis flow shall meet the FAR cycle time of the customer. In case the analysis needs additional efforts and time (verification, preparation, physical analysis, etc.) the supplier will inform immediately and provide regular updates and estimated completion date The required failure analysis time is customer specific and needs to be defined on individual basis The JESD671-A standard is used to define the component problem analysis flow and the corrective action requirements as shown in the table below. A minimum set of key milestones to be tracked and periodically reviewed. Those milestones for automotive business are provided below. Specific goals may be determined between customer and supplier. Event Problem notification and submission of component to supplier by customer Receipt of samples at supplier factory. Initial supplier problem verification complete and communicated Interim containment plan communicated to customer Supplier failure or problem analysis completed and results communicated Supplier corrective action plan communicated Supplier corrective and preventive actions implemented and verified starting point 1 day* 2 days 3 days 9 days 10 days per plan *"Days" indicate cumulative working days after problem submission by customer. 9

10 ZVEI-Guideline: General Automotive Quality Agreement for Electronic Components 11. Notifications and Terminations / PCN, PTN The supplier shall provide the customer with the parts using the manufacturing processes, equipment and location as released for series production by the customer. If an intended change requires a PCN the customer needs to be notified for customer approval. A written customer approval is mandatory prior to delivery of changed components PCN (Product Change Notification): A PCN request must be submitted well in advance to the intended date of implementation in order to account for the qualification effort on customer side and OEM approval. The implementation of a PCN needs to be mutually agreed in a common action plan PTN (Product Termination Notification): A PTN request must be submitted well in advance to the intended date of termination in order to consider all consequences and alternative solutions. The realization of a PTN needs to be mutually agreed in a common action plan Customers having purchased parts affected by PCN / PTN within a period of the past 24 months or still carry any open orders (backlog) will be informed as defined before Change management during the design and development process has to be defined separately between customer and supplier. This is valid also for devices not qualified and/or not having a series release status at customer side Timely response on PCN/PTN from the customer to the supplier within 6 weeks is recommended. Nevertheless a missing feedback can not be considered as a acceptance of the change or termination PTN: Long-term supply can be in accordance with ZVEI White book long term supply of the automotives industry with electronics components and assembly. For further information of this topic see upcoming results of ZVEI Working Group Change Management. 12. Archiving periods for quality relevant document and records: 12.1 The archiving period has to be agreed between customer and supplier. Typically the customer requires an archiving period of 15 years Applicable quality documents and records can be identified according to the rules described in current VDA 1 - "Quality evidence - Guidelines for the documentation and archiving of quality requirements and records". 10

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12 Electronic Components and Systems Division ZVEI German Electrical and Electronic Manufacturers` Association Stresemannallee Frankfurt am Main Fon: ++49 (0) Fax: ++49 (0) Internet: