Enics uses Valor MSS Quality Management to Improve Production Efficiency

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1 uses Valor MSS Quality Management to Improve Production Efficiency, in Turgi, Switzerland, estimates a 15% improvement in efficiency due to Valor MSS Quality Management. The initial application of Valor software was automated data collection and closed repair for in-circuit and flying probe test. is a large tier two EMS company headquartered in Zurich, Switzerland. They have a total of nine manufacturing sites in Europe and Asia. specializes in providing full lifecycle services solutions for industrial and medical electronics (see ranked number four in worldwide sales of industrial electronics in The Turgi plant runs a very high mix production with about 1800 different products and is an center of excellence for Engineering and IT. Problem Statement Full life cycle management, including after-sales services, requires strict product process histories, traceability of each sub-level assembly in every system produced, and tight management of change control and revisions. goal is to achieve and maintain the highest levels of quality and customer service within this complex high mix manufacturing environment. quickly outgrew the reliability and accuracy of spreadsheets for data collection and paper based process controls which led to a decision to implement a more automated software solution. They chose Mentor Graphics Valor Division as their software partner and today has a highly successful implementation of Valor MSS Quality Management ( MSS ) as their solution for test area closed-loop repair, product traceability and total quality management. The Solution Quality Assurance Management initially brought in the MSS solution to replace older software in the test area, which was obsolete and no longer supported. The main purpose for MSS was to automatically collect all test results, provide a paperless closed loop for diagnostics and repair, and to maintain the Valor MSS Quality Management has helped to streamline the process flow which has created a benefit that is hard to measure, but I believe we are easily 15% more efficient in our operations due to the Valor software. Our success is directly tied to our very high quality and Valor MSS Quality Management is a major part of this success André Beier Quality Manager test data as part of the permanent product history for each PCB s unique serial num ber. The benefits of the MSS solution have, over time, far sur pas sed the initial expectations and have broadened in scope for a com plete quality management system. Soon the MSS implementation expanded to include functional test and warranty repair and product update processes

2 The key to success at was to expand and integrate the Valor MSS Quality Management solution as part of a real time user friendly manufacturing execution system (MES). Test and Repair support was only the initial stage of this long term project. What really needed was complete traceability and device history record for each product genealogy, which could potentially include all steps in the process operation plan, from kitting to final assembly and after sales support for warranty repairs and updates, all the way through to End of Life (EOL) of the product. MSS s scalable support for full process flow fit this need (Figure 1), along with the ability to provide instant, accurate reports that could include as customer documentation requirements. Step one for the expanded ben - efit stream at was to integrate MSS with their Enter prise Resource Planning (ERP) system supplied by SAP. This was key to preventing redundancy and errors from unnecessary keyboard entries and to streamline a Figure 1: Valor MSS Quality Management support from preparation to packaging more automated workflow. The interface to SAP creates a data transfer bridge to automatically transfer crucial SAP data, which is needed within the MSS data structure, such as multi-tier Bill of Materials (BOM), product revisions and the associated Operation Plan that defines each process step and sequence needed to build each production work order. MSS is then configured for each product revision to include intelligent graphical representations of the product, which of the steps in the operation plan will require data collection, pass/fail gate with a closed loop repair, date and time stamps for WIP tracking, or special work instructions. Integration with the Shop Floor Processes Step two was to integrate the use of MSS with critical shop floor processes for laser marking, product assemblyinspection-test, with integrated work instructions, routing sequence control and combination of manual and automated data collection actions. To facilitate the shop floor implementation installed the appropriate MSS user interface at strategic operation locations on the shop floor. This has been a scalable and expanding proce-

3 Figure 2: Visual Inspection (VI) Station uses photographs overlaid on top of CAD for complete visual information. dure as new product families and operation locations were added to the MSS implementation plan. As more and more procedures are brought under MSS control, the benefits to really add up. The following is a partial list of solution highlights. ROUTING CONTROL: is using the Visual Inspection (VI) station user interface to achieve a long list of benefits. Their implementation starts with integrating to the laser marking operation so MSS knows the work order for each laser ID, and then VI station ID will automatically bring up the correct work instruction revision for the work order at the current operation by scanning the 2D laser barcode on the PCB. In this way always knows they have the correct work instruction revision and that the product has successfully passed all previous steps in the operation plan in the correct sequence. This routing control process insures the quality of all products. DYNAMIC INSTRUCTIONS Another benefit to is the automated update of work in - struc tions in response to quality problems. For example, if the Quality data collected at test or inspection shows a sold - ering problem related to a spe cific IC location, e.g. U15, real time document delivery can put a cor rec tive action in place by engineering until the prob lem is resolved. Since all the work instructions are linked to product revisions and op - eration station ID, and each work instruction can be appended or revised off line, creating and implementing a corrective action is extremely fast. REAL-TIME DRILL DOWN REPORTS When combines this capability with real-time drill down reporting of inspection and test data, quality problems are found and quickly corrected, preventing the high cost of rework and protecting the high value of customer confidence in to deliver products of the highest quality. Custom reports are also quick - ly exported to Excel files, includ - ing any drill down variables desired, so can quickly provide exactly what each customer requires for Quality Report deliverables, including historical and current data. BOX BUILD GENEALOGY Traceability is a major requirement from customers so it is crucial that deploy a solid capability to insure the chain of process data and product configuration is never broken. accomplishes this in an automated fashion using MSS. This is especially important in the area of firmware revisions because of differences in calibration models for many of the new digital controller products. MSS builds the genealogy of each box (system) by tying the individual unit IDs to the higher level box ID, including sub unit IDs such as firmware. This is a key function of MSS as it also allows quick assessment and breakdown of system genealogy when items are returned under warranty for repair or upgrades.

4 DATA COLLECTION uses both the MSS VI station and Test and Repair (TAR) Station (figure 3) user interface for most operations that produce quality data, such as manual or visual inspection, ICT and Functional Test. The TAR station interfaces directly to test equipment to automatically capture test results and parameters. The operator then uses the diagnostic tools of the TAR station to determine if the test result is valid. The resulting diagnosis and repair procedure is captured in a knowledge base to assist in subsequent diagnosis of the same or similar problems. has taken this one step further to link the MSS TAR station with an interface to LabView (National Instruments) for even more robust diagnostic tool kits. In any case, the closed loop control feature tracks firstpass yield and second-pass yield separately and insures that any failed unit is repaired and passes Figure 3: Test and Repair (TAR) Station provides paperless diagnosis and repair Figure 4: Benefits of relational, real-time data visibility the test before moving on to the next production station. The simplest data collection feature of MSS is using the VI station as a WIP tracking check point. In this case, the operator simply scans the product ID at the station and the system collects and posts the date and time stamp, location name, and operator name into the data base. This is very helpful data when tracking progress or bottlenecks in each work order or process area. The convergence of all data items collected within the vcheck system creates a rich relational database that delivers both tangible and intangible benefits to in the areas of customer support and responsiveness, collaboration between departments and people, and continuous improvement of the manufacturing process (Figure 4). Web based accessibility helps everyone in the plant. Summary of Benefits at In an interview with André Beier, Quality Manager at Switzerland, he summarized the following benefits derived from deploying MSS in the plant. 1. We now have Quality you can see, along with the Quality processes behind the products which you cannot see. Valor MSS Quality Management has helped to make our Quality data visible and accessible. 2. Field returns from our customers have gone down. MSS insures that each process is completed correctly before moving to the next step. It also forces our operators to correctly handle the many changes. Our old paper process was more forgiving and so it was easy to

5 work with the wrong revision. 3. MSS has helped to streamline the process flow, which has created a benefit that is hard to measure, but I believe we are easily 15% more efficient in our operations due to MSS. 4. We now work paperless, which eliminates error due to lost or misplaced paper, eliminates personalized paperwork that adds confusion, and creates a centralized and standardized process that everyone can follow. 5. With MSS our work instructions can use a variety of color photos instead of line drawings. This communicates to our operators in a much better way. The intelligence of the CAD data layer behind the photo creates a clear graphical view that is unambiguous and represents true reality. 6. MSS has greatly im proved our reaction time. In our very high mix environment, flexibility is a must. MSS provides a standard tool so that people can move to other process areas with out special training. Everything is clear on the screen. This keeps our flexibility high without slowing us down. 7. is performing very well is a very tough competitive business. Our success is directly tied to our very high quality and MSS is a major part of this success. Field Returns Reduced Field returns from our customers have gone down. Valor MSS Quality Management insures that each process is completed correctly before moving to the next step. It also forces our operators to correctly handle the many revisions. André Beier Quality Manager For more information, contact ( ) or visit us on the web at Copyright The marks for the Mentor products and processes mentioned in this document are trademarks or registered trademarks of Mentor Graphics Corporation. All other trademarks mentioned in this document are trademarks or registered trademarks of their respective owners. Corporate Headquarters 8005 SW Boeckman Road Wilsonville, OR Phone: Sales and Product Information Phone: Silicon Valley Headquarters 1001 Ridder Park Drive San Jose, CA USA Phone: Fax: North American Support Center Phone: Europe Headquarters Arnulfstr München Germany Phone: Fax: fx: Pacific Rim Headquarters Mentor Graphics (Taiwan) Room 1603, 16F International Trade Building No. 333, Section 1, Keelung Road Taipei, Taiwan, ROC Phone: Fax: Japan Headquarters Mentor Graphics Japan Co., Ltd. Gotenyama Hills 7-35, Kita-Shinagawa 4-chome Shinagawa-Ku, Tokyo 140 Japan Phone: Fax: MF 8-10 rev w