Dell Computer Corporation
IPO On Board Training
Supplier Process Audit
Prepared by: Eric Hoh
10/23/00
Supplier Process Audit
Differences Between Dell Audit and ISO Audit
ISO Audit
Audit to the compliance against to the 20 elements required
Dell Audit
Audit to both adequacy and compliance underlies the 20 ISO elements for the type of product, and verify the effectiveness with quantified and documented evidence
Supplier Process Audit
Basic Principle - Always be SMART!
S M A R T
PECIFIC
EASURABLE
CHIEVABLE
ELEVANT
IME
BOUND
Supplier Process Audit
What is Process?
Inputs
Outputs
Process
Y= F(X)
Xs
Ys
Supplier Process Audit
How Does a Process Work?
Suppliers
Input Requirements
Customers
Output Requirements
Process
Supplier Process Audit
Audit Check List
Audit Check List is available for reference for Communications, Monitor, Power Supply, PWA, and RMSD.
Fill in the result with “Yes”, “No”, or “N/A”.
Pass criteria is set at 80% compliance.
The use of the Check List is not mandatory.
Supplier Process Audit
Work Instruction
Available at each process step
6 major portions:
Document/Product Information - Product part number/revision, process step/name, approval status, revision level, ….
Direct materials P/N, description, usage, and designator
Work process/instruction for the station
Illustration
Machine name & station number, machine program name/revision, fixtures name/part number & revision, tools/gages part number/name, indirect materials with detailed description, and their working conditions
Call out highlights/special notes for the operation
Who is the CUSTOMER of Work Instruction?
Supplier Process Audit
Operator
Trained and certified for the operation
Adequate supervision for under training or green-hand operator
Ongoing program for re-certification
Operation step complies with Work Instruction
Operation follows Work Instruction
Performance monitoring and feedback system
Supplier Process Audit
Materials
Specified in Work Instructions and under AVL control
Materials are under revision controlled & at current level
Handling & storage guidelines called out in Work Instruction, and compliance documented guidelines
Scrap and nonconforming material are isolated
Material preparation is documented ,controlled, and recorded
Controlled Slow-Moving, FIFO, Shelf Life control systems
Verify traceability of materials
Self audit system to ensure correct material usage
Materials are clearly marked/identified on line and storage area
Supplier Process Audit
Equipment/Tooling/Fixtures
Calibration procedure is available, schedule is established, recall list in place, calibration record is kept, disposition is documented.
Preventive maintenance (PM) schedules, maintenance log, and records
Hour/shift log maintained between PM’s, replacement, line change, etc.
Tooling & fixtures identified by part number/revision
Operating procedure available at each operation
Cycle count management / hour/shift log for tooling
ECO/ECN tracking
Machine & tool capability studies performed and recorded
Supplier Process Audit
ESD Control
All ESD systems are properly installed and maintained
People, semiconductor materials, machines, instrument, tools, fixtures, and working benches at ESD sensitive operation stations are grounded
All semiconductor materials are in ESD free container, package or bin during storage, transfer, and handling
ESD earth ground rod is checked for grounding impedance and recorded on annual basis
ESD grounding main system is checked for grounding impedance and recorded on monthly basis
Instrument/fixtures/benches are checked for grounding impedance and recorded on weekly basis
Wrist/heel strip, and/or conductive shoes are checked and recorded by shift
Wireless wrist strip is not allowed unless used with ionic blower and conductive floor
Supplier Process Audit
Quality Control
SPC in place and closed loop corrective action is taken when out-of-control occurs
Control limits of control chart are reviewed on monthly basis
Effective Continuous Improvement Process (CIP) in place
Quality acceptance/rejection criteria established for each process step
Effective quality inspection and measurement capability in place at each inspection station
Evidence that operators receive quality feedback and are responsible for the quality of their work
Self audit system in place and effective
Supplier Process Audit
Production Process / Flow
Prevent mis-routing and minimize handling
Proper line balance and prevent potential bottlenecks
Documented defective product flow
Line stop criteria established and documented
Documented Dell process flow
Supplier Process Audit
Test Process
Documented test process
Test equipment/software under revision control
Test yield and defect data collection system exists, prefer automated, and collects all data
Feedback to the defect source from test yields and defect data for improvement
Test process and production flow prevents test escapes or mis-routing (.: Make sure that the Test Passed identity is removed before re-test the trouble-shot units)
Supplier Process Audit
Failure Analysis
Documented process procedure
Proper skills, training, and equipment to support failure analysis
Production materials and repair materials effectively controlled to prevent mis-routing or wrong parts being used
Age and quantity of debug WIP is controlled
Effective method to prioritize debug activities
Failure analysis result is used to drive corrective actions
Failure analysis data communicated to Dell on regular basis
Process to verify effectiveness of FA and corrective actions
Process in place to evaluate No Fault Found defects (also CND – Can Not Duplicate)
Supplier Process Audit
Rework Process
Documented rework procedure is available
Documented rework process flow and instruction with accept/reject criteria defined, and available at rework station for all reworks
Rework history is kept for each P/N
Proper tools used for rework
Reworked units are marked
Reworked units properly re-tested and re-inspected
Rework quality is verified
Rework data is collected, recorded, and feedback to defect source
Supplier Process Audit
Packaging / Shipping Process
Procedure in place at packaging and shipping station
Procedures are part number specific
Procedures comply with Dell Packaging and Shipping spec
Supplier Process Audit
RMA Process For Returned Materials
RMA process documented
RMA test process flow documented
System to keep line and field returns segregated
Closed loop corrective action process in place
Minimum shippable revision level control and marking system in place
Data collection for all rework performed
Data collection filing computerized
Data feedback to defect source
