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1、Dell Quality System TrainingFoxconn DMDI2022-5-81Dell quality system TrainingAgenda:The Character Of Dell Quality SystemThe Expectation Of Dell Supplier Management SVLRR DefinitionThe Requirements of DellDeployment of Dell supplier management - Design Control/NPI - Process Control - IQA (incoming as
2、surance) - Sub-tier Supplier Management - Reliability TestingTools of Dell supplier Management - PC/Ten steps - STSM - BPI2022-5-82Character of Dell quality system HP CEO Appreciation Of Dell The way make Dell success The way make Dell degenerateThe supplier management is one of the way make dell gr
3、ow so faster in last time and degenerated today 2022-5-83Character of Dell quality systemThe essence of Dell supplier management - CLCA - I-P-D-C-A - Continual improvement - Make the process simpleThe index of dell quality system - DMAICThe base of dell quality system - ISO90012022-5-84 Get Results
4、The Right WayThe Expectation Of Dell Supplier Management Deploy Business Process Improvement 50% Improvement Sub-Tier Quality Meet 233 DPPM2022-5-85Getting Results the Right WayIndustry-wide Collaboration is Driving Alignment & Best Practices2022-5-8690 Day Verified Field Incident RateFY05FY0642% Im
5、provement in 90 Day VFIR From FY05 FY0670% Customer Failures from Sub-Tier!GoalActual2022-5-87Sub-Tier Supplier ManagementDell FactoriesUse Dell SEQ Model to Eliminate Excursions Sub-TiersOurCustomers50% S_VLRR5 VLRRs50% 90D VFIR50% S_VLRR50% S_VLRRSupplier Factories2022-5-88Component EngineeringPro
6、curementReliabilityQualityTogether We Can Achieve Zero Defects Specifications Qualification Application RoHS COS / Hubs AVL Ratings Cost Contracts Design Validation Production Testing Critical Process De-Rating Process Control Documentation Design Control Quality System BPIDell Supplier Management M
7、odel2022-5-890246810121416Total Induced Run-out (mg/cm)FrequencySub-Tier BPI Case Study: Fan Balancing Avg = 420Fan Supplier Process: Normal Distribution at 12X Specification Too Much Variation! Process Not Capable2.4 Million Fan Replacements in 2005 Spec = 342022-5-810The Power of BPI in Sub-Tier M
8、anagementApply Business Process Improvement Tools to Get It Right First Time 02468101214161820Total Induced Run-out (mg/cm)Frequency Spec = 34 Avg = 160 $3 M Projected Savings62% Reduction!2022-5-811The Power of Business Process Improvement (BPI)Dell Achieved $2.4 B in BPI Savings during FY06Busines
9、s AlignmentRight MethodsPeople DevelopmentLeadershipSponsorshipHoshinPlanningSix SigmaProcess CapabilityClosed LoopCorrectiveActionLeanDesign forSix SigmaBelts2022-5-812Business Process Improvement (BPI)Many Dell Certified BPI Consultants Available to You!External QualityConsultantsQuality, Reliabil
10、ity and Sub-Tier Supplier Mgmt ExpectationsProvides How-To ConsultingPower of BPI:Dells Experience &Knowledge DellSuppliersTaiwan IndustrialDevelopmentBureau (IDB)Contact: Christina_Y_C2022-5-813S-VLRR InstructionWWP SEQ DT MB TeamNo More Defects.Build Reliable Products.Be The Reason2022-5-814Sub-Ti
11、er VLRR DefinitionsSVLRR = VID / Qty built * 1,000,000VID = Verified as Vendor Induced DamageMonitor CND and PID as wellIncludes any component defects at any test station except for Incoming inspection and L6.Calculation MethodsLevel 1: Component / ComponentNumber of verified failure component / Tot
12、al consumed same componentLevel 2: Single component / BoardNumber of verified failure component / Number of built boardLevel 3: Component total / BoardNumber of failed component total / Number of built boardLevel 4: Component / BoardNumber of failure board caused by component / Number of build board
13、2022-5-815Supplier SVLRR Instruction1. Supplier to select top 10 suppliers based on first half of this year performance in suppliers manufacturing line. It doesnt include Dell mfg line or field.2. Supplier to review overall component performances half yearly and select Top 10 suppliers again based o
14、n the performance.3. For those components failing in Dell mfg line and field most, supplier should have separate control plan to improve performance. Monthly report. 4. Supplier to gather information to be able to calculate all 4 levels of data.5. Merge all data from different lines and platforms, a
15、nd make one set of data. L3/L4Combine all numerator and combine all denominator2022-5-816Supplier SVLRR Instruction6. Supplier to report Level 2 and 3 to Dell weekly basis.Supplier to set up a failure verification procedure for top 10 selected sub-suppliers.Failure verification should be finished wi
16、thin a week.Report shall be posted on value chain.7. Supplier to provide 3 up chart for the component which is over goal monthly basis.nTop 10 suppliernGoal 8. 3 up chart is required for the component supplier showed spike or upward trend even outside of Top 10 suppliers monthly basis9. Supplier to
17、create a control document governing SVLRR management procedure based on Dells instruction.- End of Sept2022-5-817QBR scoringHow to score for QBR?nSection A1:wSupplier to create a internal controlled document for managing S-VLRR based on Dells instruction.nSection A2:wMonitoring only top 10 sub-tier
18、suppliers that suppliers selected and approved by Dell.wGoal should be set up based on Q1-Q2 aggregate performances of top 10 suppliers.wTo get one point, supplier should have:1.Align with Dell improvement target To get the 2nd point, supplier should:1.Create a plan to achieve target on each compone
19、nt with milestoneStrategic EFSR, QBR, QSA/QPA, QMP, NPRR, Safe Launch, etc.Tactical Top 5 failures, root cause, corrective action, preventive actionsTo get the 3rd point supplier should:1.Show progress at meeting the milestone 2022-5-818QBR scoring (Contd)How to score for QBR? (contd)nSection A3:w5
20、points:nOverall S-VLRR meeting goalnAll top 10 suppliers meeting goalw4 points:nOverall S-VLRR meeting goaln80% of top 10 suppliers meeting goalw3 points:nWithin 10% of overall S-VLRR goalw2 points:nWithin 20% of overall S-VLRR goalw1 point:nWithin 30% of overall S-VLRR goalw0 pointnOver 30% of over
21、all S-VLRR goal2022-5-819Overall Supplier Line SVLRRSupplier Line Sub-Tier VLRR Template 2022-5-820Component 1 Action Item #Loc.IssueOwnerStartLast UpdateEndFA Result/Root CauseCorrective/ PreventiveActionImpact1FCTNo videoDPPM2FCTHang3ICTInternal ShortBridge to Goal2022-5-821Requirements of Dell qu
22、ality system Total 18 items 11 items Related to us 2022-5-822PC/Ten steps2022-5-823Implementations of Dell supplier managementv Purpose & Policyv OfficeFacilities Requirementsv Sub-tier Resource Investigationv NPI Model Deploymentv Sustaining Monitorv Dell SEQ Model Copy Exactlyv On Site SQE Reporti
23、ng2022-5-825Foxconn Sub-tier Management Purpose & PolicyPurpose: Driver sub-tier meet Dell FY07 S-VLRR goal or have 50% improvement in this yearPolicy: Impel sub-tier implement Dell SEQ model Dell FY07 S-VLRR Goals for key connector Socket T (350 DPPM) DIMM (100 DPPM) SATA & IDE ( 50 DPPM each) NIC/
24、USB (150 DPPM) Package (10DPPM) LRR (Lots Rejected Rate) of IQC for each supplier: LRR Goal: 99.7%2022-5-826Office Facilities RequirementsA JQE as a single contact window to FoxconnAn office for On-site SQEThe basic facilities in the office - An internet port - A desk - A computer - A Projector ( if
25、 necessary) - A printer ( if necessary) - A meeting room with high priority 2022-5-827Sub-tier Resource Investigation On site SQE must investigate the resource of sub-tier especiallySQE resource and evaluate whether or not those can meet therequirements of Dell SEQ model deployment , if not, a recov
26、ering planshould be submitted.Human resource Review:The organization of sub-tierHow many QEs are delicate for Dell parts and whats their background?How many SQEs are in sub-tier plant and whats their background?Has sub-tier a assigned JQE as contact window for Foxconn? The contact way of each depart
27、ment responder2022-5-828Sub-tier Resource Investigation On site SQE must investigate the ability of sub-tier JQE and SQE whether they can meet the sub-tier management requirements of Dell.Sub-tier resource abilities:knowledge of Dell SEQ modelKnowledge of Dell NPI processThorough understanding of Qu
28、ality Assurance SystemExperience of SPC & FMEA & CLCAKnowledge of Dell Process capabilityKnowledge of Dell BPIKnowledge of RoHS Control FA process & capability 2022-5-829NPI Model DeploymentNPI Flow ChartInformation InputMetrics / Target DefinePilot Build Qual Build ReviewPilot Build ReviewFAI In Fo
29、xconnModify DesignNNNMass Production1 New Product 2 ECN3 Design Change 4 New Supplier 1 Matrices Goal target for Qual/pilot Build2 QMP 3 RoHS complianceYQual build 2022-5-830NPI Model DeploymentCondition of approval NPI to sub-tier:DFMEA must have been finishedOriginal drawing of component have issu
30、edProcess design have been finishedPFMEA must have been finishedCritical station have been definedKey parameters of component have been definedQC flow chart have been finishedControl Plan have been finishedMetrics goal of each critical station have been definedGR&R have measured and the data is acce
31、ptable (below 30%)CPK of key parameter have been work out and the result is acceptableFirst Article inspection report, including visual/function testing and key parameter measure reportReliability testing reportThe Ingredients or part List of Environment-related Substances have been finished and com
32、pliance RoHS standard2022-5-831NPI Model DeploymentQual build readiness Review: On site SQE must make sure items below have been done by suppler then approve the starting of qualification buildReview the information and make sure those are acceptableThe equipments on line have been calibrated and se
33、tupIPQC have finished the process check, have no any issue a: the SOP is the latest version b: all material are right c: all setup of equipments are right Criteria for Qualification BuildKey parameter measure passFunction testing passVisual inspection passFPY Meet GoalRTY Meet GoalCP/CPK meet goal20
34、22-5-832NPI Model DeploymentPilot build readiness Review:Top Three quality issue of each critical station have taken corrective actionsThe equipments on line have been recalibrated base on CAControl plan/SOP have been updated via CAIPQC have finished the process check, have no any issue a: the SOP i
35、s the latest version b: all material are right c: all setup of equipment are right Criteria for pilot build: Key dimension meet SpecFunction test meet GoalVisual inspection meet GoalFPY Meet GoalRTY Meet GoalCP/CPK no less than 2.0/1.5Top Three quality issues have been taken corrective actionsContro
36、l plan/SOP have been updated via CAFAI passed by Foxconn 2022-5-833Sustaining monitor Sub-tier Factory Data Collection System Review:Incoming inspection record statistic system Component product data collection systemComponent product statusesFail components statistic record and feedback statues On
37、site SQE must review the below report of IQC of supplier and impel sub-tier supplier do supplier management - Incoming LRR of each supplier - Incoming VDCS issue and feedback status Items of supplier management Deploymentdefine top ten worst suppliers supplier managements status (follow dell SEQ mod
38、el) - Strategic plan of top ten worst supplier - CIP meeting plan / implement status / correction action tracking - QBR meeting plan / implement status / correction action tracking - EFSR meeting plan / implement status / correction action tracking 2022-5-834Sustained monitor Sub-tier IPQC and QA1 O
39、n site SQE must review the below report of process of supplier and impel supplier do continual improvementRTY of each dell partFPY of critical station of each component / FA (3 up chart)VLRR data of each critical station/ FA (3 up chart)SVLRR of each component/ FA (3 up chart)CA/CP/CPK of key parame
40、ter or Critical stationVLRR and SVLRR Data review process for supplier internal2 Check the implement status and the effect of corrective actions3 Base on SVLRR and the affect of component select Top Ten/ Top Five Focus Supplier (Sub-tier is difference) do supplier management4 Push supplier take corr
41、ective actions for the quality issue that happened in Foxconn module and check the effect On site SQE must Hold weekly CIP meeting to review those report and drive supplier to improve RTY and implement the Dell sub-tier supplier management 2022-5-835Dell SEQ Model Copy Exactly On site SQE must do be
42、low working to sub-tier SQE for dell SEQ model deployment1 Training Sub-tier SQE PC/Ten steps CLCA BPI NPI2 Qualify Sub-tier SQE SPC FMEA Audit skills3 Sub-tier supplier supplier management plan review4 confirm the progress weekly with supplier SQE2022-5-836On Site SQE Report form On site SQE must r
43、eview following report timely with supplier that he on site1 Weekly reportContinuous improvement Plan Critical station FPY and correction action for top three issue: 3 up chart CP/CPK for key setup in the process Cp/CPK for key parameters of component SVLRR review and FA/CA Supplier managementLRR (l
44、ot rejected rate) of IQCSupplier management progress of sub-tier supplierSub-tier supplier Quality strategic plan deployment 2 Monthly report (base on weekly report add 2 item) Progress of Certification of ISO14000&OHSAS18000&EICC Dell PC and ten steps implement statusORT testing report3 Quarter report (base on monthly report add 1 item)PFMEA updating base on CAR2022-5-837Thank You !2022-5-838演讲完毕，谢谢观看！