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Discussion Outline
SPC Goals
When special cause variation is present...
Unpredictable
???
Target
Target
Target
Target
Day 1
Day 2
Day 3
Tomorrow
Target
Target
Target
Yesterday
Today
Tomorrow
Target
LSL
Target
USL
LSL
USL
3
Data Collection
Data Collection
Data Collection
Take 1 data
1 record per module
Include fail data that is product
performance related
(just a guideline, focus should be
more on failure pareto analysis)
st
Distribution Study
Normality Assessment:
Assess & locate the best fitted distribution
Outlier:
Remove outlier that due to assignable causes
Typo error, tester wrong reading, defective component
that is batch related issue
Remain outlier that is product performance related
Defective / bad performance component that unable to
be resolved for time being, tuning related issue
Cpk Analysis
Calculate Cpk based on the best fitted distribution
Calculation may be done based on diff channel / temp depends on the objective of study
2014 Finisar Corporation Confidential
Some sharing from Phil Kiely on data collection for capability study:
Data could be collected using the following options:
1st pass data.this will have one record per module, but the data will include any issues
associated with tester capability, etc
Cum data, with rework..this will have one record per module, but the data is distorted as
modules can be reworked many times to make work (but its hard to call modules that require lots
of rework capable)
All data.failing modules may have many records, and so will distort this dataset it will be
excessively pessimistic as to the actual capability
Passing data only..this will have at most one record per module, but on the whole will likely
give an excessively optimistic view of the actual capability
Cum data, prior to any rework.this will have one record per module, and will include failing
data for any module that required rework to make it ultimately passthis is the preferred dataset,
and is aligned with the Cum yield, no rework requirement that is set for phase exits
Example data
The attached query is an example of how to get this data (example is for QSFP LR module)
The attached data is an example output from that query
Note: the drawback of the query as written is that if the module was reworked as part of 2 nd
ops (ie:prior to any testing), no data will be shown for that module. This should not be too
much of a problem, as it is expected those modules should perform the same in testing as
those which did not get reworked in 2 nd ops
Example query
95% confidence
interval
Normal:
P-value > 0.05
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Eg 1: Non-normal Data
The crossing is tuned just within spec if it fails on
the lower side, not tuned to center of spec
range
14
Outlier:
> Upper Quartile + 1.5*IQR
< Lower Quartile 1.5*IQR
Cpk computed based on
normal distribution
In this case, the normal fitted distribution (left) can be seen to not be
very
representative, the non-normal fit (right) is much more accurate.
2014 Finisar Corporation Confidential
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Sigma Level
Yield
X-Bar 0.5
X-Bar 1
X-Bar 1.5
X-Bar 2
X-Bar 2.5
X-Bar 3
X-Bar 3.5
X-Bar 4
X-Bar 4.5
X-Bar 5
X-Bar 5.5
X-Bar 6
38.30%
68.27%
86.64%
95.45%
98.76%
99.73%
99.95%
99.9937%
99.99966%
99.999943%
99.999996%
99.9999998%
DPMO
617,000
317,310
133,612
45,500
12,419
2,700
465
63
3.4
0.57
0.038
0.002
841,345
691,462
500,000
308,538
158,655
66,807
22,750
6,210
1,350
233
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3.4
Cpk
0.27
0.33
0.50
0.67
0.83
1.00
1.17
1.33
1.50
1.67
1.83
2.00
20
68.26%
95.46%
99.73%
99.993%
99.999943%
99.9999998%
2014 Finisar Corporation Confidential
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Case Study 1: Mean shift > Cpk improved > Yield improved
Eg1: bad sensitivity on 12RZOL product code
Cpk = 0.081
In WW2014
the 1st pass yield in Final is 29.17%
Major contributor is bad sensitivity failure
Failure rate is 9/25 = 36%
The average sensitivity = -25.8 dBm
Upon analysis, the best fitted distribution is
Johnson SI
Cpk estimated is 0.081
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Case Study 1: Mean shift > Cpk improved > Yield improved
Upon evaluation, observed apd was over
biased. Action taken to optimize apd manually.
In WW4314
the 1st pass yield in Final improved to 52.38%
Failure rate drop from 36% to 7/42 = 16.67%
The average sensitivity = -26.3 dBm
Cpk = 0.252
eg1
Mean shifted
2014 Finisar Corporation Confidential
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Case Study 2: Spec Relaxation > Cpk improved > Yield improved
Eg 2: OSNR failure on 12RZOL product code
eg2
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Case Study 3: Distribution change > Cpk improved > Yield improved
Eg3: Rxpowalrmthresh failure on 12RZZT product code
In WW814
the 1st pass yield in corner is 21.8%
Rxpowalrmthresh failure contribute to 10.3% of
total test failure
The big drift between diff temperatures contribute
to big delta that resulted in poor Cpk
Upon analysis, the best fitted distribution is
Johnson SU
Cpk estimated is 0.236
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Case Study 3: Distribution change > Cpk improved > Yield improved
Eg3: Rxpowalrmthresh failure on 12RZZT product code
Cpk = 0.236
In WW4714
After cut in improvement action on tuning optimization,
the 1st pass yield in corner improved to 70.3%
Rxpowalrmthresh failure contribute to 4.5% (improved
from previous 10.3%) of total test failure
The big drift between diff temperatures reduced
Cpk = 0.92
eg3
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9th Subgroup
X-Bar (9) = 598
Subgroup
1st Subgroup
R (1) = 5
Subgro
up
X1
X2
X3
# of subgroup = 20
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12
13
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16
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XXXXXXXXXXXMean X-Bar1 X-Bar2 X-Bar3 X-Bar4 X-Bar5 X-Bar6 X-Bar7 X-Bar8 598
Bar10 Bar11 Bar12 Bar13 Bar14 Bar15 Bar16 Bar17 Bar18 Bar19 Bar20
Range
5
R2
R3
R4
R5
R6
R7 2014
R8Finisar
R9Corporation
R10 R11
R12 R13 R14 R15 R16 R17 R18 R19
28 R20
Confidential
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Q&A Session
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