CONTROL PLAN

Prototype Pre-Launch Production Key Contact/Phone

Control Plan Number
Part Number/ Latest Charge Level Core Team
Power Supply
Part Name/ Description Supplier/ Plant Approval/ Date
XXX 240 8th September 2003
Supplier/Plant Supplier Code Other Approval /Date(If Req'd)

Characteristics
Part Process Name/ Machine, Device No Product Process Spec Product/Process
Procs Operation Jigs, Tools Char Specification
No. Description for Mfg Clas Tolerance
1 Incoming Digimatic Caliper part description Inspection std.
Inspection Magnifying Glass Appearance Purchasing Spec
Dimension Operation std.

2 Bond Coating Chip Mount No sticking out Assy/location Dwg

Chip Mounting machine Mounting condition Std Sample
Adhesive Part Rating
Polarity
Chip Mount machine Drawing
Set up (part list)

Bond application Operation Std

(Glue )
3 Bond Oven Drying Oven set up Temp 130 deg C
Hardening For 90 sec min
4 Chip Mounted EVC Checker Rating Drawing
PCB Check(EVC) Spot heater Polarity Inspection standard
& Repair Tweezer Mounting Condition
(Subcon or TML) EVC Checker Program control
Set up

5 Mounting Magnifier Glass Rating Drawing

Incoming Check Microscope Missing Inspection Std
part alignment Operation Std
Mounting /Glue
Condition
6 Pre Assembly Forming Jig Lead Forming Dwg/specification
Lead Cutting Elect Screw Driver Tube length Operation Std
Lead forming Cutting Tool Lead cut length
Tube sleeving H/S Assemble Jig Core position
part assy on H/S Torque meter Fastened by Elec 4.1 ~ 5.6 kg
Bead core assy Torque Driver

CONTROL PLAN
Prototype Pre-Launch Production Key Contact/Phone
Control Plan Number
Part Number/ Latest Charge Level Core Team
Power Supply
Part Name/ Description Supplier/ Plant Approval/ Date
 XXX 240 8th September 2003
Supplier/Plant Supplier Code Other Approval /Date(If Req'd)

Characteristics
Part Process Name/ Machine, Device No Product Process Spec Product/Process
Procs Operation Jigs, Tools Char Specification
No. Description for Mfg Clas Tolerance
7 Transformer Winding machine Winding Turns Drawing
Winding Jig Operation Std
Tweezer Winding machine Drawing
Cutter Set up
Soldering machine Soldering Inspection std
Condition
Soldering machine Solder Type
Set up Temperature
Soldering time
Core Gapping Core Gap Drawing
machine
LCR meter Core gapping Operation Std
T Ratio Meter machine Set Up
Varnishing Varnishing Cond Operation Std
machine Drying Condition Drawing
Oven Araldite position
Varnishing gravity 0.955~ 0.970
Oven Set Up Drying
150 deg C Max
45 minutes
LCR Meter Inductance Drawing
Turn Ratio Meter Turn Ratio ( Inspection
Insulation /hipot Insulation Test specification )
Tester Hipot Test
8 Manual Insert & Insertion Station Insert position Drawing
Insertion Check Conveyor Rating ( Part location)
Wrist strap Polarity Operation Std
Wrist Strap Checker Floating
Miss insert
Parts Lot No
Wrist strap Go and No Go

9 Dip Soldering Automatic Flux Gravity 0.815~0.825

Soldering machine Pre Heat Temp. 100 +/- 10 C
Wave Solder height By Visual
Soldering temp. 245 +/- 5 C
Soldering time. 4 +/- 2 sec

CONTROL PLAN
Prototype Pre-Launch Production Key Contact/Phone
Control Plan Number
Part Number/ Latest Charge Level Core Team
Power Supply
Part Name/ Description Supplier/ Plant Approval/ Date
XXX 240 8th September 2003
Supplier/Plant Supplier Code Other Approval /Date(If Req'd)

Characteristics
Part Process Name/ Machine, Device No Product Process Spec Product/Process
Procs Operation Jigs, Tools Char Specification
No. Description for Mfg Clas Tolerance
10 Solder Nipper cutter Lead cutting Drawing
correction Solder iron length
Temperature Soldering Inspection std.
controller condition
Iron Temperature 300 ~ 370 deg C

11 Visual check Magnifier glass Soldering Inspection std.

condition Operation std.
Mounting
condition
Insertion
Condition
12 ICT Test Open Short Operation std.
Reversed polarity
ICT Tester Set Up Jpn Drawing
Operation std.
13 PCB break Breaking tool PCB crack Operating std
Damage
14 Output check Power supply Output voltage Drawing
C1 Digital voltmeter check (Inspection
Resistor load specification)
Test fixture
15 labelling By hand Labelling position Dwg/Specification
(serial number)
16 Grounding Test Digital Multimeter Continuity check Dwg/Specification

17 Manual Hipot Test Hipot Tester High voltage Dwg/Specification

safety test
18 Aging Oven Output voltage Oven set up Input AC100V
Aging jig Load 3.0 A
Temp 55 C (3 hour)

CONTROL PLAN
Prototype Pre-Launch Production Key Contact/Phone
Control Plan Number
Part Number/ Latest Charge Level Core Team
Power Supply
Part Name/ Description Supplier/ Plant Approval/ Date
XXX 240 8th September 2003
Supplier/Plant Supplier Code Other Approval /Date(If Req'd)

Characteristics
Part Process Name/ Machine, Device No Product Process Spec Product/Process
Procs Operation Jigs, Tools Char Specification
No. Description for Mfg Clas Tolerance
19 Final Auto tester Electrical Drawing
function test Functional (Inspection
Characteristics specification)
 Test &
Insulation Test

20 2nd Hipot Test Hipot Tester Leakage current Input AC 200V

Output ~FG 4.8 mA maximum

21 Final Visual Led Casing Checker Solder condition Drawing

Mounting condition Inspection Std
Insertion condition Operation Std
Label position
Led position check
Missing part

22 Packaging Description Packaging

Quantity Specification
23 Outgoing Prod line testers Visual Drawing
Inspection Caliper Function electrical ( Inspection
Function dimension Specification)
NTROL PLAN Page 1 of 4
Date(Orig.) Date (Rev B) Date(Rev. c)
9/8/2003
Customer Engineering Approval Date(Rev.D)
Date( If req'd)
Customer Quality Approval
Date ( If Req'd)
Other Approval/Date(if Req'd)

Methods
Evaluation Sample size Reaction plan
Measurement Frequency Control Method
Technics
Visual check Follow Inspection report Lot rejection :
Dimension Check Incoming Insp IQC check record Issue Incoming
Std or proc Rejection report.

Visual Check 100% Check Sheet Repair & reinspect

again

Bond coat /Glue and operation Feeder position Machine Bond coating
chip mount program Standard checksheet & data adjustment for
part replenishment ideal positioning.
checksheet
Glue Expiry date Expiry Date on
control Label
Reflow checker operation Temperature Adjust machine
Standard profile data
Visual check 100% Check Sheet Repair

Visual check sample check Adjust machine

Visual Check Sampling Check Sheet Lot rejection :

Part rating check MIL STD 105D Inspection Record Issue Incoming
AQL =0.4 % Confirm Subcon Rejection report.
level 2 & 1pc/lot data & Lot rework

Visual check Forming Jig Repair

Torque meter Daily check Check Sheet Adjust meter

NTROL PLAN Page 2 of 4

Date(Orig.) Date (Rev B) Date(Rev. c)
9/8/2003
Customer Engineering Approval Date(Rev.D)
Date( If req'd)
Customer Quality Approval
 Date ( If Req'd)
Other Approval/Date(if Req'd)

Methods
Evaluation Sample size Reaction plan
Measurement Frequency Control Method
Technics
Winding machine Winding machine
program
Winding program Operation
Standard
Visual Check 100% P Traceability Sheet Repair or Adjust

Thermometer Daily Check Check Sheet

Stop watch

Inductance Check 100% P Traceability Sheet

Turn Ratio Check

Visual Check 100% P Traceability Sheet

Hydrometer Daily check Check Sheet

Thermometer Operation Std Check Sheet
Timer

Auto Tester 100% P Traceability Sheet issue Non

Conforming
corrective action
Sheet
Visual Check 100% P Traceability Sheet Repair
Polarity ,Missing
Component
Check n=1/lot

Grouding Continuity Daily check Checksheet Replace for rejected

ESD checker wrist strap
Gravity meter Daily check Check Sheet Inform responsible
Dip Tester Touch Up data person to readjust
Visual Check (Sampling check) machine

NTROL PLAN Page 3 of 4

Date(Orig.) Date (Rev B) Date(Rev. c)
9/8/2003
Customer Engineering Approval Date(Rev.D)
Date( If req'd)
Customer Quality Approval
Date ( If Req'd)
Other Approval/Date(if Req'd)

Methods
Evaluation Sample size Reaction plan
 Measurement Frequency Control Method
Technics
Measure with P.Traceability
steel ruler or jig sheet
Visual check 100% P.Traceability Repair
sheet
Iron temperature Daily check Checksheet Adjust by tempera-
checker ture controller
Visual check 100% P.Traceability Repair according
sheet to repair flowchart

Auto detection 100% CheckSheet Repair according

Open Short Test P Traceability to repair flowchart
ICT Test Program Operation Std Daily check with
OK and Ng sample
Visual check 100% P.Traceability
sheet
Output voltage 100% P.Traceability Repair according
sheet to repair
flowchart

Visual check 100% P.Traceability Repair manually

sheet
Continuity check 100% Daily check sheet Line Stop and issue
Nonconforming report
High voltage test 100% Daily check sheet Line Stop and issue
Nonconforming report
Output voltage 3pcs/lot P.Traceability Issue
( 1lot = 200 pcs) sheet nonconforming
report

NTROL PLAN Page 4 of 4

Date(Orig.) Date (Rev B) Date(Rev. c)
9/8/2003
Customer Engineering Approval Date(Rev.D)
Date( If req'd)
Customer Quality Approval
Date ( If Req'd)
Other Approval/Date(if Req'd)

Methods
Evaluation Sample size Reaction plan
Measurement Frequency Control Method
Technics
Output Voltage 100% P.Traceability Repair according
Noise/ripple sheet to repair
Overcurrent flowchart
Insulation resistance Issue
nonconforming
report
Leakage Current 100% P Traceability Sheet Segregate Ng unit
Distribution Check for analysis and
by Histogram replace with Good
unit
Visual Check 100% P Traceability Sheet Repair according
to repair flowchart

Visual Check Packaging label

Auto tester Inspection Std Outgoing Lot Rejection :

Caliper Inspection Data issue non conforming
Manifying Glass Sheet corrective action
Sheet
 CONTR

Production Key Contact/Phone

Control Plan Number UT/CP/004-02

Part number / Latest Change Level Core Team
Refer to CP Matrix
Part Name/Description Supplier/Plant Approval/Date
Refer to CP Matrix
Supplier/Plant Supplier Code Other Approval/Date (if Req'd)
ABC -
Characteristics
Part/ Process Name/ Machine, Device
Process Operation Description Jig, Tools No. Product Process
Number For Mtg.

P1 Material mixing - Tumbler P1.1 Mixing time

- Weighing
machine

P1.2 Mixing ratio

SOP: ASDS123 R
Machine No. AD12433, Mixing Time : 18
Machine Maintenance: cycle,
Nov and Dec 04 available.
SOP: ASDD112 R
Mixing Ratio: A
RMMCS

PFMEA: SDF12122 Rev: 10/10/04,

Prevention not matching Process
Control but Detection matching QC
Control.

PFMEA stated that there is

controlling mixing sequence but not
found in the Control Plan and in the
SOP.
 Control.

PFMEA stated that there is

controlling mixing sequence but not
found in the Control Plan and in the
SOP.
 CONTROL PLAN

Date (Orig.) Date (Rev.) 07.08.03

22/3/2002 07.12.04 (rev 2)

Customer Engineering Approval/Date (if Req'd)

Customer Quality Approval/Date (if Req'd)

Other Approval/Date (if Req'd)

Methods
Special Product/Process Evaluation Sample
Char. Specification/ Measurement Size Freq. Control Method
Class. Tolerance Technique

15 minutes/ cycle Timer 100% Continuous Check list

As per RMMCS Weighing 100% Continuous Refer RMMCS

SOP: ASDS123 Rev; 1,

Mixing Time : 18 min / Checklist: SSP2211,
cycle, dated 1/1/05, Time:
0900am, QC: Badaruhin.
SOP: ASDD112 Rev: 0, Weigher calibratio due
Mixing Ratio: As per date 1/5/05. Rejected Bin available,
RMMCS
Operator knows the
reaction.

0/04,
ess
g QC

s Auditor: Mick Ng, Dated: 1/1/05, Time: 2100pm, Night Shift

ut not
in the Comment:
Overall, Controlling is weak. Might not be capable to achieve < 230ppm during
injection process.
s
ut not
in the Comment:
Overall, Controlling is weak. Might not be capable to achieve < 230ppm during
injection process.
 Page 1 of 1

Date (Rev.) 07.08.03 (rev 1)

07.12.04 (rev 2)

Reaction Plan

Readjust timer/
scrap.

Quarantine material/
scrap.

Rejected Bin available,

Operator knows the
reaction.

Time: 2100pm, Night Shift

achieve < 230ppm during

achieve < 230ppm during
 CONTROL PLAN

Prototype Pre-launch Production Key Contact/Phone

Control Plan Number

Part number / Latest Change Level Core Team

Part Name/Description Supplier/Plant Approval/Date

Supplier/Plant Supplier Code Other Approval/Date (if Req'd)

Characteristics
Part/ Process Name/ Machine, Device Special Product/Process
Process Operation Description Jig, Tools No. Product Process Char. Specification/
Number For Mtg. Class. Tolerance
AN
Page 1 of 1

Date (Orig.) Rev Rev:

Customer Engineering Approval/Date (if Req'd)

Customer Quality Approval/Date (if Req'd)

Other Approval/Date (if Req'd)

Methods
Evaluation Sample
Measurement Size Freq. Control Method Reaction Plan
Technique