Track: Quality Control and Quality Management

Abstract

Burn-in is generally known as a compelling methods for screening out early failures to prevent defective parts shipped to consumers. This project was conducted in a burn-in service provider industry that has been a leading provider of semiconductor testing and burn-in services for more than 45 years. With significant milestones in achieving internationally recognized quality awards such as QS 9000, the company strive towards service excellence, seeking to expand capacity in all laboratories and expand the markets for extensive range of test and measurement products. This project focuses mainly on 144lds ICs since this product is always having customer complaint due to the sliver defect escaping to their end customers causing premature failures due to short circuits. Additional process like 40x inspection is required to screen out the defect which affected the overall cycle time and output for this 144lds product. This process is time consuming and delays other lots for shipment and production facing hard time to meet the output. More over the company is spending additional man power cost which is none value added to the company to screen out the defects. Therefore the root cause of misload which creates the sliver defect was identified to be mainly on machine related issues and the most cost effective solution by installing misload sensors and single press plate was successfully implemented to eliminate the defect using six sigma approach. Besides that, the overall cycle time was improved by 19% by solving sliver issue and man power cost of around 400,000 Ringgit Malaysia was reduced by the elimination of  40X inspection process. The successful implementation of the misload sensors and single press plate at autoloader has lead to zero returns from customers and substantial cost saving for this company's Burn-in test operations through the elimination of manual 40X inspection process.