How to improve the yield of a highly workmanship-dependent process.

[ccHoongcc]

One of our product are have the yield 60 - 70% (this consider very low), therefore we start to find out a way to improve this. However, we found that 1 defect may come from few different different root cause. This is because our product is too dependant on the workmanship such as a wire bonding (microwave industrial). and because of this, the defect is not direct pin point to certain process or rootcause therefore we found difficulty on controlling the process. How to improve the yield of the product, can someone advice? what is the correct system or tool may help? someone at microwave industrial please kindly advice?

[Marc]

Does anyone have any advice on improving workmanship dependent processes?

[Stijloor]

Originally Posted by ccHoongcc

One of our product are have the yield 60 - 70% (this consider very low), therefore we start to find out a way to improve this. However, we found that 1 defect may come from few different different root cause. This is because our product is too dependant on the workmanship such as a wire bonding (microwave industrial). and because of this, the defect is not direct pin point to certain process or rootcause therefore we found difficulty on controlling the process. How to improve the yield of the product, can someone advice? what is the correct system or tool may help? someone at microwave industrial please kindly advice?

Welcome to The Cove Forums!

There are various sources of information available on the 'net. I am not an expert at this, but there are some firms that provide advice. Also, there are technical papers written and available, but you have to pay for them.

Any other Covers that can help?

Stijloor.

[e006823]

Originally Posted by ccHoongcc

One of our product are have the yield 60 - 70% (this consider very low), therefore we start to find out a way to improve this. However, we found that 1 defect may come from few different different root cause. This is because our product is too dependant on the workmanship such as a wire bonding (microwave industrial). and because of this, the defect is not direct pin point to certain process or rootcause therefore we found difficulty on controlling the process. How to improve the yield of the product, can someone advice? what is the correct system or tool may help? someone at microwave industrial please kindly advice?

ccHoongcc,

Can you tell us what your current wire bonding process is?


regards,

[prototyper]

Originally Posted by ccHoongcc

One of our product are have the yield 60 - 70% (this consider very low), therefore we start to find out a way to improve this. However, we found that 1 defect may come from few different different root cause. This is because our product is too dependant on the workmanship such as a wire bonding (microwave industrial). and because of this, the defect is not direct pin point to certain process or rootcause therefore we found difficulty on controlling the process. How to improve the yield of the product, can someone advice? what is the correct system or tool may help? someone at microwave industrial please kindly advice?

Study the process to determine the best method of manufacture. This should involve considerable input from the people actually performing the work.
Document the best method as a standard operating procedure (SOP).
Train all people doing the job to the SOP.
Explain to them how the part they are making works and the problems created if the part is defective.
Have the next person in the process perform checks to ensure the previous operation is correct.
Test them to ensure they have understood the training.
Audit the area periodically to ensure everyone is following the SOP.

People do make mistakes. The best way to reduce these mistakes is to standardise the process and encourage discipline.

Study Poka Yoke or foolproofing techniques and implement them where possible.

[Sidney Vianna]

Originally Posted by ccHoongcc

This is because our product is too dependant on the workmanship such as a wire bonding (microwave industrial). and because of this, the defect is not direct pin point to certain process or rootcause therefore we found difficulty on controlling the process. How to improve the yield of the product, can someone advice?

If you can't automate the process, you should consider an operator certification program whereby a clearly established criteria exists to qualify operators performing tasks that require special skills. Only certified operators would be allowed to perform work. Once this is in place, you want to make sure that all potential sources for variation are eliminated/mitigated, including operator visual fatigue due to repetitive work.

Once a defect is observed, engage the operator on the discussion if/how the problem could have been avoided.

[ccHoongcc]

When we test it at the end of the process, we found failure at certain test such as frequency test fail or so on... but once we feedback to production, they may due to different root cause.

What is the solution? any advice?