Is there any place for sampling plan if customer requirement is 20 DPPM

L

learningcurve

#1
I have a 100% visual inspection in my back-end process to check for contamination on a solder pad before packaging. I am not sure by visual inspection I can meet the customer requirement of 20 DPPM. I am also afraid that by operator carelessness or fatigue, defect parts may slip through the inspection. Could I set a AQL sampling check to ensure that if any defective lot more than 20 DPPM will be rejected? I also have IPQC 2 hour roving audit in my process, but I wonder how effective is this. Hope my question here is clear enough to get a reply. Thanks in advance !
 
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Bev D

Heretical Statistician
Staff member
Super Moderator
#3
well, I'm not sure you would really want an AQL plan - an AQL is an "Acceptable Quality Level" plan. in essence, 95% of the time you would accept a lot that is 20ppm and you really want to reject a lot that is 20ppm or worse 95% of the time. And you would need to calculate the sample size manually as the standard tables don't go down to 20 ppm. Your sample size will be fairly large...

But then again a reject plan based on the binomial and a 95% confedence level has a sample size of 149,786 units per lot.

The real bottom line is that a sample plan won't help you.
100% inspection may not help either if it's human visual.
process improvements that eliminate or significantly reduce contamination are probably your best options...
 
J

John Nabors - 2009

#4
Learning curve-

I know less than nothing about your industry but I'll suggest at least giving this a thought - any chance of a poka-yoke? It's always a beautiful thing to take natural human fallibility out of the equation. Could something like a vision system help? I am assuming since you are using human vision that the contamination is visible. I posted links to two existing threads below, one concerning poka-yokes (or as Jim Wynne prefers, 'mistake proofing') and one concerning vision systems. If you bump those up to the top of the queue I'm sure you will get some more cogent answers than what I can give you.

If I know even less about your problems/solutions than I think I do, please disregard.

Kind Regards -John

http://elsmar.com/Forums/showthread.php?t=13989&highlight=poka-yoke

http://elsmar.com/Forums/showthread.php?t=27663&highlight=vision+system
 
Last edited by a moderator:
L

learningcurve

#5
Hi Bev,
Hi John

Thanks for your time for reply ! really appreciate ;)

this is what I have gather so far......

a. by sampling plan, the sample size really get too large to get such high confidence.
b. eliminating the root cause or poke yoke looks promising but it need much persuasion and long approval time, testing for PCN change especially for automotive customers
c. vision system may help filter out the contamination but cost can be a consideration factor.

Thanks again !

Best regards,
Lawrence
 
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