２Quality Assurance System
2.1 Quality Control in Manufacturing Process
We consider that quality control in the manufacturing process is a matter of primary importance related to the quality and reliability of semiconductor products, in order to provide high-quality and highly-reliable products that are required by our customers.
For this purpose, we define the control conditions determined based on a variety of technical information of the Technology and Development divisions in the Control Plan (in which a process flow, equipment used, components used, each quality control item and control standard as well as inspection standards are described or systematized), document them, and conduct various manufacturing operations using them.
The semiconductor manufacturing process is comprised of the wafer process as the upstream process and the assembly process as the downstream process. The following shows the Process Flow Chart example for the typical product:
2.2 Control of Standards and Measuring Equipment
1) Control of Standards
Our product quality management system has established a documented quality system by hierarchically organizing control regulations, control standards, manufacturing standards, and procedures with quality manuals at the top, in order to maintain quality and reliability. The above standards are established as systematized standards.
The following shows the Standard System Chart:
2) Control of Measuring Equipment
The quality of the measuring equipment for electrical and optical characteristics can be ensured and improved by always maintaining it in a normal condition and allowing it to operate within the required accuracy. We have established the “Standards on Measuring Equipment Control and Operation” in our Company Regulations and implement regular inspection and calibration using internal and external calibration organs to ensure that traceability to the national standards is established.
The following shows the Traceability System Chart for Measuring Equipment:
2.3 Product Traceability
The traceability of the products shipped to our customers is controlled in such a way that their manufacturing history can be traced by sealing each product name and lot number on the product body.
The product name and lot number of the supplied product are described on the label affixed to the shipment packing box, excluding some products. Therefore, the traceability to the manufacturing history is ensured even in the packed condition.
With regard to nationally manufactured products (typical package), the sealing example is shown below.
*The following notation is used for the production month (typical example):
2.4 Handling of Complaints from Customers
Where any defect occurs on a customer’s premises, it will be processed according to the complaint handling flow shown below.
With our customer service for returns due to complaints, our distributors or Sales division receive complaints. The person in charge of Sales who has received a complaint enters failure details, product name, user name, receipt date, set name, defect rate, lot and other information in the complaint information sheet in our electronic processing system based on the complaint information from the customer, and communicates the complaint information to the Quality Assurance Division.
Actual defective parts are delivered to the Quality Assurance Division.
The Quality Assurance Division grasps defect conditions based on the complaint information sheet and takes action by identifying the cause according to the results of the investigation and analysis.
We work toward thoroughly maintaining and improving reliability and preventing recurrence, by feeding these investigation results back to the Technology and Development Divisions as well as the manufacturing process as needed.
In addition, we report the investigation status through the Sales Division to our customers as the complaint investigation report.
2.5 Quality and Reliability Training
We implement education and training related to quality and reliability for all employees that impact quality according to our “Employee Training Implementation Standards.”
The established system also allows employees to actively participate in outside seminars and correspondence courses.
The table below shows training courses from basic to practical courses for general engineers.
With regard to workers in charge of inspection and testing in the manufacturing process, certified verifiers who have received the training required for manufacturing and inspection before performing their work are involved in such work to stabilize quality.
The level of understanding is checked in the practical work by an instructor as needed.
|Explanation of ISO9001:2008 Standard Requirements||Statistical Method Practice 1 (Xbar-R Control Chart)|
|IATF16949:2016規定要求事項の解説||統計的手法実践 - Ｐ管理図|
|Explanation of IATF16949:2016||Statistical Method Practice 2 P Control Chart)|
|Explanation of PPAP||Problem Solving Method|
|Value Engineering (VE)||Design (D) FMEA|
|Product Liability Law (PL Law )||Process (P) FMEA|
|Problem Solving Method - Basic||Fault Tree Analysis (FTA)|
|Statistical Method - Basic||Quality Function Deployment (QFD)|
|Fool Proofing (Poka-Yoke) - Basic||Measurement System Analysis (MSA)|
|Customer Satisfaction - Basic||5 Whys|
|5S - Basic|
2.6 Our Approach to Quality Standards
1) Approach to Quality Assurance Standard ISO 9001
ISO 9001 is an international standard for “quality assurance” which was established by the International Organization for Standardization in 1987. Not the quality of a product itself but the quality management system is evaluated. The standard was revised from the “quality assurance” standard to the “quality management system” standard in 2000 and was established as the standard to manage organizations in terms of quality. The purpose of ISO 9001 is not only to “manufacture quality products” but also to “manage the system to create (provide) quality products and service.”
The “quality products and service” refers to the “products and service required by customers.” More specifically, they refer to the establishment of the system for “customer satisfaction” by providing quality products and service.
2) Approach to the Standard for Automotive Quality Management Systems IATF 16949
IATF 16949 is a international technical specification for automotive sector quality management systems which is based on the ISO 9001 standard. As ISO 9001: 2015 was issued in 2015, we superseded ISO / TS 16949 with IATF 16949: 2016.