industrial.panasonic.com · 2018. 3. 28. · Created Date: 11/30/2017 9:45:44 AM
1 Quality Assurance - industrial.panasonic.com · ensure the stable operation of manufacturing...
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1 Quality Assurance
Transcript of 1 Quality Assurance - industrial.panasonic.com · ensure the stable operation of manufacturing...
1 Quality Assurance
Contents
1.1 Quality Assurance Philosophy 1- 1
1.1.1 Panasonic corporate ideology 1- 1
1.1.2 Panasonic quality management 1- 1
1.1.3 Quality policy for Semiconductor Business Group,
Industrial Devices Company 1- 2
1.2 Product Groups and Organization of
Industrial Devices Company
the Semiconductor Business Group,
1- 4
1.3 Quality System for Semiconductor Devices 1- 6
1.3.1 Role of quality assurance section for
Semiconductor Business Group,
Industrial Devices Company 1- 6
1.3.2 Quality assurance system 1- 7
1.3.3 Quality assurance contract 1- 9
1.3.4 Design control 1-10
1.3.5 Documentation control 1-12
1.3.6 Quality assurance system for parts and
materials 1-13
1.3.7 Ensuring traceability 1-14
1.3.8 Process control 1-14
1.3.9 Inspection process 1-16
1.3.10 Control of equipment and measuring
instruments 1-17
1.3.11 Corrective actions and preventive measures 1-18
1.3.12 Handling of problems at customer side 1-19
1.3.13 Quality assurance system for packaging 1-20
1.3.14 Distribution quality 1-20
1.3.15 Quality auditing 1-20
1.3.16 Quality education 1-21
1.3.17 Small group activities 1-22
1.3.18 ISO 9000s and ISO/TS16949 certification status
in the Semiconductor Business Group,
Industrial Devices Company 1-22
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1. Quality Assurance
1.1 Quality Assurance Philosophy
1.1.1 Panasonic corporate ideologySince our founding in 1918, all corporate bodies in the Panasonic Group advocate the corporate
ideology of the general plan: “We will fulfill our true position as an industry and work for the change and
improvement of society, and will anticipate opportunities to contribute to the advancement of world
culture.” Specifically, we have promoted carrying out our activities as a single entity based on the slogan
“To provide products of infinitely high quality to society, and offer a rich electric lifestyle to people.”
Based on this philosophy, we believe in truly serving customers by constantly conforming to the desires
of customers and society and offering products and services that provide satisfaction, and we have
evolved numerous yearly, medium-term, and long-term management guidelines in this regard.
1.1.2 Panasonic quality managementTo make this general plan a reality, all Panasonic business locations work to provide true CS (customer
satisfaction) by rapidly grasping global standards and needs and quickly responding to them, and aiming to
offer products with not only convenience and comfort, but also assuring product safety, assuring reliabil-
ity, and achieving good productivity. Further, through cooperation with parts and materials suppliers, we
are working hard to realize quality management with the aim of contributing to our stockholders.
Since 1993, the Panasonic Group has developed the Q-MAP (currently called P-QMS) evaluation
system, and has been promoting involvement in the improvement of quality. This P-QMS is a system for
performing internal auditing of Panasonic Group business locations from the viewpoint of both the quality
assurance system and the quality results of all business locations of the entire Panasonic Group, and
assigns rank to each location. For the system, there are of course some contributions from ISO 9000s, but a
major evaluation viewpoint is the Panasonic quality philosophy − whether it fits the Panasonic brand in
both name and reality, and whether it will be accepted by customers.
In 1996, the “New QIG” (New Quality Independence Guarantee) was introduced to improve the quality
of items purchased by the Panasonic Group. This system is a system for increasing the quality assurance
level of parts and materials suppliers by performing an overall evaluation from the viewpoint of both the
quality assurance system and the quality results.
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1.1.3 Quality policy for Semiconductor Business Group, Industrial Devices Company We have received the Panasonic Group quality policy of “truly serving customers by constantly
conforming to the desires of customers and society and offering products and services that provide
satisfaction”, and in order to secure quality closer to the origin with the aim of customer satisfaction or in
other words achieving the satisfaction of society, have published and are implementing the following three
policies:
1) Thorough focus on customer as the first priority.
Offer 100% good products.
Achieve quality and reliability that satisfies a wide range of usage conditions.
Provide comprehensive quality service.
Be kind to the earth.
2) Thorough focus on quality at origin.
Weave quality in from the planning and design stages.
Thoroughly grasp performance limits and analysis of quality and reliability characteristics.
3) Ensuring global quality.
Create a comprehensive overall quality assurance system and management system.
Perform comprehensive standardization throughout the world.
These policies require the promotion of activities that can respond to the demands of customers for Q
(functions/quality), C (cost), D (delivery), and S (service) as well as S (safety) and E (environmental
characteristics) in all stages from product planning through design/development, production, sales,
marketing, etc. A variety of educational and training opportunities have been prepared for carrying out
these activities in reality in order to improve the specialized knowledge, skills, morale, and work efficiency
of all members of the Semiconductor Business Group, Industrial Devices Company.
1) Thorough focus on customer as the first priority.
For our group, “customer” includes not just the set makers that directly use our semiconductor
devices, but also encompasses the customers who use those sets (general consumers), parts and materials
manufacturers, collaborating companies, etc. or in other words everyone that supports our group. This
follows the general plan of Panasonic.
As the first step from set makers for satisfying the final customers who use the product, it is necessary
to start by offering 100% excellent products that can be manufactured at high yield. In order to ensure
these “excellent products”, it is essential to sufficiently understand the wide range of usage conditions of
the customer and to ensure the quality (basic functions, performance, reliability, safety, price/performance,
environmental characteristics, etc.) that can satisfy those conditions. In addition, we feel that it is our
responsibility as the manufacturer to prepare various types of quality data that can help the customer to
use the product and obtain 100% of the provided quality.
2) Thorough focus on quality at origin.
Not only for higher-level products with advanced functionality and vertical startup of mass production
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but also to create a more robust quality structure from various aspects such as more economical quality,
reliability, and safety, etc., we aim to improve the design completeness of our semiconductor devices by
performing thorough and comprehensive design review and weaving quality into our design rules by
evaluating the reliability of fundamental technology during the initial stages of planning and design. For
mass production, it is essential to not only perform source control of parts and materials but also to
ensure the stable operation of manufacturing equipment.
In addition, we perform thorough evaluation and analysis of the reliability of semiconductor devices,
and by clearly understanding the product limits (life, performance, etc.) and further, the end-of-life
product safety, we can provide customers with high-level quality service as well as helping to improve the
quality and reliability of not only semiconductor devices but also higher-level products in upstream chain
before completing sets. In order to achieve this ensuring and thorough focus on quality at origin, we
promote cooperation with customers and sharing of establishment of proprietary technology and quality
technology and estimation forecasting technology.
3) Ensuring global quality.
For customers and parts and materials manufacturers, and furthermore, to cope with the global
expansion of manufacturing and sales bases, it is necessary to construct a global quality management
system for effective utilization of information. In this way, it becomes possible to handle the
diversification of demanded quality and cope with product liability. In addition, by obtaining certification
under the ISO 9000s international standards for quality assurance systems and maintaining and improving
the system, establishment of a comprehensive quality assurance system and management system can be
performed, which can respond to the trust of customers.
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OverseasAffiliate Companies
System LSI Business Unit
Industrial Devices Company
Semiconductor Business Group
DomesticAffiliate Companies
ASSP Business Unit
Power & Optical Devices Business Unit
Manufacturing Division
Solution Promotion Division
PT. Panasonic Industrial Devices Indonesia: PIDID
Panasonic Semiconductor Asia Pte. Ltd.: PSCA
Panasonic Industrial Devices (Shanghai) Co., Ltd.: PIDSH
Panasonic Semiconductor (Suzhou) Co., Ltd.: PSCSZ
Panasonic Industrial Devices Discrete SemiconductorCo., Ltd.: PIDDSC
Panasonic Industrial Devices Optical SemiconductorCo., Ltd.: PIDOSC
Image Sensor Business Unit
Panasonic Corporation
1.2 Product Groups and Organization of the
a) Semiconductor devices researched, developed, manufactured, and sold by the
System LSIs
Bipolar ICs
Image Sensor
Compound Devices
Discrete Devices (Transistors, Diodes)
b) Semiconductor organization
The that handles semiconductor business in
is comprised of four business units and two promote divisions plus various
overseas affiliate companies and domestic affiliate companies. The organization of the Semiconductor
Business Group, Industrial Devices Company is shown in Figure 1.1
Figure 1.1 Organization of Semiconductor
Semiconductor Business Group,
Business Group, Industrial Devices Company
Industrial Devices Company
Semiconductor
Business Group, Industrial Devices Company:
Business Group, Industrial Devices Company
Semiconductor Business Group Industrial Devices Company,
Panasonic Corporation
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: Production factory
: Manufacturing-related company
Arai Factory
Uozu Factory
Tonami Factory
Global Manufacturing Center
Okayama Factory
Panasonic Industrial Devices (Shanghai) Co., Ltd.: PIDSH
Panasonic Semiconductor (Suzhou) Co., Ltd.: PSCSZ
Panasonic SemiconductorAsia Pte. Ltd.: PSCA
PT. Panasonic Industrial DevicesIndonesia: PIDID
Japan
Other Countries
Panasonic Industrial Devices DiscreteSemiconductor Co., Ltd.: PIDDSC
Panasonic Industrial Devices OpticalSemiconductor Co., Ltd.: PIDOSC
The manufacturing bases of Semiconductor Business Group in Japan and in other countries are shown in
Figure 1.2. There are 6 bases in Japan (Tonami, Uozu, Arai, Okayama, Kagoshima, and Shirakawa) and 4
bases in other countries (Singapore, Indonesia, Shanghai, and Suzhou).
Figure 1.2 Manufacturing Bases in Japan and Other Countries
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1.3 Quality System for Semiconductor Devices
Industrial Devices Company
Industrial DevicesCompany
1.3.1 Role of quality assurance section for Semiconductor Business Group,
SemiconductorBusiness Group
In order to make the aforementioned quality policy a reality, Semiconductor Business Group,
Industrial Devices Company possesses the quality assurance system shown in Figure 1.3.
Figure 1.3 Quality Assurance System
At Semiconductor Business Group, for direct control we have established the Global Quality Control
Center as well as factory quality sections in each manufacturing factory as part of our efforts to make the
quality policy a reality.
The Global Quality Control Center carries out identification of process quality and reliability, development
of evaluation and analysis technology, measurement control including calibration of measuring devices,
handling of product complaints from users, adjustments and solutions for quality themes both within and
outside of the Semiconductor Business Group, Industrial Devices Company, and quality education and training.
The factory quality sections carry out process quality control on the manufacturing lines, product quality
control, and verification of the quality and reliability of each product to promote quality stabilization as well
as promote and develop various improvement activities.
These quality activities are intended to be shared throughout the Semiconductor Business Group, Industrial
Devices Company through quality meetings, etc. in order to make adjustments to carry out unified activities.
Corporate Engineering QualityAdministration DivisionPanasonic Corporation
Quality ControlLife End Product SafetyEnvironmental ProductManagementWafer process ReliabilityEngineeringAssembly ReliabilityEngineeringQuality Assurance
Factory QualitySection
(Manufacturingprocess
quality control)Image Sensor Business Unit
System LSI Business Unit
ASSP Business Unit
Power & Optical Devices Business Unit
Solution Promotion Division
Global Quality Control Center
DomesticFactories
DomesticAffiliateCompanies
OverseasAffiliateCompaniesManufacturing Division
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Main flow Meeting
Flow Work process
Investigation/Inspection
StageExternal
party Planning Business
Process evaluation; Design;
Development
Applicable technology Manufacturing
Quality control
Production technology
Materials; Purchasing
Production control
Measurement control; Etc.
Establishment of standard documents
Management meeting
Planning Market research
Business plan
Required specifications
Sales plan
Preliminary plan
Development plan
New product development meeting (development decision)
Determination of specifications; Product design
Design review
Development test production release meeting
Development test production
Design review
Mass production test production release meeting
Production plan
Inspection plan
Evaluation of quality/reliability
Long-term control test
Intermediate inspection
Quality inspection of long-term-
storage products
Customer complaints
Mass production test production
Mass production
Diffusion process
Assembly process
Shipping inspection
Warehousing
ShipmentShipment instructions
Receiving orders
Delivery
Reporting; Treatment
Final inspection
Creation of standards and standard documents
Mass production release meeting
Establishment of standards and standard documents
Quality investigation
Quality meeting
Treatment of quality abnormalities
Recurrence prevention committee
Approval of parts/materials
Evaluation of quality/reliability
Market
Development design
Development test production
Mass production test production
Mass production
Use
Customer
Customer
Collaborating companies
Parts/materials
manufacturers
Managem
ent and c
alib
ration o
f m
easuring e
quip
ment
(Sto
ck c
ontr
ol)
Managem
ent of sta
ndard
s a
nd s
tandard
docum
ents
Technic
al contr
ol of w
ork
ers
; sm
all
gro
up a
ctivitie
s
Ordering
Receiving inspection
Customer
Market
Parts specifications
Materials specifications
Product standards
Product specifications
New product evaluation standard
Inspection standards
Work procedures
Diffusion process control network
Assembly process control network
Receiving inspection specifications
New-QIG
Purchasing specifications
Periodic control standards
Quality report
Recurrence prevention databank
Lot control
1.3.2 Quality assurance system
In order to ensure the quality and reliability of products that match customer needs and offer them in a
timely manner, we have established and operate quality systems that meet international standards starting
with ISO 9000s as well as conforming to industry and customer needs at all product stages from planning
through development, design, test production, evaluation, mass production, shipment, marketing, to
service. Our quality assurance system of products is shown in Figure 1.4.
Figure 1.4 Product Quality Assurance System
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1) Planning stage
While investigating and studying customer needs and requests from a variety of aspects, we conduct
market research and furthermore clarify the technical demands and prospects, and conduct a development
planning review to verify the target quality. Based on the verified target quality, the development
specifications are decided on and a development plan is established, and the product commercialization is
decided.
2) Development stage
Design policy to make the decided development specifications a reality is reviewed. This review is an
examination of the characteristics of the parts, materials, and process and of topics related to quality and
reliability. Then, the designed circuits are examined to verify that the expected electrical characteristics can
be obtained. After that, work on the mask design is performed. In the stages up until now, verification is
performed from a variety of aspects, with particular care and attention focused on quality and reliability.
For semiconductor devices with high-level functionality, product design, structural design, and circuit
design interact in complicated ways, so these examinations are extremely important.
3) Development test production/Mass production test production
In the development test production stage, verification of achievement of aimed characteristics, quality
and reliability in design process is performed. In the mass production test production stage, investigations
are performed to make sure of the process quality with mass production products and verify that the
manufacturing conditions are optimal for ensuring that the target quality is achieved. After verifying that
the target levels for functional characteristics, quality, reliability, etc. have been achieved by the test
production products, the product is shifted to mass production.
4) Mass production stage
In order to maintain uniform, stable quality, in addition to establishing process control network for
every stage from receiving of parts and materials until shipment, a computerized system for quality
information management, feedback, and feed-forward has been introduced and is being developed.
Further, for ensuring quality, we have introduced methods for ensuring the stability and reliability of
facilities and equipment and SPC (statistical process control) methods, and are developing various
activities based on the ISO 9000s quality system for carrying out education, training, small-group
activities, measurement/weight management, quality records management, environmental activities,
revision control activities, etc. of quality of workers and engineers.
Moreover, periodic reliability testing is performed to verify that there are no problems with long-term
reliability in mass production products.
5) Use stage
For the rare occasion when a problem occurs at the customer side or in the market, we examine the
customer usage conditions and the product quality records, analyze the problem, investigate the cause, and
feed back countermeasures to manufacturing and technology divisions as well as activities for diffusion of
information and preventing recurrences.
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These various activities are recognized at the organizational and individual levels of all areas included in
the quality assurance system and in addition, in each stage of the quality assurance process, the P-D-C-A
(Plan-Do-Check-Action) cycle is operated continually to provide continual advancement of the creation of
quality through maintenance and improvement. For this purpose, placing importance on contact with
customers in all aspects is essential.
1.3.3 Quality assurance contract
Semiconductor devices are used in an ever-widening range of applications and are built into large
numbers of electronic devices.
During the use period of electronic devices and the equipment or systems containing such devices, not
only the functions and performance but also their safety is demanded.
The quality, reliability, and safety of electronic devices, etc. are in fact greatly affected by the quality
and reliability of the semiconductor devices used therein and their use methods. In addition, although
ensuring the quality, reliability, and safety of electronic devices during their use period can be considered
to be the role of the electronic device makers, we ourselves as manufacturers of semiconductor devices also
have a very strong interest.
To ensure the quality, reliability, and safety of electronic devices, etc., it is important for a partnership
to be created centered on the electronic device manufacturer and including all related businesses (such as
passive components makers, mechanical parts makers, etc.), and for each member of that partnership to
fulfill their roles.
With this background, we conclude a “Contract/Agreement Related to Quality Assurance” as an
addendum to basic trading agreements, etc. defining the points that each party should follow and clarifying
what actions should be performed to ensure, maintain, and improve the specified quality.
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1.3.4 Design control
In order to manufacture and offer products which match the purpose of use, thoroughly verifying the
specifications requested by the user and thoroughly investigating and understanding the use conditions,
and then feeding back that information to the design is important. Because of this, in the planning stage
after clarifying the customer requirements (requested specifications, quantity, delivery, price), a broad
investigation of product use conditions or set circuit conditions, mounting/assembly conditions, etc. is
carried out, and then a development plan for the new product is created. At this time, whether there are
any problems or omissions with the development targets and basic development principles in the planning
stage is verified and checked by conducting a development planning review.
After that, before design starts, a design policy review is conducted in which the principles of the
design methods and test methods, parts and materials, process development specifications, reliability
examination, etc. are examined. For the reliability examination, points in the circuit, wafer process,
assembly process, etc. that are newly added in order to satisfy the customer’s required specifications are
determined, and whether or not there are issues regarding quality and reliability due to those points is
examined. Then, for the examination of any issues, what verification methods, etc. can be used is
examined, what evaluation circuits or evaluation elements are necessary for such methods is determined,
and a verification plan is established. An example of this is the reliability evaluation performed by the
TEG (Test Element Group), which is an effective method for evaluating the reliability of circuit designs
and processes for ICs and LSIs with complex functions built in. It is used at the time of implementation of
a new process, and is utilized for the estimation and investigation of the relationship between malfunction
mode and malfunction mechanism, relationship between malfunction cause and manufacturing cause, etc.
From the examinations using this TEG, we are working hard to establish detailed design rules for circuit
design, pattern design, structural design, process design, etc., and promote efficient design without
omissions.
After the start of design, in the circuit design inspection, the validity of the target specifications and
product standards are verified, and at the time of ordering the mask, a mask design inspection is conducted
to check the completeness of development and design and extract any issues for the time of mass
production shipment. At the test production stage, the prototype product is used to verify various types
of product characteristics, function, reliability, and safety as a design inspection. At this stage, evaluation
by the customer is also performed. Prior to moving to the mass production stage, the test programs,
various work standards, etc. that are necessary for mass production are assembled, and a final product
inspection relative to mass production is conducted.
This design quality assurance system is shown in Figure 1.5.
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Development plan review Verification of target quality
Examination of characteristics and reliability
of parts, materials, and processes
Verification of target specifications
focusing on electrical characteristics
Verification of quality and reliability
of development test production
Verification of quality and
reliability for mass production
Technical requests from market
Quality assurance activities
Decision of commercialization
Design policy review
Circuit design
Circuit design inspection
Mask design
Mask design inspection
Mask ordering
Test production
Design inspection
Creation of manufacturing
specification documents
Evaluation by customer
Approval
Decision on mass production
Decision on shipment
Start of mass production
Product inspection (New product
factory introduction meeting)
Prototype evaluation. Function characteristics evaluation. Safety. Reliability
Decision on development specifications
Development plan
Mass production
Test production
Development
Planning
Requests from customers
Standardization; Creation of
work standards
Assurance of quality and
reliability of standard product
Figure 1.5 Design Quality Assurance System
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Adoption/rejection decision
Standardization committee
Various related departments
Official in charge
Implementation Regulation documents control
Executive office of standardization
committee
4
5
2
6
18
3
9 7
7
Deliberation Draft
Registration
Application for establishment/revision/discontinuation
Establishment; Distribution
Pu
blica
tion
Ap
pro
val o
f a
do
ptio
n/re
jectio
n
Note: Numbers in figure indicate steps in workflow.
1.3.5 Documentation control
At Panasonic, in order to grasp and act on comments from customers and to respond appropriately to
customer needs as rapidly as possible, the work from planning and design to shipment has been
standardized to enable systematic and timely advancement and improvement of work.
For this purpose, we have created standard documents (regulations and standard forms) that clarify the
handling, storage location and period, and responsibility for all documents such as company regulations,
specification documents, contracts, laws and regulations, industry-group related documents, safety
documents, technical data, documents related to negotiations with administrative organizations, etc., and
these documents are controlled so that work always proceeds based on the newest versions. The storage
period for these documents is defined to be in conformance to the related laws and regulations.
At Panasonic, regulation document types are classified and managed as described below and the
establishment of regulation documents is performed. In addition, through these activities, we strive to
satisfy all customers throughout the world regarding not only product functions and reliability but also
price, delivery, service characteristics, safety, environmental conservation, resource utilization, etc.
1) Classification
Regulation documents are classified into the following 7 types:
1. Regulations 2. Standards 3. Technical standards 4. Specifications documents
5. Procedure documents 6. Instructions 7. Manuals
2) Maintenance, improvement, publication
For each regulation document, drafting (creation of a proposal and submission to an inspection
committee), maintenance, improvement, publication, and implementation are carried out under the
responsibility of 18 work functions, including development, materials, production engineering, quality, etc.
3) Establishment, revision, verification, discontinuation system
The procedures for establishment, revision, verification, and discontinuation of regulation documents
are shown in Figure 1.6.
Figure 1.6 Procedures for Establishment, Revision, Verification, and Discontinuation
of Regulation Documents
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Contracting with cooperating company
ReceivingManufacturing Section
Technology SectionQuality Section
Cooperating company approval
Mate
rials
/Purc
hasin
g S
ection
Selection
Investigation/observation
Process change notification
Supply of various documents
Pro
ble
m
no
tifica
tio
n
Periodic meeting
1.3.6 Quality assurance system for parts and materials
With higher levels of functionality and reliability for semiconductor devices, the importance of quality
control of the parts and materials needed in manufacturing processes, such as semiconductor substrates,
lead frames, fine wires for wire bonding, packages, various chemicals, etc., is increasing. For this purpose,
we introduced the New QIG (New Quality Independence Guarantee) system with the aim of improving
the quality of purchased items. This system is a system for working together with parts and materials
makers to increase the quality assurance level of purchased items by performing an overall evaluation from
the viewpoint of both the quality assurance system and the quality results, and clarifying the purchase
method standards (receiving inspection, etc.) according to the quality assurance level.
Further, for some processes the processing is contracted out to cooperating companies. Even when
contracting out processing, after verifying the work details, various conditions, quality standards, and
organizational system with the person responsible for the work at the cooperating company, a product is
run through the actual line and inspected to verify whether or not it meets our quality standards, and
factory approval is then issued accordingly. Documents that accompany factory approval, such as
processing drawings, inspection standards (shipping, receiving), inspection methods, handling of
problems, prior notification of process changes, etc., are exchanged according to the internal rules. After
factory approval, quality meetings, process auditing, etc. are conducted to work for maintenance and
improvement of quality. The Panasonic standards for selecting cooperating companies are as follows:
1) The management of the cooperating company understands our management policy and is cooperative.
2) The company possesses the required level of technical expertise, and the price level is reasonable.
3) The company protects secrets thoroughly.
4) Transportation, communication, etc. are easy.
The quality assurance system for contracted processing is shown in Figure 1.7.
Figure 1.7 Quality Assurance System for Contracted Processing
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Ex.: Date: April 3, 2007 Indication: 743
Date: April 23, 2007 Indication: 743
Please note that different labeling may be used depending on the product type.
1.3.8 Process control
The manufacturing process is where the quality and reliability intended by the design is made into an
actual product. Quality assurance in manufacturing is regulated by the strictly examined process control
network (QC process diagram), and the parts, materials, equipment, conditions, environment, and
monitoring characteristics are constantly controlled to prevent any causes of unreliability from being
overlooked. In order to maintain uniformly stable quality, the particularly important control items in the
1.3.7 Ensuring traceability All products display the manufacturing year and month, and a control number (precise number) that can
be used for verifying the manufacturing history is applied. The manufacturing history includes the
manufacturing equipment and worker as well as information on the parts and materials lot numbers. An
example of the application of the number is shown below.
For the manufacturing year and month, the following two methods are mainly used.
1) Method 1
Eight characters of alphanumeric characters are used, with the first four indicating the last digit of the
year (1 character), the week (2 characters), and the manufacturing factory (1 character) in that order,
and the remaining 4 (or fewer) characters indicating the individual date code for each Business Unit.
Definition of week 1
According to ISO 8601, the beginning of the week is Monday, and the week of that year that includes
January 4 is set as the first week.
The definition and code for the manufacturing factory is set according to each product group.
For products that cannot be labeled in this way due to the shape being small, a separate method is
used.
2) Method 2
Three characters of alphanumeric characters or symbols are used, indicating the last digit of the year (1
character), the month (1 character), and the last digit of the date (1 character) in that order.
For the month, the months up to and including September are indicated with numerals. For the
months of October and later, the first letter of the month (“O” for October, “N” for November, and
“D” for December) is used.
The period within the manufacturing month is indicated by the presence/absence of a bar (-, -) and
the position of the bar if present. A bar above the month character indicates the first period, no bar
above or below the month character indicates the middle period, and a bar below the month character
indicates the last period.
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Receiving inspection
Oxidation
Oxidation inspection
Photolithography
Visual inspection
Ion implantation
Chip electrical characteristics inspection
Dicing
Breaking, selection
Die inspection
Die bonding
Die bonding inspection
Wire bonding
Wire bonding inspection
Sealing/molding
Stabilization baking
Lead surface finishing
Finishing inspection
Marking
Lead cutting; FormingElectrical characteristics inspection of all productsAppearance inspection of all products
Packaging
Quality assurance inspection
Shipment
Appearance; Dimensions; Warpage; Resistivity
Appearance; Membrane thickness; Surface cleanliness
Development characteristics;Etching characteristics; Line width
Main device characteristics; Electrical characteristics
Appearance
Appearance; Bonding strength
Appearance; Tensile strength
Heating; Time contaminationWire flow characteristics
Components; Temperature;StainingThickness; Uniformity (soldered characteristics);Plating composition; Plating thicknessTemperature; TimeMarking characteristicsMold cut characteristics; Mold dimensionsElectrical characteristics
Appearance
Packaging specifications; QuantityElectrical characteristics; Appearance
Improper dimensions; Scratches; Removal of products with crystal defects; Ensuring resistance values
Determining pinholes; Checking membrane thickness and surface cleanliness; Membrane thickness control
Development acceptance/rejection; Pattern checking; Line width control
Ensuring device characteristicsRemoval of products with faulty electrical characteristics
Removal of cracked or chipped products
Ensuring quality of die bonding
Ensuring quality of wire bondingEnsuring wire tensile strength
Ensuring forming characteristicsEnsuring wire shape
Ensuring finishing quality
Removal of products with faulty plating
Ensuring quality of plating
Ensuring marking quality
Abnormal stress on resin section; Breakage prevention; DimensionsRemoval of products with faulty electrical characteristics
Removal of products with faulty appearance
Verification of quality of products for shipment
Wafers
Lead frame
Wire
Sealing resin
Note:
: Materials introduction
: Processing
: Inspection process
Receiving inspection
Receiving inspection
Receiving inspection
Process Control purposeControl item
process control network are input into statistical process control (SPC) methods with the aim of their
stabilization. The quality information from the various control items indicated in this process control
network (QC process diagram) are used as data for quality improvement as well as being utilized for data
for design, and play a role in quality maintenance and improvement.
Further, from the aspect of building the designed quality into the product, the consciousness of each
individual worker toward quality is of the utmost importance, and through small group activities such as
QC circles, etc. the quality consciousness of all workers is increased with the aim of individual work
improvements.
An example of general process control for semiconductor devices is shown in Figure 1.8.
Figure 1.8 Example of General Process Control for Semiconductor Devices
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Shipment
(Specific products)
(All products)
(Periodic sampling)
(Lot sampling)
(Periodic sampling)
Shipment inspection
Reliability testing
Final inspection
Screening
Manufacturing
Thermal cycle; Burn in
Static characteristics testing;
Dynamic characteristics testing;
Function inspection; Appearance inspection
Appearance and electrical characteristics;
Thermal environment testing;
Mechanical environment testing;
Humidity resistance testing;
Soldering characteristics testing;
Terminal strength testing;
High-temperature storage life testing;
Operating life testing
Electrical characteristics; Appearance;
High-temperature operation testing;
High-temperature testing
Soldering characteristics testing and electrical
characteristics testing that conduct lot inspection
as necessary of warehoused products
Warehousing
1.3.9 Inspection process
During manufacturing there are numerous inspection processes, and the data from those processes are
not used only as data for ensuring product quality, but are also used as data indicating the levels of various
types of quality in each process and are fed back to the design and development stages, equipment
control, etc.
In the final process of manufacturing section, inspection of all products is performed. By inspecting all
products, an initial quality of 100% good products can be obtained. Further, to ensure various types of
quality and reliability, sampling for shipment inspection and periodic testing are performed for
verification, and whether or not the products satisfy the various demands of customers is verified. An
overview of the inspection process is shown in Figure 1.9.
Figure 1.9 Overview Diagram of Inspection Processes
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1.3.10 Control of equipment and measuring instruments
a) Equipment control
In order to ensure products that have high quality and high reliability, the equipment for semiconductor
manufacturing requires high precision and high reliability. Because of this, inspection to introduce new
equipment is performed at the design stage to ensure that the required characteristics can be obtained.
Further, for mass production equipment, startup verification and periodic inspection based on standards is
performed before the start of use. In addition, for daily inspection, standards are set for items that will
affect quality and reliability characteristics in each process, and those control parameters are checked.
b) Measurement control
The manufacturing of semiconductors is characterized by high-temperature, ultra-fine, multi-layer
processing. Because of this, Panasonic performs thorough control of the measuring equipment which is
necessary for manufacturing with high accuracy. Panasonic has been designated by the Ministry of
Economy, Trade, and Industry (METI) as a Proper Measurement Control Business Place under the
Measurement Act, recognizing that a system for performing measurement control has been established. In
addition, for calibration technology, Panasonic has been accredited as an International MRA-compatible
JCSS Accredited Organization (JCSS0135), recognizing Panasonic as an internationally trusted
organization. Calibration of measuring equipment is performed by a specialized section, recognized
calibration organization, or accredited calibration business, and is definitely traceable to an international
standard or national standard. Calibration frequency is defined for each measuring instrument and the
viewpoint of repeatable accuracy is also taken into consideration. Measuring instruments that have been
calibrated are affixed with a label specifying the expiration date and are controlled by the Measurement
Instrument Use Section. The Measurement Instrument Use Section ensures that the Calibration Section
performs calibration of the measuring instrument prior to the expiration date to ensure the accuracy of
measuring instruments. The relationship to national standards is shown in Figure 1.10.
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Figure 1.10 Semiconductor Business Group, Industrial Devices CompanyCalibration Traceability System Diagram
1.3.11 Corrective actions and preventive measuresWhen a problem occurs with a product or manufacturing process, countermeasure management of that
product or process is performed promptly. Cause investigation and analysis are performed, and the details
of measures to prevent recurrence from the root cause are determined. When the details of measures
include changes of procedures, materials, processes, or systems, problems due to the change details are
sufficiently verified and evaluated, and corrective actions and preventive measures are performed.
Depending on the details of the corrective actions or preventive measures, prior approval is obtained from
the customer.
After performing corrective actions and preventive measures, the results are investigated, and it is
verified that the expected effects were obtained.
The details from abnormality occurrence to countermeasures are promptly provided to related sections,
and are recorded in quality records. In addition, for recurrence prevention and horizontal development, a
quality report is created, which plays a role in preventing recurrence. This quality report is added to the
overall Panasonic Group database, and is utilized in design, development, and checking during process
change review to prevent recurrence.
Traceability Diagram for Semiconductor Business Group, Industrial Devices Company, Panasonic Corporation (PC)
National Standard
Official Standard supplyOrganizationsCalibration Organizationsspecified by minister ofeconomy, trade and industryOrganizations certified byminister of METI
Medium StandardPC Standard Semiconductor Business
Group, Industrial DevicesCompany Standard
MeasuringInstrument
National Institure ofAdvanced Industrial
Science and TechnologyAIST
Length, Luminosity,Time, Current, Mass,
Temperature, Quantity
CommunicationsResearchLaboratory
CRL(Std wave, Time)
Overseas StandardInstiture
NIST etc.Electricity,
Temperature, Illuminance
Japan Bearing Inspection Institute
(JBI)(Length)
Corporate Engineering
QualityAdministration
Division PC
LightingBusinessGroup,
Eco SolutionsCompany
Measuring
Global QualityControl Center
Semiconductor BusinessGroup, Industrial Devices
Company
ControlTeam
Site/Factory
LengthMassTime
ElectricityTemperatureIlluminance
Others
Japan Quality Assurance Organization
(JQA)(Length, Electricity)
Japan Electric Meters Inspection Corporation
(JEMIC)Electricity,
Temperature, Illuminance
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Returned product
(Lot)
Analysis request
(Single product)
Complaint report
Receipt of response
ReceivingSending of response
Malfunction analysis Report
Decision on handlingVerification of
countermeasure
Improvement countermeasure
Re-inspection Disposal Standardization
Customer
Sales section
Quality control section
Manufacturing/
Engineering sections
1.3.12 Handling of problems at customer side
After product shipment, if a problem occurs with a product, the product may be returned by customer
request or a request from Panasonic. In such case, the sales section will investigate the usage equipment,
usage conditions, usage period, and malfunction occurrence status, and together with the quality section,
will strive to rapidly solve the problem at the customer side. The quality section will work together with
design section, manufacturing section, etc. to clarify the cause of the malfunction, feedback the information
to design or manufacturing process, and will strive their best for quality maintenance and improvement
and to prevent recurrence. In addition, in order to ensure high quality and high reliability, even for minor
problems, information on problem details, status, etc. will be requested the customer to be offered. The
handling status of such problems at the customer side is reported to the customer by sales section upon
demand. The system diagram for countermeasure treatment of problems at the customer side is shown in
Figure 1.11.
Figure 1.11 System diagram for countermeasure treatment of problems at customer side
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1.3.13 Quality assurance system for packagingA variety of packaging forms are provided, including packaging to protect products from stress during
distribution, trays, magazines, tapes, or anti-humidity packaging for them which take into consideration
the mounting process at the customer side. These packaging forms also meet industry standard
regulations. In addition, we perform packaging using environmentally-friendly materials.
Each packaging is designed and inspected by the Packaging Technology Committee according to the
packaging standards created based on industry standards, examples of countermeasures to past problems
with packaging, distributing, mounting processes, etc., environmental assessment, etc. Newly designed
packaging is subjected to a variety of tests, and it is verified that problems will not occur during
distribution with the new packaging.
1.3.14 Distribution qualityIn order to ensure distribution quality, particularly to ensure that only the requested quantity of the
specified product is delivered on the specified delivery date for incoming orders from customers,
Panasonic has introduced a direct receiving/ordering system. This system uses serial numbers to control
orders from the customer's order form to the control form at the time of production to centralize the form
information and production control information. By doing this, problems with product or quantity
differences are eliminated, and in addition, centralized control via computer from the customer form details
to production conditions is possible, so that when such information is necessary, it can be called up
promptly.
In addition, since product or packaging damage or quality deterioration during distribution can be
affected by product storage or shipping environments, various checks and audits are conducted to ensure
quality in the distribution process and maintain and improve such quality.
1.3.15 Quality auditingAt Panasonic, verification of the quality assurance system aiming to improve quality and eliminate
quality problems, and verification of the effective operation of such system are performed, and quality
auditing is performed for the purpose of creating products that match customer requests.
This auditing includes but is not limited to:
First audit: Quality system audit; Product safety audit
Devices CompanyPerformed by: Internal auditing by Semiconductor Business Group, Industrial
Second audit: Quality system audit; Product safety audit
Performed by: Customer, Panasonic
Third audit: Quality system audit, etc.
Performed by: Certification organization
After the conclusion of auditing, a report is created and a reporting meeting is held. If necessary, the
section that was the subject of the audit creates improvement plans, carries out improvement activities,
follows up regarding progress status and results, and verifies whether the expected target was achieved.
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Seminars for quality management, product liability, and various positions of responsibility
Level
Managers/
supervisors
Intermediate
employees
Quality management
Quality control activities
Product liability
ISO fundamentals
Data analysis methods (Weibull analysis)
Employment of statistical methods
(Experimental design method)
(Taguchi method)
Reliability technology (Proprietary technology)
(Analysis technology)
(FMEA/FTA)
Novice
employees
New
employees
Research/design Manufacturing Sales
Fundamentals of quality management; Fundamentals of statistical methods (7 QC tools)
Quality control activities
Product liability
ISO fundamentals
Fundamentals of statistical methods
(7 new QC tools)
(Examination, assumptions)
Fundamentals of reliability
Quality managementQuality control activitiesFundamentals of product liabilityISO fundamentalsFundamentals of statistical methods (7 QC tools) (Examination, assumptions)Reliability technology (Proprietary technology)
(Analysis technology)
Quality management
Quality control activities
Fundamentals of product liability
ISO fundamentals
Fundamentals of statistical methods
(7 new QC tools)
(Examination, assumptions)
Reliability technology
(Proprietary technology)
(Analysis technology)
PanasonicInternal
certification
S class
Quality control activitiesISO fundamentalsFundamentals of statistical methods (7 QC tools)Fundamentals of reliability
A class
B class
C class
Function
1.3.16 Quality education
Based on the Panasonic Group policy since its founding of “Creating people before creating products”,
our employees carry out self-improvement with the proper spirit and healthy bodies through the
conducting of education aiming for broad knowledge and diligent application of the knowledge learned.
To ensure high quality and high reliability of products, it is important for the quality assurance section
to perform quality assurance activities for personnel education in all sections, such as research, design,
manufacturing, sales, etc. At Panasonic, in order to maintain and improve the high level of quality and
reliability of our semiconductor products, we conduct various kinds of quality and reliability education for
our employees. For types of quality education, education is classified into education by level (new
employee, novice employee, intermediate employee, managers/supervisors), education by function
(research, design, manufacturing, sales), and companywide education, and appropriate education is
conducted for each classification. Further, at Panasonic our employees work hard to increase their level of
knowledge, technology, and technical skills through active participation in various types of education and
training courses and various types of seminars, such as those held by the Union of Japanese Scientists and
Engineers, Japanese Standards Association, etc. In addition, the teaching materials issued by Panasonic for
quality and reliability were originally developed and used by us with actual examples taken from daily
quality assurance activities in close contact with work areas. The system diagram for quality and
reliability education is shown in Figure 1.12.
Figure 1.12 Quality and Reliability Education System Diagram
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1.3.17 Small group activities
1.3.18 ISO 9000s and ISO/TS16949 certification status in the Semiconductor BusinessGroup, Industrial Devices Company
In the Semiconductor Business Group, Industrial Devices Company, activities to obtain ISO 9000s
certification were begun in 1992 with the aim of strengthening the overall quality control system within
the group, creating a quality assurance system for global development, and respond to customer demands.
As a result of these activities, we completed the obtaining of certification starting in October 1993. Since
then, we have continued to maintain and improve our initially established quality assurance system, and
organization.
have passed the periodic follow-up inspections conducted annually by the inspection registration
Our ISO 9000s and ISO/TS16949 certification status is shown in Table 1.1.
At Panasonic, QC circle activities were introduced in 1965, and activities were carried out centered on
the manufacturing section. In 1967, cooperation between ZD (zero defect) activities and QC circle
activities were promoted. Thereafter, in 1980 QC activities by function for 14 projects were promoted
and given the name “TQC80s strategy”. In 1986, the “CREATE-1” exercises were developed as activities
to strengthen the management constitution, and in 1987 QM (Quality Matsushita) activities were
promoted throughout the Panasonic Group. From 1994 to 1996, VQ (Vital Quality) activities were
developed to actively promote quality improvement, and currently “Vitalization of QC circle activities”
are being promoted continuously to promote quality improvement actively, with a focus on ingraining
them in work areas based on the environmental changes such as overseas deployment.
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Table 1.1 Table of ISO Certification Status
Business location Certification Date of Certification authority/standard certification Certification number
Japan Semiconductor Business ISO9001 2003.11.18 JQA/ JQA-QMA14019
Products related to integrated TS16949
TS16949
2008.5.21 JQA/ JQA-AU0211-1 to 3circuit for Automobiles Arai, Uozu, TonamiProducts related to ISO9001 1994.3.14 JQA/ JQA-QMA14036camera module TS16949 2006.6.5 JQA/ JQA-AU0213
Overseas PSCSG ISO9001 1993.12.30 SGS/ SG93/ 02645
PIDID ISO9001 1999.3.16 SGS/ ID99/ 15783
PIDSH ISO9001 1997.12.28 SGS/ CN10/ 20267
2010.3.4 SGS/ CN10/ 20261
TS16949 2009.5.29 JQA/ JQA-AU0207
PSCSZ ISO9001 2005.2.21 LRQA/ QAC6003270
Affiliated PIDDSC
PIDDSCN (Niigata)
PIDSCMY (Malaysia)
Kyoto
Semiconductor
AV module
ISO9001 2001.3.9 JQA/ JQA-QM6255companies Kameoka ISO9001 1995.6.12 JACO/ QC-99J1022
TS16949 2008.5.4 LRQA/ QAC0071035/ C
TS16949 2009.9.11 SIRIM/ AR4992
ISO9001 2001.3.9 JQA/ JQA-QM6255
ISO9001 1996.9.18 SIRIM/ AR0907
PIDOSC ISO9001 1994.12.28 JQA/ JQA-0728
JACO : Japan Audit and Certification Organization for Environment and Quality
JQA : Japan Quality Assurance Organization
SGS : SGS United Kingdom Limited
SIRIM : Standards and Industrial Research Institute of Malaysia
LRQA : Lloyd's Register Quality Assurance Limited
Group
