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2016 Quality and Reliability Manual

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2016 Quality and Reliability Manual 2016 Quality and Reliability Manual 1623 Buckeye Road, Milpitas, CA, 95035 Tel: 408.969.6600 www.issi.com Contents Content Page Chapter 1 Quality Management 1 1.1 Quality Policy 1 1.2 Quality Organization 1 1.3 ISO 9001 Year 2008 Revision 2 1.4 Quality Systems 5 1.4.1 Process Map 5 1.4.2 Advanced Product Quality Planning 6 1.4.3 Quality Assurance in the Project Approval Stage 8 1.4.4 Quality Assurance in Design Development Stage 8 1.4.4.1 Product Development and Design 8 1.4.4.2 Design Review 8 1.4.4.3 Product Release 9 1.4.4.4 Production Part Approval Process (PPAP) 9 1.4.5 Quality Assurance in Production Stage 9 1.4.5.1 Wafer Processing 9 1.4.5.2 Assembly Process Technology 12 1.4.5.3 Testing 14 1.4.6 Quality Assurance of Product Shipping 20 1.4.7 Monitoring Data for AOQL 20 1.5 Customer Complaint 21 1.5.1 ISSI RMA Process 21 1.5.2 RMA Flow Chart 22 1.5.3 RMA Trend Chart 23 1.6 Change Control 23 1.7 e-CAR 25 1.7.1 Corrective Action 25 1.7.2 Preventive Action 25 1.7.3 FMEA 27 Chapter 2 Management on Subcontractors 30 2.1 Task Force 30 i Content Page 2.2 Methodology 30 2.3 Quality Rating/Audit 31 2.4 Supplier Relationship 32 2.5 Subcontractor Process Control 32 2.6 Production Line ESD Control/Management 33 Chapter 3 Product Reliability 34 3.1 Reliability Assurance 34 3.1.1 Product/Process Qualification 34 3.1.2 Qualification Test Method and Acceptance Criteria 39 3.1.3 Semiconductor Device Failure Region 46 3.1.4 Failure Rate Calculation 47 3.1.5 Philosophy of Reliability Monitor 53 3.1.6 Reliability Test Equipment 55 3.2 Device Related Test Data 60 3.3 Package Related Test Data 64 3.4 Lead-Free Package Roadmap 65 3.5 Process Average Testing (PAT), Statistical Yield Analysis (SYA) And Junction Verification Test (JVT) 66 Chapter 4 Failure Analysis 72 4.1 Establishment of Failure Analysis (FA) Laboratory 72 4.1.1 Electrical Failure Analysis (EFA) Laboratory 72 4.1.2 Assembly Engineering and Chemical Laboratory 72 4.1.3 Physical Failure Analysis (PFA) Laboratory 72 4.2 Failure Analysis Function 73 4.3 Failure Analysis Flow 74 4.4 Failure Analysis Instruments 76 Chapter 5 Environmental Management 81 5.1 Environmental Policy 81 5.2 Environmental Management Quality Assurance 82 5.2.1 ISO14001 Certificate - Taiwan 82 5.2.2 Environmental Management Organization 84 5.3 Environmental Substances Management 84 5.3.1 Legislation and SONY Policy 84 ii Content Page 5.3.2 Green Partner Certification 86 5.3.3 Industry Definition of Lead-free & Halogen-free 87 5.3.4 Product Composition 93 5.3.5 Lead-free Solution 94 5.3.6 Halogen-free Solution 97 5.3.7 Pb-free/Halogen-free Evaluation/Qualification Information 97 5.3.8 Current Status 100 5.3.9 Solder Heat Resistance for PCBA (PC Board Assembly) 101 5.3.10 Lead Time from Ordering to Delivery 101 5.3.11 Distinguishing Mark of Lead-free and RoHS Compliance Package 101 5.3.12 IR Re-Flow Temperature Profile for Lead-free Package 102 5.3.13 Recommended Storage Condition 103 5.3.14 ISSI Declaration of Compliance 103 iii Appendices (Available upon request from Marketing) Contents Page 1 Milestones and Awards 114 2 Process Data 2.1. Table 1-1 AOQL (SRAM) 115 2.2 Table 1-2 AOQL(DRAM) 115 2.3 Table 1-3 IQC/Visual Mechanical LRR Trend Chart 116 2.4 Table 1-4 OQC LRR Trend Chart 116 3. RMA Data 3.1 Table 1-5 RMA’s by Month 117 3.2 Table 1-6 RMAs by Product Type 117 4 Device Related Test Data 118 Table 3-7 FIT Value for product of SRAM, DRAM, and ANALOG 118 Table 3-8 High Temperature Operating Life Test 123 Table 3-9 Electrostatic Discharge (ESD) and Latch-up Tests 145 Table 3-10 Data Retention 159 Table 3-11 Endurance Cycling 160 5 Package Related Test Data 162 Table 3-12 Pre-condition Test 162 Table 3-13 Highly Accelerated Stress Test 193 Table 3-14 Temperature Cycling Test 222 Table 3-15 Pressure Cooker Test 253 6 Monitor Qual Table 3-16 Device Monitor Qual – 168 Hrs HTOL 284 7 Failure Analysis Cases 296 7.1 Example of FA Case - SRAM (0.18 m, 256K) 296 7.2 Example of FA Case - SRAM (0.15 m, 1M) 297 7.3 Example of FA Case - DRAM (0.15 um, 4M) 299 7.4 Example of FA Case – DRAM(0.11 um, 4M) 301 7.5 Construction Analysis 303 7.5.1 72 nm Double Data Rate DRAM (K038) 303 7.5.2 65 nm 6T SRAM (8159) 305 7.5.3 55 nm 6T SRAM (9090) 307 iv Chapter 1 Quality Management 1.1 Quality Policy ISSI Management and all other team members are committed to: - Understand and satisfy customer expectations - Provide defect-free products and outstanding service cost effectively - Continuously improve ours and our partners methods and processes - Training that enables us to do things right - Be the best in class in everything we do 1.2 Quality Organization ISSI headquarters is located at 1623 Buckeye Road, Milpitas, California, USA where the corporate policies and programs are determined and applied to world- wide operations. The Taiwan facility is located in the Science-Based Industrial Park, Hsin-Chu, Taiwan, R.O.C. The China office is located in Zhangjiang Hi-Tech Park, Pudong New Area, Shanghai and in Software Park, Xiamen. Operations in Taiwan and China consist primarily of research and development activities and Foundry and Subcontractor management. Subcontracted operations include Wafer Fabrication, Assembly and Final Test. Many of these subcontractors are located in Taiwan and China and are managed by the Taiwan and China Quality Organization. The Quality Organization is outlined in Figure 1-1. Quality and Reliability Assurance Division USA Quality China Japan Failure Reliability Quality Assurance Quality Quality Analysis Department Assurance Department Assurance Assurance Department Customer Quality Quality Customer FA Reliability Quality System Assurance and Support Engineering Engineering Section Section Section Section Section ‐ ISO 9001 ‐ RMA ‐ PIQC/OQC/ ‐ RMA ‐ Product ‐ Doc Control Handling WQC Analysis Qualification ‐ Customer ‐ CAR Report/ ‐ Subcontractor ‐ Customer ‐ Reliability Audit/Survey Follow‐up Management Technical Monitor ‐ Internal ‐ Subcontractor Support ‐ Package Audit Audit/Survey Failure Analysis Figure 1-1 ISSI Quality Organization 1 1.3 ISO 9001 Year 2008 Revision The Management team has defined the quality policy and objectives for ISSI and has established a quality management system to ensure that the quality policy and quality objectives are understood, implemented and maintained. The Quality System defined in ISSI Quality Manual is in compliance with the requirements of ISO 9001: 2008. It is stratified and compiled into documents with the Quality Manuals at the top supported by procedures, specifications, regulations, rules and detailed work instructions, etc (see Figure 1-2). Employees are trained and keep records of duties carried out according to the prescribed methods based on the latest documents to ensure that the constructed quality system is implemented in the prescribed manner. The quality system is periodically checked and evaluated through the internal quality audits and external audits by ISO certified agencies to provide opportunities for continuous improvement. Figure 1-2 Quality Document System ISSI in USA was certified to ISO 9001:1994 in Sept 1995. With the continuous effort in quality improvement, ISSI achieved the ISO 9001: 2000 standard in July 2002. And, ISSI is certified to ISO 9001:2008 in 2009. All ISSI locations passed ISO9001 assessments in 2005 conducted by Underwriters Laboratories (UL), one of the leading international certification bodies, as shown by the certificate issued in Figure 1-3. ISSI is not only certified to ISO/9001 but also achieved the required quality system level as required by ISO/TS16949 through team effort in the past few years. ISSI has implemented ISO/TS16949 quality system requirements and has successfully passed several automotive customer audits that are leaders in the international automotive industry. All employees are moving forward through continuous improvement. 2 3 Fig. 1-3 ISSI ISO 9001:2008 Certificate 4 1.4 Quality Systems ISSI Quality systems have evolved to comply to ISO/TS 16949 compliance. While not all ISSI products are shipped to automotive, the system requirements have been embraced to attain more robust quality processes. 1.4.1 Process Map The inter-relationship of ISSI systems is shown in the Fig 1-4. Fig 1-4 Process Map – Interaction Diagram 5 1.4.2 Advanced Product Quality Planning ISSI linked together the requirements of the automotive Advanced Product Quality Planning by setting up Product Planning Form (PPF) and New Project Checklist (NPCL) System. The system is web based and can be accessed by all the team members. In the NPCL system, all the steps and requirements for the life of a product can be documented and tracked. The following processes contribute to the success of the NPCL 1) Product Planning – Marketing gets the new project approved 2) New Product Plan – Marketing endorses the project to Design who will work with Marketing, Development and Engineering to put the product plan together 3) Design and Development – at this stage, Design works with Technology Development for the actual Design of the product taking into consideration customer requirements for the product. One tool used at this stage is the Design FMEA.
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