PRODUCT REALIZATION FLOW CHART - Sahasra Electronics
CONTRACT REVIEW
Input
Customer RFQ /PO
Customer Product
Requirements
Quoting/Order Acceptance and review of
PO Process
5.2 Customer Focus 5.4 Planning 7.1 Planning of Product Realization 7.2 Customer Related Process
Contract Review
New Product
RepeatProducts
Quoting
Order Acceptance
Production Control
Purchasing Document
Control Sales Accounting Engineering
N0
Pre-Quote
Meeting
YES
Send Quote to Customer for Review
Scheduling
Send Completed copy of Order Acknowledgement to customer
Approved and Scheduled Production OUTPUT
PURCHASING
Input
(Approved BOM )
Purchasing Process
Turnkey
5.2 Customer Focus 5.4 Planning No 7.4 Purchasing
YES
Parts Shortages
Report
(MRP
Data Base)
Place Parts Order (AVL)
Supplier
Yes
Accepts
Order
NO
Customer Supplied Materials
NO
Alternate Component
s Request
Required
YES
Alternate Components Request to Customer
Completed Material Orders OUTPUT
PRODUCT REALIZATION FLOW CHART
MaterialReceiving
Off-Line Codes Programming
Surface Mount Production
INPUT ( Received Raw
Material)
Preservation & Delivery
Product ID & Trace ability Moisture Sensitive
Devices ESD Procedure
Receiving Process
5.2 Customer Focus 5.4 Planning 8.3 Control of Non-Conforming Products
Devices Required Off-
Line Codes Programming
Off-Line Codes Programming
5.2 Customer Focus 5.4 Planning 8.3 Control of Non-Conforming Products
NO
Off-Line codes Programming
Work Instructions
Verify Quantities & Verify
to AVL
Yes
IQC
No
Control of Non-Confor
ming Products No
Yes
Preservation
Off-Line Codes Programming
Device ID & Traceabilty Moisture Sensitive
Devices ESD Procedure
NO Checksum Verifications
YES
KitRelease
Completed & Verified Kit OUTPUT
Control of Non-Conforming
Completed Kit OUTPUT
SMT Work Instructions
SMT Build Work Instructions
( Print & Placement Program )
First Article Run
NO
First
Article
Validation
YES
Productio n Release
Pre-reflow Inspection/Tweaking
Re-flow Profile Work Instructions
VI AOI AXI
Surface Mount Production Process
5.2 Customer Focus 7.2 Customer Related Process 7.5 Production 8.2 Monitoring & Measurement 8.3 Control of Non Confirming Products 8.5 Improvement
Post Re-flow work NO instructions
SMT Rework
YES
PCB
NO
Cleaning
Required
Yes
PCB Cleaning
NO
Non Confirming
YES
Control of Non Confirming Products
NO
YES
Post Cleaning Work
instructions
Completed Assemblies ready for Pth,mounting or Shipping OUTPUT
Through Hole Preparation & Mounting
Pth mounting Work
Instructions
NO
YES
Preparation Work Instructions
NO
First
Piece/Validation
YES
Board Masking
ManualPth Parts
Population
Pth mounting Work
Instructions Product ID & Traceabilty ESD Procedure
YES NO
First Article
Wave Soldering
Wave Soldering Work
Instructions
ESD Procedure
Pth Process
5.2 Customer Focus 7.2 Customer Related Process 7.5 Production 8.2 Monitoring & Measurement 8.3 Control of Non Confirming Products 8.5 Improvement
NO
First
Piece/Validation
YES Production
Release
Final Touch-up/PTH
Final Cleaning
Completed Assemblies ready for Final Visual Inspection & testing
In-Circuit Testing
INPUT
( Populated assemblies)
NO
ICT
Required
YES
ICT & Visual Inspection Process
5.2 Customer Focus 7.2 Customer Related Process 7.5 Production 8.2 Monitoring & Measurement 8.3 Control of Non Confirming Products 8.5 Improvement
In circuit Testing NO work
Instructions
YES
Reject
Re-work
Control of Non-Confirming
Products
NO Sample Inspection
YES
Reject
Re-work
Control of Non-Confirming
Products
Completed & Inspected assemblies ready for Functional Testing/Conformal Coating/Epoxy Potting/Shipping
Functional Testing
Test Work Instructions
Functional Testing
Test Procedure Work
Instructions
Product ID & Trace ability
ESD Procedure
Calibration
Training
5.2 Customer Focus 7.2 Customer Related Process 7.5 Production 7.6 Control of monitoring & measurement systems 8.2 Monitoring & Measurement 8.3 Control of Non Confirming Products 8.5 Improvement
Pass NO Test YES
FinalQC Work Instructions
YES
YES
100% Visual Inspection Work
Instructions
PTH Rework/SMT Rework
Non-
NO
Confirming
YES
Control of Non-Confirming
Products
PCBA ready for Conformal Coating/Epoxy
Potting/Shipping
Conformal Coating/Epoxy Potting
Conformal Coating Required
YES
Conformal Coating Work Instructions
Epoxy
Potting
NO
YES
Epoxy Potting Work
Instructions
Special Process
5.2 Customer Focus 7.2 Customer Related Process 7.5 Production 8.2 Monitoring & Measurement 8.3 Control of Non Confirming Products 8.5 Improvement
Shipping
Packaging & Delivery Work Instructions Product ID & Trace
ability ESD Procedure
Training
Preservation & delivery Work Instructions
Shipping
5.2 Customer Focus 7.2 Customer Related Process
Procedure Work Instructions
Product ID & Traceability ESD Procedure
Training
Procedure Work Instructions
Product ID & Traceability ESD Procedure
Training
NO Ist
Piece YES
Release Production
NO
Ist
Piece
YES
Release Production
Rework NO
100% Visual Inspection Work
Instructions
YES
Rework NO
100% Visual Inspection Work
Instructions
YES
Completed assemblies for
Shipping
Customer Specific Instructions NO
Shipping Profile
YES
Packaging & Delivery
Final Product is packaged & Ready for delivery
Customer Feedback
SEPL Product Realization Chart Created Date: November,01,2009 Rev: A Created By: Parvez A. Khan
Document Controlled Approved By:
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