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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