exa3000/2200 product champion report july 25, 2003

EXA3000/2200 Product Champion Report

July 25, 2003

5/16/2003 NPTest Confidential 2

Content

Overview of the Product Champion Team ID and ObjectiveEXA2200

– EXA2200 Status – MTBF Indicator– Parts Usage– Outstanding Issues– Hot Watch List– Plans for Next Period

EXA3000– EXA3000 Status– MTBF Indicator– Parts Usage– Outstanding Issues– Hot Watch List– Plans for Next Period

Manufacturing FPYIIP IndicatorsHCR IndicatorsNew Product DevelopmentEXA2200/3000 Summary


Enhanced Product Champion

• The Enhanced Product Champion (EPC) Process is a company wide initiative that has allowed all pertinent units within the NPTest organization to strategically merge as one team, move as one team, and together, implement our strategy for a continued and enhanced level of success.

• The goal of the Enhanced Product Champion team is to monitor our worldwide system fleets, looking for development areas and risk potentials while driving those items for a fast and efficient reaction time to containment and solution.

EXA2200 Key Indicators

July 25th, 2003


EXA2200 Status

• MTBF fleet goals achieved for both 4wk and 13wk indicators, (>1000hrs compared to goal of 700hrs). Sustained since Q3 2002.

• Parts usage achieving goal since Q4 2002, (<1 bd/sys/month compared to a goal of 1.2 bds/sys/month).

• High speed cable plan moving forward. – Vendor now providing new style cables.– Spacers available through logistics. Material sent to Malta and currently

installed on 5 systems.

• Test head power monitor kits available through logistics.– 10 kits shipped to Taiwan and 10 to Malta.

– 5 installed in Malta, 1 installed in Taiwan


EXA2200 Key Indicators: MTBF

• EXA2200 fleet MTBF trend continues to increase.• All ST sites exceeding target of 700hrs for 4wk and 13wk indicators.• Continued and sustained success with high level focus committed

through SOP process.

ST EXA2200 Fleet MTBF

0

400

800

1200

1600

2000Ja

n-01

Feb

-01

Mar

-01

Apr

-01

May

-01

Jun-

01

Jul-0

1

Aug

-01

Sep

-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02

Feb

-02

Mar

-02

Apr

-02

May

-02

Jun-

02

Jul-0

2

Aug

-02

Sep

-02

Oct

-02

Nov

-02

Dec

-02

Jan-

03

Feb

-03

Mar

-03

Apr

-03

May

-03

Jun-

03

MT

BF

(h

rs)

0

10

20

30

40

50

60

Sys

tem

Co

un

t

No. of Systems

MTBF Target

13w k MTBF

4w k MTBF


EXA2200 Assembly Failure Pareto

• EXA2200 parts usage better than target.• Continued focus through SOP and Technical Services reliability reviews.• Repair processes well defined at all sites.

EXA2200 ST Fleet Assembly Failure Paretoparts / system / month

0.0

0.4

0.8

1.2

1.6

2.0

Feb

-01

Mar

-01

Apr

-01

May

-01

Jun-

01

Jul-0

1

Aug

-01

Sep

-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02

Feb

-02

Mar

-02

Apr

-02

May

-02

Jun-

02

Jul-0

2

Aug

-02

Sep

-02

Oct

-02

Nov

-02

Dec

-02

Jan-

03

Feb

-03

Mar

-03

Apr

-03

May

-03

Jun-

03

Other

APE

PSU

Pin Slice

PEC

Target


EXA2200 Outstanding Issues

• Test head power sequence monitor– Material available through logistics.

– 10 kits shipped to Taiwan.– 10 kits shipped to Malta.– 6 kits successfully installed to date, will continue to track.

• H-cage high speed cable solution– Cables built to new specifications now being supplied by vendor.– Back plane spacers available through logistics.– Supplied material to Malta for initial field installation.– Next steps:

– Track Malta systems to insure there are no new issues.– Release Tech Bulletin 161 to field.


EXA2200 Plans Next Period

• Test head power monitor.• Drive and track field implementation.

• Complete implementation plan for high speed bus cable solution.• Track system performance in Malta.

• Deploy tech bulletin.

EXA3000 Key Indicators

July 25th, 2003


EXA3000 Status

• MTBF continues above goal, (>2200hrs compared to goal of 1900hrs).

• BBC usage currently under control in Taiwan.• BBC Source gull wing upgrade in process, 19 of 22 systems completed.

• Target failure rate for VI needs to be established.

• Test head valve contamination issue continues to increase with no defined plan to address.

• Pec76 repair center data needs to be collected and understood.


EXA3000 Key Indicators: MTBF

• MTBF exceeding target for fleet.

EXA3000 Fleet MTBF

0

800

1600

2400

3200Ja

n-01

Feb

-01

Mar

-01

Apr

-01

May

-01

Jun-

01

Jul-0

1

Aug

-01

Sep

-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02

Feb

-02

Mar

-02

Apr

-02

May

-02

Jun-

02

Jul-0

2

Aug

-02

Sep

-02

Oct

-02

Nov

-02

Dec

-02

Jan-

03

Feb

-03

Mar

-03

Apr

-03

May

-03

Jun-

03

MT

BF

(h

rs)

0

20

40

60

80

100

Sys

tem

Co

un

t

No. of Systems

MTBF Target13wk MTBF

4wk MTBF


EXA3000 Assembly Failure Pareto

• Parts usage still above goal.– ST VI failures still high. 8 boards used in June.– Others bucket contains no commonality, no trend found.– For example, Malta’s Other bucket contains: secondary manifold, 2 VI

boards, An. Clock, SCP, HFE Pump.

EXA3000 Assembly Usage Paretoparts / system / month

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Feb

-01

Mar

-01

Apr

-01

May

-01

Jun-

01

Jul-0

1

Aug

-01

Sep

-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02

Feb

-02

Mar

-02

Apr

-02

May

-02

Jun-

02

Jul-0

2

Aug

-02

Sep

-02

Oct

-02

Nov

-02

Dec

-02

Jan-

03

Feb

-03

Mar

-03

Apr

-03

May

-03

Jun-

03

Other

APE

PSU

Pin Slice

PEC

Target


EXA3000 Outstanding Issues - VI Update

VI Reliability Update

• VI failures declined in May but not attributed to any field or reliability improvement action.• Repair center actions dominated by JFET and relay replacements.• Need to know the expected failure rate of the VI board.

– Systems running VI: Crolles-15, Grenoble-10, Malta-5– June data: 8 boards / 30 systems / 1 month = .26 VI boards per system per month. Too

high if we want to achieve .6 parts/system/month.

VI Board Repair Center Data

JFET 10Relay 7SRAM 4OP AMP 3NPF 2Fuse 2Cap 2ADC 1FPGA 1

VI Board Repair Center Data

0

2

4

6

8

10

12

JFET Relay SRAM OP AMP NPF Fuse Cap ADC FPGA

VI Board Failures by Month (Grenoble, Crolles, Malta)

Month Total FailuresJan-03 8Feb-03 8Mar-03 2Apr-03 15May-03 6Jun-03 8

VI Board Failures by Month

0

4

8

12

16

20

Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03

Total Failures


EXA3000 Outstanding Issues - HFE Contamination

Test Head HFE Leaks• Test head valves leak or spray HFE after removal of PEC boards.

HCR 11265, submitted 3/7/03, accepted 3/24/03– Evaluation received by engineering includes the following possibilities:

• Contacted 3M for an alternative to Monostat.• Redesign test head HFE valves - under consideration.• Replace all hoses in system with conductive hoses as in Sapphire to eliminate the

need for Monostat.• Establish a valve replacement schedule as has been done with pogo pins.• Add a second HFE filter specific for the test head.• Add an external flush/filter unit to clean the system.

– Need a defined plan to address this issue.

No update since June product champion meeting.


EXA3000 Outstanding Issues - PEC56 Crash

Malta PEC56 Test Head Crash• Defective system PMU caused all PEC56 boards to fail.

SCR 32521, submitted 3/11/03– Root cause analysis performed in Saint Etienne confirmed the system PMU was defective and

damaged the PEM on all pins when executing caltree_diag, path resistance subtest.• PMU is connected directly to the output of each pin during this test.

– caltree_diag was removed from the diagnostic script in Malta.– Notice sent to the field for all PEC56 systems.– SCR submitted to add a PMU check at the beginning of all diagnostics that connect the PMU to

the PEM output of the PE board, (SCR #SJS32521).– Containment plan in place in the field.

SCR completion date scheduled for end of July.


EXA3000 Outstanding Issues - BBC Status

BBC Field Data

• BBC failure rate continues to significantly decrease through June.• BBCS gull wing relay upgrade in process.

– 19 systems completed to date.• 12 systems at Sigurd• 6 systems at SPIL• 1 system at MediaTek

• Spares in place to support Taiwan, all new spares upgraded with gull wing relays.• New device in production at Sigurd, (MT1379), that does not use the BBC.

BBC consumption per system per month

0.0

0.2

0.4

0.6

0.8

1.0

1.2

Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03

0

5

10

15

20

25

30

35

Nb

of te

ster

s

Nb of testers

BBCS/sys/month

BBCM/sys/month


Intel EXA3000 MTBF

• Lowered 4wk MTBF on both 98194 and 98198 due to Pec76 usage.

• 4 Pec76’s have been replaced in June on these two systems.

• 5 Pec76’s have been replaced in July so far on these two systems.

• 98194 has used 3 Pec76’s• 98198 has used 6 Pec76’s• Reason boards are rejected in

the Field:• 2 for levels_cal• 2 for th_accuracy• 2 for FPGA loading failures• 2 for spechk• 1 failing customer program

Intel 13 Wk MTBF

0

500

1000

1500

2000

2500

ww

0318

ww

0319

ww

0320

ww

0321

ww

0322

ww

0323

ww

0324

ww

0325

ww

0326

ww

0327

ww

0328

ww

0329

98154

98194

98198

Target

Intel 4 Wk MTBF

0

100

200

300

400

500

600

700

800

ww

0318

ww

0319

ww

0320

ww

0321

ww

0322

ww

0323

ww

0324

ww

0325

ww

0326

ww

0327

ww

0328

ww

0329

98154

98194

98198


EXA3000 Plans Next Period

• Sustain MTBF trend.

• Develop long term BBC solution.

• Understand impact of VI issues and drive for resolution as parts consumption vs. goal is too high.

• Determine next steps to resolve test head valve contamination issue and develop implementation plan.

• Understand Pec76 failures, get repair center data.

HCR Metrics

July 25th, 2003


EXA3K HCR Metrics

EXA3K HCRS (Submitted)

0

2

4

6

8

10

12

14

16

18

20

Jan-

02

Feb-0

2

Mar

-02

Apr-0

2

May

-02

Jun-

02

Jul-0

2

Aug-0

2

Sep-0

2

Oct-0

2

Nov-0

2

Dec-0

2

Jan-

03

Feb-0

3

Mar

-03

Apr-0

3

May

-03

Jun-

03

Month

# o

f H

CR

S

Severity 1

Severity 2

Severity 3

Severity 4

Severity 5


EXA3K HCR Metrics

EXA3K HCRS (Accepted and Open)

0

5

10

15

20

25

May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03

Month

# o

f H

CR

S

Severity 1

Severity 2

Severity 3

Severity 4

Severity 5


EXA3K HCR Metrics

EXA3K HCRS (Accepted and Open)

0

5

10

15

20

25

May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03

Month

# o

f HC

RS

Severity 1

Severity 2

Severity 3

Severity 4

Severity 5


EXA3K HCR Metrics

Active Serverity 1 and 2 HCRS

HCR # Serverity Owner DescriptionOriginal Due

DateRevised Due

Date

11265 1 R. Gupta

HFE valves do not seal properly causing leaks, root cause: monastat is attacking the brass in the system generating zinc and copper particles that clog up the test head vales. Corrective action is to add a secondary 100 micron filter after the primary man 4/11/03 On Hold

11188 2 G. Iafrate

Cable lug thru hole isi too small for mounting stud, pn 79000579 neg 5.2V. Simi is replacing lug prior to shipment. no commit date

11218 2 R. GuptaAdd stiffener to pn 65132370, cal tree for test fixture. 3/21/03 On Hold

Manufacturing First Pass Yield

June 13, 2003


Functional Test - FPY


Margining - FPY


Final Test - FPY

InTouch Key Indicators

July 25th, 2003


InTouch 2k and 3k ticket count• Ticket count is holding steady with ups and downs based on the end of the quarters• InTouch had a large role in getting many of last minute Q2 systems and options

installed and accepted• InTouch is very busy supporting escalations, onsite support, installs and upgrades• We are in the process of changing primary 3k/2k support personnel to Sapphire and

training replacement


InTouch Content growth on EXA3k and EXA2k

• Excellent content growth results due to release of new options and lower ticket count

– When ticket count increases, content grow declines because of limited resources

• InTouch now has 4871 items on all products and 1424 for EXA3k/2k

EXA3000 Roadmap Update

July 25th 2003

Stuart Pearce


New option Updates

• This Period– SUN CPU EXA3K (same as ZX1280)– Deployment of 12 LCDPS program

• Upgrade DCITF, VVI, new cal diag loadboards• required for SUN ASIC and CPU• ASET8,9

– Deployment of 6.4 SW– Deployment of EXA3K MTK Giga3200– Deployment of 3.2Gbs TIA– ST TPA upgrade for Giga3200,GBS,TIA– ISE Analog upgrade (GBS)– Intel IDC EXA3K with Giga3200 and SS

exa3000/2200 product champion report july 25, 2003

Documents