npi expectations

Rules of Engagement for Proto / Pilot PCAs

The following are requirements that are needed in order to be successful to support proto / pilot PCAs. This is in order to improve the accuracy of Foxconn product schedule, time to market and quality with respect to assembly and test of PCAs as well as fabrication of PCBs. This will set the level of expectation up front for internal functional groups as well as NPI PCB/PCA vendors.

Assumptions:

Time line assumes business days Complexity is defined as

o Low – No logic involved i.e. PCI switch boardso Medium – some logic involved i.e. Memory, Backplane, Peripheral boardso High – High level logic involved, parts count 2200+ and test nodes 3500+ i.e. I/O, Processor, Host boards

Add additional time for materials when build is scheduled at international sites e.g. Mexico, Scotland etc

Expectation Deliverables Action Item Owner

CONCEPT

1.

Assess design requirements vs. EMS manufacturing capabilities; identify design requirements that are outside of stable /reliable EMS capabilities

EMS capability matrix ISS SC

2. Develop processes partnering with EMS resources to support new component / design requirements.

Align development of new processes to HPQ program

requirementsNew processes validated prior to

1st HPQ proto board

ISS SC

3. EMS provides DFx Feedback as and when HPQ (ISS SC) provides the data

DFx issues list to be provided back to ISS SC within 1 business

day

EMS

4. EMS to coordinate with HPQ Process / Design / PCB procurement engineering to optimize PCB panelization to minimize PCB costs during the mechanical design phase

Optimized PCB dimension within 1 business day from dxf file is

available.

ISS SC

MATERIALS1. Materials list to be provided to EMS via soft

copy at least 1 business day in advanced prior to actual receipt of materials at EMS site. Hard copy to come with shipment.

Materials list of the items shipped in an attached format

HPQ Program teams

2. 80% of the consigned materials to be made available at the EMS site at least 5 days in

advanced of scheduled PCA build start (except for PCBs and unique chip set).

(Materials to be shipped as early as possible as there could be multiple builds

scheduled at the EMS site)

Materials kitting and shipment

See Appendix A for attrition values

HPQ Program teams

Rev 5.0 HP CONFIDENTIAL – Need to Know Required May 6, 2003 3


3. Remaining 20% of the materials to be made available at EMS site at least 1

business day in advanced of scheduled PCA build start (including PCBs and unique

chipset)

Shipment tracking info to EMS HPQ Program teams

4. HP be notified of any materials issues within 2 business days after receipt of initial

material kit

Detailed list of material issues to HP – attached format

EMS

5. HP p/n labels on the reels should not be covered up by other labels when EMS

applies their labels

Apply labels in a clear area EMS

6. EMS to provide the excess material list (Qty shipped – qty used) to HP after

completion of the scheduled PCA quantity. This report should be provided within 10 business days of start of the PCA build

Attached format EMS

7. COMMON MATERIALEMS will provide common material upon Hp’s request.

8. If material kits include more than one skid and/or 100+ part numbers, materials to be

made available to EMS site at least 7 business days in advanced of scheduled

PCA start.(Materials to be shipped as early as

possible as there could be multiple builds scheduled at the EMS site)

Materials kitting and shipment HPQ Program teams

9. EMS to provide material process plan for HPQ consigned material and EMS provided

materials

EMS NPI Materials Team.



10. EMS to provide process plan to transition materials from site to site

EMS NPI Materials Team.

11. SMT parts are required to be in Tape/Reel and/or Trays per supplier specification. No

loose SMT parts in ESD bags or tubes allowed (except SMT parts for 2nd

assembly)

SMT parts in T/R HPQ Program teams

12. If SMT parts required to be Tape/Reel by EMS, parts are to be made available at least 3 business days in advanced of

scheduled PCA start date.

SMT materials highlighted in material list that Tape / Reel is

required

EMS T & R capability HPQ Program teams

13. If the materials are made available to EMS within 1 business day window, all the SMT

materials need to be in Tape/Reel packages (except QFP/BGA where applicable). No loose parts, parts in

tube/trays allowed

SMT parts in T/RException to be handled on a

case by case basis

HPQ Program teams

14. HP to identify the moisture sensitive devices with labels

MSD parts to be provided in a sealed bags

HPQ Program teams

15. EMS to comply with J-STD-033 for MSD Bake the parts as necessary and reseal after build completion. EMS to keep the log of open

parts and baked parts

EMS

16. SMT materials shipped in a T/R should have at least 14” leading and 18” trailing

empty tape.

Tape & Reel with sufficient length HPQ Program teams

17. Untested PCAs to be shipped to HP with following schedule(business days) after the

start of the PCAs (typically low qty)

Complexity is defined as: Low – No logic involved

i.e. PCI switch boards Medium – some logic

EMS NPI Production

Team.



50% 75% 100%Low 3 days 6 days 7 daysMed 4 days 7days 8 daysHigh 5 days 8 days 10days

involved i.e. Memory, Backplane, Peripheral boards

High – High level logic involved, parts count 2200+

and test nodes 3500+ i.e. I/O, Processor, Host boards

18. Tested PCAs to be shipped to HP with following schedule after the receipt of

“working” test fixture/programs from HP (see item 51 for definition of working ICT

fixture and program)50% within 2 days75% within 5 days

100% within 7 days

EMS NPI Production

Team.

BOM / CAD19.CAD, Gerber, BOM locked and released at

least 5 business days prior to scheduled start (for all PCAs except Highly complex PCAs) Known formats. As much advance notice (1-2 days) as possible is needed for

new formats so that a parser can be created.

Data files to be encrypted and released to EMS

HPQ Program teams

20. CAD, Gerber, BOM locked and released at least 7 business days prior to scheduled

start for Highly complex PCAs,

Data files to be encrypted and released to EMS

HPQ Program teams

21. EMS should use EDB format for BOM ONLY when there is an upper level

assembly (mechanical parts) involved.

EMS PM, PE and Records Department



22. HPQ to provide mechanical drawings for the 2nd assembly operation to EMS at least 3 business days prior to start of PCA build

Mechanical drawings HPQ Program teams

23. HPQ to communicate 6-8 weeks in advance the process requirement for

unique component to EMS (e.g. VHDM, BGAs)

Provide component spec or process requirements

HPQ NPI Engineering

24. All the part numbers on the BOM should have associated reference designators.

HPQ Program teams

25. No bogus part numbers on the BOM allowed. If HPQ part numbers are not

available (including off-line programmed parts), use the PCA # with dash number as

5xx (eg 010391-501)

Only valid HPQ part numbers on the BOM

HPQ Program teams

26. EMS to provide a parser for duplicate part numbers or a process to combine them on

the BOM before parsing

EMS will process EM’s on an internal Special

Instruction Process.

EMS Records Dept

27. Exception memo for the purpose of making changes to an NPI build to have a standard

HP format

Attached format HPQ Program teams

28. Exception memo to be provided to EMS at least 24 hrs prior to schedule start of the

PCAs

EM to be released EMS will process EM’s on an internal Special

Instruction Process.

HPQ Program teams

29. Exception Memo to be provided to HP internal teams (Test, NPI & Procurement

engineering) at the same time it is provided to EMS

EM to be distributed to “ISSG EM Distribution” list

HPQ Program teams

30. Identify the programmed parts (ICT), socketed parts, off-line programmed parts

on Exception memo

Edited EM for ICT / offline programmed parts

HPQ Program teams



31. For off-line programmed parts, HPQ to release Hex code, AVL info for the blank and checksum at least 5 business days prior to the start of the PCA build so as to complete first articles and get HPQ approval of the programmed device(s).

EMS will deliver 1st article to HPQ for approval within 3 business

days provided the supplier being used for programming can obtain

the blanks.

HPQ to provide 1st article approval/reject within the

same day of receipt.

HPQ program teams/

EMS NPI Materials Team

32. EMS to provide real time support for CAD layout and checking prior to ordering tools – i.e., stencils, etc.

Timely / regular reviews of PCAs. All DFx input prior to 3 business days before final check during

database release process

EMS

33. PCB suppliers to provide DFm review at each gerber release

Timely / regular documented reviews of PCBs by production supplier within 5 business days

Corp PCB Procurement

34. HP to provide PCA New Product Introduction readiness checklist to EMS at least 5 business days prior to scheduled

start of the PCA build

HPQ NPI Process

Engineering

35. PCB order checklist complete prior to release of PCB artwork

Checklist signed off HP teams

36. HPQ to provide a central repository/server with FTP link for EMS to access data /

documentation

HPQ to investigate the feasibility On Going – iSDP HPQ / EMS

37. EMS should provide build reports within 5 business days from the completion of 75%

of the scheduled PCA quantities

Build report should include but not limited to process issues, DFx issues, process yields, test

yields, root cause analysis, program risk etc. See attached

sample report.

EMS NPI Engineering

Team

38. EMS should provide reports/feedback on logistics (i.e. material, schedule etc) issues to program teams within 5 business days of

PCA build start(Do not include in build reports)

An E-mail from EMS within 5 days of PCA build start

EMS NPI Materials Team



Test (FP – Flying Probe)39. Artwork will be approved to Test

Engineering resources before PCB check is complete and released to PCB vendor

Artwork HPQ Program teams

40. Schematics and BOM with correct Reference designators will be supplied to Test Engineering at PCB order 7 working

days prior to build for all PCAs except Highly Complex where this requirement is

10 days.

SchematicsBOM

PDF format . BOM format

HPQ Program teams

41. Quote and Purchase order placed & maintained for test services

Purchase Order HPQ Test Engineering

42. Flying Probe Program (debugged) delivered with following schedule after

Receipt of 1st PCA Low complexity – 1 Business day Medium Complexity – 2 Business days High Complexity – 3 Business days

Flying Probe Program EMS NPI Test Engineering

43. Flying Probe machine to be made available within the same area of NPI

Currently, no plan to have FP within NPI. Will be

available on site due to the lack of builds requiring FP.

44. EMS to provide Testability Design guidelines

Test (ICT)45. Artwork will be approved to Test

Engineering resources before PCB check is complete and release to PCB vendor

Artwork HPQ Program teams

46. Schematics & BOM with correct Reference designators will be supplied to Test

Engineering at PCB order 7 working days prior to build for all PCAs except Highly Complex where this requirement is 10

SchematicsBOM

PDF format. BOM format

HPQ Program teams



days. 47. A mechanical sample of the PCA will be

supplied to Test Engineering at PCB order 7 working days prior to build for all PCAs

except Highly Complex where this Requirement is 10 days.

Previous rev / run fully populated PCAs

HPQ Program teams

48. Initial program complete and Test fixture ordered 5 working days prior to build for all PCAs except Highly Complex where this

requirement is 10 days

Initial ICT Code Fixture Ordered HPQ Test Engineering

49. At least 5 Golden PCAs to be made available to HP within 3 days (highly

complex within 5 days) of start of PCA build to support test development.

100 % of 5 PCAs to go thru visual, AOI, X-ray inspection.

Coverage should include but not limited to all PTH, BGAs etc

EMS Test Document: EMS NPI Production

Team

50. EMS to provide AXI/AOI guidelines51. Debugged ICT program 4 working days

after receipt of first “GOLDEN” PCA except Highly Complex where this requirement is

10 days

Working ICT is defined as a fixture that has successfully passed agreed

upon quantity of "golden boards." When fixture is returned or used at

the NPI site it is the expectation from HPQ to have ICT Engineering from the contract manufacturer to provide the first level of debug and maintenance. HPQ will also provide

the list of tested and untested components to the contract

manufacturer at commencement of each NEW BUILD. If and when there are issues that can not be

successfully resolved by the contract manufacturer due to

software/hardware issues, HPQ will get involved. The assumption is that

the contract manufacturer has eliminated ALL process issues.

HPQ/ EMS Test Engineering

52. 100% of remaining PCAs need to have PCAs to go thru visual, AOI, EMS to provide a proposal EMS



Visual, AOI/Xray analysis done prior to final shipment.

X-ray inspection.Coverage should include but not

limited to all PTH, BGAs etc

to HPQ – see above EMS Test Document

Test (FBT – Functional Board Test)53. All the PCAs need to have passed either

the Flying Probe or the ICT requirement before FBT will be made available.

Completion of Flying Probe or Completion of ICT

EMS to perform Flying Probe or ICT before the

FBT station

EMS

54. All IUR (Internal User Orders) requirements fulfilled or a minimum of 3 functional sets of

PCAs with all necessary, cables, power supplies, processors, etc to be supplied to

Test Engineering a minimum of 6 weeks with a preference of 8 weeks before

expected date of service for Pilot

Necessary PCAs, Cables, processors, power supplies

HPQ Program teams

55. Appropriate System level specification, block diagram and theory of Operation Supplied, Schematics, and Access to

Design’s Shared File location 8 weeks prior to expected date of service. Access to

appropriate design resources.

Access to information HPQ Program Teams

56. Design, Build and Debug Prototype/Pilot test Equipment. Validate equipment

against Diagnostics before shipment of fixtures to site.

Competed Functioning Validated Test Equipment

Designs. ATEs/Hmus to supply to sites.

HPQ Test Engineering

Team

57. If HP is unable to validate test equipment before shipment. Supply adequate and

technically enable resources to handle this at supplier end. First level of responsibility

is HP’s

Validated Test EquipmentSupply adequate and technically

enabled resources.

EMS Test Engineering

Team



58. Supply adequate resources to trouble shoot Test Equipment or PCA issues. Supply

adequate communication to HP Corporate Test Engineering for Problem resolution

Supply adequate and technically enabled resources.


Team

Test (Run-in)59. All the PCAs need to have passed all

previous test steps.Completion of all previous tests. EMS NPI

Production Team

60. Validate Run-IN Diagnostics at HP before placing Requirement for RUN-IN on

Supplier.

Validated Diags HPQ Test Engineering

61. If HP is unable to validate diags EMS to assist in Diag validation. Supply adequate

and technically enabled resources to handle this at supplier end. First level of

responsibility is HP’s

Supply adequate and technically enabled resources. Supply adequate communication to

resolve issues.


Team

Packaging

62. HP to provide packaging information highlighting the requirement.

HPQ to discuss internally with design engineering and

packaging group

HPQ Program teams

63. If EMS is to provide packaging solution, provide PCA samples to EMS at least 3

weeks prior to the start of the PCA

PCA Samples to EMS. EMS to provide packaging samples

HPQ / EMS

Shipping64. HP to identify the PCA shipment

information identifying contact, phone, address, carrier etc and provide this info to

EMS

HPQ Program teams

65. EMS to provide the shipping information with tracking number to HP by 10 AM EST

the following day.

EMS



General66. At the time of scheduling PCA build with

EMS, communicate the PCA test (FP, ICT, FBT) requirements

# of boards and complexity will determine the type of test

HPQ Program teams

67. HPQ to provide the contact list of employees to EMS NPI 24 hrs in advance

of their visit to EMS with the function defined

HPQ

68. EMS to communicate on a daily basis the status of the build to HPQ teams, including but not limited to WIP, build, test, schedule

etc

Daily e-mail and/or WIP report

69.H

HPQ to provide report card to EMS for each build within 5 business days of the

completion of the build and receipt of build report from EMS

Report Card HPQ to provide sample report card to EMS for

review

HPQ NPI Team

70. EMS should submit final DFm / DFt /DFSC feedback to HPQ for approval and

incorporation into the NPIR as a step 3 gate

Final DFm / DFt reports to HPQ Process engineering /

Procurement engineering

EMS

Scheduling71. Any factory / line downtime, materials

issues, resources issues need to be communicated immediately to HP program

teams.

Contact HPQ Program Coordinator or Procurement

Engineering via phone, pager and follow-up with email.

EMS Program Management or

Engineering Team

72. HP to provide updated PCA build schedule once a week to EMS

PCA build schedule HPQ to provide upcoming 6 months schedule

HPQ Program teams

73. EMS to feedback to HPQ confirming the schedule within 1 business day for

immediate need and within 3 business days for subsequent PCA builds

PCA build schedule EMS Program Management

Team

Process



74.EMS to provide the rework/repair capability for BGAs

Rework profiles and yield EMS NPI Production and

Engineering Team

75. HPQ to provide non-functional PCAs to EMS for thermal profile development.

Sample PCAs HPQ / EMS


Appendix: A

General SMT material attrition guideline:

* Additional 100 pcs + 2% if description contains:Res ChpRes VarCap ChpFerrite beadPackaged: 0402, 0603, 0805, 1206, 1210

* Additional 30 pcs + 2% if description contains:Cap, TantPackages: 18182, 2010, 2512, 3216SOTSMT LED

* Additional 10 pcs if description contains:RADAXLPTHIcs

Note: BGAs and unique chipsets may be an exception

Appendix: BEMS = Environmental Management System

npi expectations

Documents

ems resources

common material ems

ems hpq program teams

sc materials

materials list

attached format ems

materials issues

ems manufacturing capabilities