Table 1. Illustrative A-Matrix for a...

Table 1.

Illustrative A-Matrix for a control module assembly in an electronics company

Location (of manifestation)	Scrap (component damage) - IF	Rework (soldering defect) - IF	Cost of In-Process visual Inspection - AP	Warranty claim (module failure) - EF	Cost of supplier Qualification - PR	Excess inventory (buffer for defects) - IF	Downtime (machine jam) - IF
Supplier and incoming system
component kitting area	$▴$		$■$		$▴$	$■$
incoming Inspection - PSU	$•$	$▴$	$▴$ (high test time)			$▴$	$■$
raw PCB storage	$■$ (oxidation)
Production process system
SMT Line 1 - Paste Print	$■$ (smearing)	$▴$ (clean and rerun)	$■$				$▴$
SMT Line 1 - Pick and Place M/C A	$•$ (misplacement)	$▴$ (manual correction)				$▴$	$•$
Manual Soldering Station #1	$■$	$•$	$▴$ (100% Visual)			$•$	$■$
automated conformal coating	$▴$ (uneven coat)	$▴$ (strip and recoat)	$■$
In-Process quality control system
automated optical inspection (AOI)			$•$ (high cycle time)
In-Circuit test (ICT) station	$▴$ (false fails)	$▴$ (retest)	$•$ (fixture maint.)				$▴$
Finished goods and outgoing quality system
functional test station	$•$ (boot failure)	$▴$ (firmware reload)	$■$ (test records)			$▴$
packaging and dispatch	$■$ (label error)	$■$ (repack)	$■$ (final check)
Customer and post-sales system
customer returns processing				$•$ (high RMA volume)
field service team				$•$ (repeat visits)
QMS support system
training department					$•$ (cost of outdated materials)
calibration lab			$▴$ (overdue calibrations)

Location (of manifestation)	Scrap (component damage) - IF	Rework (soldering defect) - IF	Cost of In-Process visual Inspection - AP	Warranty claim (module failure) - EF	Cost of supplier Qualification - PR	Excess inventory (buffer for defects) - IF	Downtime (machine jam) - IF
Supplier and incoming system
component kitting area	$▴$		$■$		$▴$	$■$
incoming Inspection - PSU	$•$	$▴$	$▴$ (high test time)			$▴$	$■$
raw PCB storage	$■$ (oxidation)
Production process system
SMT Line 1 - Paste Print	$■$ (smearing)	$▴$ (clean and rerun)	$■$				$▴$
SMT Line 1 - Pick and Place M/C A	$•$ (misplacement)	$▴$ (manual correction)				$▴$	$•$
Manual Soldering Station #1	$■$	$•$	$▴$ (100% Visual)			$•$	$■$
automated conformal coating	$▴$ (uneven coat)	$▴$ (strip and recoat)	$■$
In-Process quality control system
automated optical inspection (AOI)			$•$ (high cycle time)
In-Circuit test (ICT) station	$▴$ (false fails)	$▴$ (retest)	$•$ (fixture maint.)				$▴$
Finished goods and outgoing quality system
functional test station	$•$ (boot failure)	$▴$ (firmware reload)	$■$ (test records)			$▴$
packaging and dispatch	$■$ (label error)	$■$ (repack)	$■$ (final check)
Customer and post-sales system
customer returns processing				$•$ (high RMA volume)
field service team				$•$ (repeat visits)
QMS support system
training department					$•$ (cost of outdated materials)
calibration lab			$▴$ (overdue calibrations)

Note(s):

Legend: $•$ Very Significant; $▴$ Significant; $■$ Minor. CoQ categories: IF = Internal Failure, AP = Appraisal, EF = External Failure, PR = Prevention

[ViewLarge]

Sharing Unavailable