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30ManagementofSubcontractors1TaskForceOnaverage,40%ofproductioncostisduetomaterialprocurement;therefore,subcontractormanagementisextremelyimportant.Itfollowsthatasubstantialportionofqualityproblemsisrelatedtothesubcontractor.Establishmentofapartnershipisessentialinorderforbothpartiestosucceedintheirbusiness.Thesubcontractorshouldmakeapositivecontributiontodesign,production,andcostreduction.Emphasisshouldbeplacedonthetotalmaterialcost,whichincludesthatofpriceandquality.Inordertoensurehighquality,ISSIQAandrelevantengineeringdepartmentsareperformingon-siteprocessmonitoringviaataskforceunitasshowninFigure1.Figure2-12MethodologySubcontractormanagementactivitiesinclude:1)Subcontractorqualification&ApprovedVendorListcontrol2)Controlofbillofmaterial(BOM)andprocess3)PackageIQC4)MonthlykeyprocessCpk1(>1.67)report5)Reliabilitymonitoring(plusde-lamination,diecrack,andcrateringcheck)6)Foundry/Assembly/Testinghouserating7)Monthly/Quarterlymeetingwithkeysubcontractors1Cpkisanindexofprocesscapability.Itmeasurestheprocessstabilitywithrespecttothestandardsoveracertainperiod.TocalculateCpk,itisnecessarytocalculateanotherindex,Cp,whichmeasuresthedatabiastowardthestandardcenter.6)limitlowerimitlupper(Cpand3|average-valueaveragetheclosesttolimitstandard|CpkwhereisthestandarddeviationTestingMonitorBurninMonitorAssemblyprocessMonitorIn-processMonitorFoundryprocessMonitor318)In-processmonitor9)Processcontrol(Man,Machine,Material,Method)10)Productoutput(inspectgoodandrejectpartsineachstage)11)ISSIfindingandreporting12)Subcontractor’sactionandcontinuousimprovement13)ReviewFMEA(correctionseffectivenessvalidation)14)Regularandnon-regularonsideaudit3QualityRating/AuditSubcontractorqualityratingsprovideanobjectivemeasurementofasubcontractor’sperformance.Thismeasurementwillleadtoasubcontractorreview,allocationofbusiness,andidentificationoftheareasforqualityimprovement.ISSIsubcontractormanagementteamconductsmonthlyreviewmeetingonsubcontractors'performance,productqualityandrelevantbusiness.ItisnotonlymonthlyreviewbutalsoquarterlyratingandrankingreviewmeetingatISSI.Inordertocontinuouslyimproveproductquality,ISSIteaminformsratingandrankingtoindividualsubcontractorsinordertoaskforimprovementactionsparticularlyiftheratingislowerthan70%.ISSIauditteamismainlycomposedofseniorQAengineer,QSengineerandrelevantPE,RE,TD,PCengineeringpeople.QAistheleaderofannualauditteamwhenperformingauditatsubcontractorsite.Auditsareplannedatbeginningofeveryyear.Theannualauditscheduleisthebasisoftheauditplan.Also,arandomauditcouldbeperformedincaseofanomalyoroccurrenceofaseriousproductqualityproblem.Thevendorqualityratingsarebasedoncertainmeasuresandareweightedasfollows:ElementPointValue1.QualityContribution402.Technology153.Flexibility/Service154.Cost155.Delivery15324SupplierRelationshipSubcontractorrelationshipisvitaltoproductquality.InISSI,bi-directionalcommunication/meetingswithsuppliersareperiodicallyheldtoreviewifthesupplierperformancefollowsISSI’srequirementsclosely.Thekeycommunicationitemsaredefinedinthefollowingdiagram(Figure2-2):Figure2-2SupplierRelationshipISSIQRASupplierQRAISSIQRA•Qualifyingallprocessandmaterialchanges•YearlyauditarrangementforQSandprocess•Yieldmonitoring&failbinanalysis•Continuousimprovements•Physical/ConstructionAnalysisforalltechnologies•Reliabilitymonitoringplan•Monthly/Quarterl...