Process Quality Control / Yield Management

To ensure consistent World Class Quality levels, requires a well-controlled manufacturing process that has an effective Real-Time Process Control system.

This enables measurement of change in Process Trends / Yields well in advance of customer shipment.

Poor Process Yields will result in excessive rework costs and high customer failure levels, at both product installation point and during the Early Life Period of warranty period.

Setting up effective Process Control programmes requires training of personnel in the aspects of Process Measurement and Problem Management, using well defined 'Corrective Action Procedures' and Problem management principles such as Ford 8D process, etc.

Process defects must be driven back to the earliest point in the process before the product accumulates too much value at later process stage, hence the need to map each key process and identify measurement 'pulse points' upon which process will be best controlled.

Without such control, a high % of production batches will be rejected at Outgoing Inspection stage. The nett result is high manufacturing costs and REDUCED PROFIT.

Reliability Solutions have set up several types of Statistical Process Control systems for electronic manufacturers, often the most simplest, manual systems work best, but it is important to identify the appropriate control process for the product type.

Hands-On consultancy to map the process and identify optimum measurement points (' pulse points') is followed by training on how to use the measurements and problem manages.

Continuous Improvement programmes are implemented and Process Improvement trend measurements used to measure effectiveness of change.

Reliability Solutions has helped companies improve yield levels by up to 70% and reduce Customer Quality fail rates by more than 60%