Planning, Control and Improvement of QualityPlanning, Control and Improvement of Quality
CERTI executes projects to develop, operationalize and reorganize systems to guarantee industrial quality, understanding this to be a strategic factor, because it is directly related to the satisfaction of external clients and to losses due to costs caused by a lack of quality. These systems can be used by client companies from the development phases of their new products and production (systems of quality planning systems) to the phases of routine operations of industrial production (systems of quality control and improvement).
QUALITY CONTROL PLANNING
The planning ranges from the definition of the quality characteristics, considering in the case of mechanical design the GD&T specifications, to the specifications of measurement systems and laboratory infrastructure.
Quality control planning in production
In this line of quality control planning, used in industrial production, CERTI acts in different activities and applies distinct and integrated methods of quality engineering, such as:
- Critical analysis of product design documentation
- Failure mode and effects analysis (DFMEA/PFMEA)
- Preparation and implementation of quality control plans
- Documentation and standardization of quality controls
- Acceptance planning by sampling
Coverage analysis and strategy of production tests of printed circuit boards
Development of automatic inspection strategies and production tests of printed circuit boards based on: analysis of defects per opportunities; coverage analysis and definition of testing strategy; analysis of design for test; definition of requirements for production tests and implementation analysis at potential suppliers of printed circuit boards.
Specification of inspection equipment and tests applied to printed circuit board assembly
CERTI supports the client in specifying and selecting inspection and test equipment employed in printed circuit board assembly. This activity relies on a coverage analysis and evaluation of different strategies, and on the requirement specification/evaluation for different types of inspection and test equipment for printed circuit boards, considering:
- Solder Paste Inspection - SPI
- Automatic Optical Inspection - AOI
- Manual Visual Inspection - MVI
- Automated X-ray Inspection - AXI
- Manufacturing Defects Analyzer - MDA
- In-Circuit Testers - ICT
- Boundary Scan Testing - BST
- Flying Probe Tester FPT
Selection of measuring equipment Development of measuring methods/procedures and calibration plans Design of laboratories and measuring rooms Implementation of statistical process control (SPC) and measurement systems analysis (MSA)
QUALITY PLANNING IN THE DEVELOPMENT OF NEW PRODUCTS AND PRODUCTION PROCESSES
Aiming the prevention, detection and control of internal failures and defective units in a production process, and at evaluating and validating new products and/or processes and new parts for production supplied by third parties, CERTI applies quality planning techniques based on distinct quality engineering methods.
Analysis of the product specifications and requirements
CERTI provides technical support for specifying product and process development requirements. Example: information survey and analysis, verification and validation test requirements, standards and certifications of concern.
Planning and execution of the product verification and validation tests
Definition of verification and validation test strategy, planning of prototype tests (alpha and beta) and of pilot production, coordination and/or execution of tests, preparation of required documentation, preparation and publication of test reports needed for product certification, such as performance test, reliability test, lifetime test, safety test, electromagnetic compatibility test, and so forth.
Verification Tests for new product certification
Identification, evaluation and selection of suppliers of accredited test services, interface between different interested parties (client, project development team, certification agencies, accredited testing laboratories) and support for contracting tests related to new product certification. Critical analysis and evaluation of the results obtained in first investigation services for building new products and/or in conformity assessment of new products in accordance with specific standards.
Planning and execution of reliability tests
Planning, preparation and execution of tests associated with product development reliability, such as:
- Environmental Testing
- Lifetime Testing
- Accelerated Stress Testing - AST
- Highly Accelerated Life Testing HALT
Evaluation, development and qualification of suppliers and new production items
Evaluation, development and qualification/approval of suppliers and application of approval processes for production parts and packages.
Critical analysis of the documentation of specification of the product design
Critical analysis of the design documentation (drawings and specification sheet) prepared by product design teams in an integrating manner, involving areas such as purchasing, receiving quality control, processes.
Failure mode and effects analysis (DFMEA/PFMEA)
Identification of potential failure modes for the items of a product (DFMEA) and/or for the operations related to a manufacturing/assembly process (PFMEA). Meetings with multidisciplinary team to fill in FMEA form, to evaluate severity indices, occurrence and detection, to calculate and classify risk priority numbers (RPN). Drawing-up and implementation of the action plan for mitigating higher risk priority numbers.
Elaboration and implementation of quality control plans
Preparation of quality control plans, including receiving control plans, operation control plans, manufacturing control plan. Preparation, operation on the shop floor of production inspection and test stations, application pilot, testing and validation of the plans. Preparation of quality control documentation (log sheet, inspection sheet, test sheet, failure reports) and training of companys inspectors, operators and quality analysts
Documentation and standardization of the quality controls
Preparation of standardization documents associated with quality control process, such as:
- Receiving control plan
- Operation control plan
- Manufacturing control plan
- Controlling log sheet
- Production inspection/test sheet
- Failure report
- Product pass/fail criteria
Acceptance planning by sampling
Description of basic concepts related to statistical tables and sampling plans. Support for determining sample size and criteria associate with acceptance and non-acceptance of batches. Preparation of sampling tables to be used by quality control professionals.
EVALUATION AND IMPROVEMENT OF PRODUCT QUALITY
Planning, preparation and execution of tests, seeking to determine the thermal performance or the robustness in relation to different types of stress (heat, humidity and vibration) that can be applied individually or combined, to identify and eliminate weak points related to the design solutions for products and to improve the reliability of circuit boards and electronic products. The work begins with the analysis of the specifications and measurements are made to evaluate conformity and identify improvements that can be made. In addition to technical competence, CERTI has an extensive laboratory structure for reference and analysis measurements of the capacity of processes.
Planning and execution of reliability and thermal performance tests
Seeking to assist the client improve the reliability of its circuit boards and electronic products, CERTI undertakes:
- Planning, preparation and execution of tests to improve reliability of electronic products (for example: environmental, highly accelerated life time (HALT), combined stress and others),
- Planning, preparation and execution of tests seeking the improvement of thermal performance of circuit boards and electronic products.
Implementation of the use of geometric specification of the product according to ASME or ISSO
Statistical studies of the capacity of manufacturing and measurement processes
Reverse engineering and dimensional analysis
SPECIAL PROJECTS TO GUARANTEE INDUSTRIAL QUALITYQuality planning systems
Conception, development and implantation of new systems and tools to guarantee quality in new product development and production processes and improve the qualification of outside suppliers.
Quality control and improvement systems
Development and operationalization, on the factory floor, of new systems and tools for control and improvement of industrial quality.
Support for the definition of quality and productivity indicators
Presentation and proposal of various options for quality and productivity indicators to be employed by manufacturing companies, considering different types of categories of performance indicators, such as, for example: Process Indicators, Purchasing and Supplier Indicators, Market and Client Indicators and Indicators of Innovation.
Planning of industrial quality for new factory units
Planning of quality in the development of new production process and design of processes needed to guarantee and control industrial quality, including implantation. Transfer of knowledge related to the applicable methods to guarantee industrial quality by providing training and courses. Involves activities that range from detailed study of products and determination of the equipment needed for quality control and of the processes to be used to evaluate and qualify potential suppliers and new production parts supplied by third parties, to the detailing of solutions proposed and support for the implantation of the unit.
Development and qualification of circuit board suppliers
Applies evaluation methods (previously developed, tested and validated methods) to help client companies identify new options in companies that assemble and supply circuit boards that are capable of executing the assemblage and supply of the circuit boards with the necessary quality and reliability.