,PCBAQualityProcessAudit,

,,,

,InformationandInstructions,

,Rev.5.0,

,PURPOSE,

,ThisdocumentwasdevelopedasanAuditTooltoassessPCBAManufacturingProcessCapability.,

,ItisintendedtoprovideanassessmentofPCBAManufacturingCapabilitybasedonPCBAManufacturingComplexity.,

,LesscomplexPCBA'swillnotrequirethesamemanufacturingcapabilityasmorecomplexPCBA's.,

,"Thusbymatchingcapabilitywithcomplexity,themosteconomicmanufacturingsolutioncanbedeterminedforasustainedqualityperformance.",

,ThetoolmayalsobeusedtoassessRMA/RepairCapability.,

,Aqualifiedauditormayalsousethistoolasaguidelinetoconductaprocess'GapAnalysis'basedonproductcomplexity.,

,"TheLeadFreesectionofthisAuditToolmaybeusedtoauditasupplierscompliancewithDell's""LeadFreeSupplierAssessmentSurvey""andtheiroverall",

,readinesstoproduceLeadFreeproduct.,

,,,

,SCOPE,

,ThePCBAAuditDocumentisprimarilyintendedtobeusedforsuppliers/manufacturersofPCBAProductsforDell.,

,TheauditdocumentmayalsobeusedtoassessthemanufacturingprocessforanyPCBAthatisincorporatedintoaDellassembly.,

,"WhenusedtoassessRMA/RepairCapability,thetoolmaybeusedatanylocationwhereRMA/Repairactivitytakesplace.",

,TheLeadFreesectionofthisAuditToolisintendedtoassesstheLeadFreeprocessandproductreadinessforanysupplierwhoseprocessorproduct,

,includestheproductionorrepairofsolderjoints.ThissectionoftheAuditToolalsoappliestoanysupplierwhoseprocessorproductusessolderfor,

,mechanicaljoiningofparts.,

,,,

,PCBACOMPLEXITYandCAPABILITYMATCHING,

,TheSQEAuditorwilldecidewhatPCBAComplexitycategorytoauditasupplierfacilityorpotentialsupplierfacilityagainst.,

,ThisdeterminationismadebasedonthecomplexityofthePCBAproducttobeoutsourcedorevaluated,

,"Todothis,thecomplexityoftheproductmustfirstbecalculatedusingDellToolCOR.40.WWP.SQ.0229.ThisisavailableonValueChain,DocVault,Common",

,"Root,PCBASQEToolKit.",

,"Knowingtheproductcomplexity,itisthenpossibletousethistooltomakeanassessmentofthelineinstalledforaproductofthatcomplexity.",

,"Thereare10categoriesofcomplexityusedbyDell,rangingfrom1(MostComplex)to10(LeastComplex).",

,"Inthisaudit,complexitycategoriesaregroupedintofivecategoriesascanbeseenontheindividualauditworksheets.",

,,,

,LeadFreeCommodityComplexityMatrix,

,TheLeadFreesectionofthisAuditToolisdividedinto3commoditycomplexitycategories.Thecomplexitylevelusedforthisauditwillbedetermined,

,bytheDellCommodityteamandtheDellSQE.,

,,,

,Category3isthehighestcomplexity.ThiscategorywillincludeMotherboardsassembliesandOEM/ODMmanufacturers.Anysupplierauditedinthis,

,"categorywillberequiredtocompletetheleadfreesectionofthisAuditTool,theSupplierLeadFreeAssessmentSurvey,aproductlevelqualification,",

,"L3ReliabilitytestingasdefinedinDellspecificationD4559,andparticipateinaLeadFreesectionoftheirQBR.",

,,,

,"Category2isformediumtocomplexPCBA's.SupplierswithproductinthiscategorywillberequiredtocompletetheleadfreesectionofthisAuditTool,the",

,"SupplierLeadFreeAssessmentSurvey,aproductlevelqualification,L2orL3ReliabilitytestingasdefinedinDellspecificationD4559,",

,andparticipateinaLeadFreesectionoftheirQBR.,

,,,

,AuditrequirementsarethesameforCategory3andCategory2.,

,,,

,"Category1isforlowcomplexityPCBA'ssuchascontrolpanels,risers,etc.Supplierswithproductinthiscategorywillberequiredtocompletetheleadfree",

,"sectionofthisAuditTool,andtheSupplierLeadFreeAssessmentSurvey.QualificationmaybeperLevel1requirementsasdefinedinDellspecification",

,"D4559orbycertificateofcompliance,asdefinedbytheDellCommodityteam.IfthesupplierparticipatesintheQBRprocess,aLeadFreesectionwillbe",

,addedtotheQBRscorecard.,

,,,

,AUDITBYSELFASSESSMENT,

,Asupplier'sfacilityisrequiredtocompleteaselfassessmentusingthistoolinadvanceoftheDellAudit.,

,BydoingthisthefacilitywillbeabletopreparefortheauditandseekadvancehelpandguidancefromDellSQEtobebestpositionedtosucceed.,

,"Itisexpectedthatduringtheself-assessmentprocess,thatthesupplierwillusethisopportunitytoaskquestionsforeitherclarificationortobetterunderstandintentoftheauditcriteria.WaitingfortheformalDellaudittoaskthesetypesofquestionsistoolate.Itisalsoexpectedthatbasedonselfauditresults,asupplierwillinformtheDellteamoftheirreadinessforaformalDellaudit.",

,Aselfassessmentiscompletedbyaddingascoretotherelevantcolumnineachworksheetonceproductcomplexityhasbeendetermined.,

,"IfafacilityhasmultiplelinesbuildingDellproductofthesamecomplexity,thesuppliershallensurealllinesareavailabletobeaudited.",

,TheSQEAuditorwillrandomlyselectonelinetobeauditedfortheproductcomplexitytobeassessed.,

,"Duringtheauditprocess,theDellSQEmaywishtorevieweveryquestion/criterionlistedontheauditdocument,oralternativelytheSQEmaychoose",

,tofocusonlyonthosequestionsforwhichthesupplierawardedthemselvesascoreof1byself-assessment.ThepathtakenislefttoSQEdiscretion.,

,ThescoreawardedbytheSQEAuditorwillbeenteredinthe'Actual'columnoneachworksheet.,

,"Inthiswaythedeltabetweentheselfassessmentandtheactualscoreisknown.Thesizeofthisdeltaisameasureofauditpreparednessandunderstanding.Thedifferencebetween""selfscore""and""actualscore""willbeapproximately5%ifpreparationandunderstandingisgood.",

,"TheLeadFreeselfauditinformationshouldcomefromthesuppliers""LeadFreeSelfAssessment""surveyinput.",

,,,

,AUDITRESULTS,

,TheSQEAuditormustcompleteatleast7ofthe14processesbeforeanAuditResultcanbedeclared.,

,Itisstronglyrecommendedthatall14sectionsoftheauditbecompletedforsupplierswhohavenopreviousexperiencewithmanufacturingPCBA'sforDellorforexistingDellsupplierswhoareattemptingtobuildahighercomplexityPCBAproductforthefirsttime.,

,TheLeadFreesectionismandatoryforanyauditscore.,

,,,

,TheoverallprocessaverageresultdeterminestheAuditscoreachievedforthePCBASupplierassessed.,

,The'Pass'scorefortheAuditis80%forallPCBAProductsirrespectiveofcomplexity.,

,"Ifanoverallprocessaveragescoreofequalorgreaterthan80%isachieved,andnoindividualprocesseshavefailed,a'Pass'resultisawarded.",

,,,

,"Ifoneormoreindividualprocesseshavefailed,butanoverallAuditscoreofequalorgreaterthan80%wasachieved,eithera""ConditionalPass""ora""Fail""Resultshallbeawarded.ThedeterminationofthisauditresultisatthediscretionoftheLeadSQEAuditor,basedontheseverityoftheissuesforanyofthefailingsections.

Iftheoverallprocessaveragescoreislessthan80%,a""Fail""resultisawarded.",

,"NOTE:Anindividualprocessfailswhenthesectionscoreisbelow80%ORifan""non-negotiable""questionscores0.(see""AuditMechanics""instructionsforadditionalinformation.)",

,,,

,"Ifthe""LeadFree""sectionfails,anoverallfailresultisawarded.",

,"IfthesupplierdoesnotreceiveapassingscoreontheLeadFreesection,thentheymaynotshipLeadFreeproducttoDell.Thesuppliermustaddressany",

,actionitemsassociatedwiththeLeadFreesectionandreceiveapassingscorebeforeshippingLeadFreeproducttoDell.,

,,,

,"Ifa""ConditionalPass""or""Fail""Resultisawarded,aCorrectiveActionPlanisduefromthesupplierwithintwoweeksofthedateofauditcompletion.",

,TheCorrectiveActionPlanmustcontainatimelineto'bridge'toaPassstatusandmustproposeatargetdateforaDellfollow-upAudit.,

,FailuretoachieveaPassResultonthefollowupAuditmayimpactbusinessawarddecisions.,

,,,

,APASSRESULT,

,"Onceasupplier'sfacilityhaspassedtheAuditforaparticularproductcomplexity,thefacility'sprocessisapprovedforallproductsofthatcomplexity.",

,"Thus,thefacilityhasproventheircapabilitytobuildaproductofthatcomplexityforthelineaudited.Aslongasthesameprocesscapability",

,"isdeployedforanynewlines,thereisnoneedtodo'official'auditsforanyadditionallinesaddedforproductofthatcomplexity.",

,"NOTE:Whileitisnotan'official'requirementtousetheaudittoolforadditionallines,itisstronglyadvisedthattheSQEutilizetheaudittooltoverifythatthecapabilityofanynewlineismatchedtotheexistingcapabilityoftheexistinglinesforagivenPCBAcomplexity.",

,"NOTE:Forthepurposeof""provencapabilitytobuildaproduct"",a""facility""isdefinedasthesamephysicalbuilding,ANDthesameproductcomplexity,ANDthesamesupplierproductionandqualitymanagementteamresources.",

,,,

,"IfafacilityisapprovedforthemostcomplexPCBAproduct,thisdoesNOTnecessarilymeantheyareautomaticallyapprovedforalllesscomplexproductsatthatfacility.Regardlessofproductcomplexitylevel,anytestprocessesrelatedtoanewproductshouldbeauditedbecausetestprocessesareunique,basedonproducttype,notPCBAprocesscomplexity.",

,,,

,AnAuditwillneedtobeconductedtoensurethecapabilitydeployedatleastmeetstheminimumrequirementsforthelesscomplexproduct.,

,,,

,AsuppliersfacilitymustpasstheLeadFreesectionoftheauditbeforetheywillbeallowedtoshipLeadFreeproducttoDell.Aminimumscoreof80%mustbe,

,obtainedtopasstheLeadFreesection.,

,,,

,AUDITMECHANICSandQUESTIONS,

,"TheAuditbreaksdownthePCBAManufacturingProcessintoindividualprocesssteps,eachofwhichisrepresentedbyanindividualworksheet.",

,Withineachworksheetiscontainedaseriesofquestionsspecificallypertainingtotheprocessbeingexamined.,

,"ThesequestionsarefocusedonevaluatingProcessDisciplines,ControlMethods,ProcessCapability/Technology,andAttentiontoDetail.",

,Thequestionsweredevisedanddevelopedasclosedquestionswitheveryattempttoavoidambiguity.,

,"Becauseoftheclosednatureofthequestions,therecanonlybeoneoftwoanswerstoanyquestion,i.e.Yes(1)orNo(0).",

,"Thus,thecriterioniseitherfullymetoritisnot.IftheCriterionismet,ascoreof1isobtained.IftheCriterionisnotmet,ascoreof0isobtained.",

,"IfthereisanydoubtastothescoretoawardforanygivenCriterion,ascoreofzeroshallbeawardedbydefault.",

,"AnyCriterionthatscores1shallbeclearlydemonstrated,followed,andbebeyondreproach.",

,"Intheeventthatasupplierclearlymeetstheintentoftheauditquestion,butdoesnotexactlydowhatthequestionasks,ascoreof1shallbegiven.",

,,,

,Therearecellswithintheauditdocumentthatareshadedingray.ThesecellsmaybecodedasNotApplicable(NA)undercertainconditions.,

,"IfcodedNA,thedenominatorinthescorepercentagecalculationwillautomaticallybeadjustedtoaccountforthisNAallocationtothecell.",

,TheconditionsunderwhichNAmaybeallocatedareasfollows:-,

,1.NAmaybeallocatedtoacellifthequestionisnotapplicabletotheproductduetosome'real'physicalreason.,

,"Forexample,iftherearenoMSDdevicesareonaproduct,thenthequestionspertainingtoMSD'swouldbecodedNA.",

,2.NAmaybeallocatedtoacellifthequestionisnotapplicabletotheproductbecausethephysicalproductdoesnotundergoaspecificprocess.,

,"Forexample,iftherearenopressfitconnectorsonaproduct,thenthequestionspertainingtothepressfitprocessmaybecodedNA.",

,"3.NAmaybeallocatedtoacellifbyansweringsomequestions'yes',otherquestionsbecomeredundantorirrelevant.",

,"Forexample,ifAOIisdeployed,thenthequestionspertainingtoManualInspectionmaybescoredNA",

,,,

,Note1:NotallgrayshadedquestionswillbecodedNA.TheNAstatusisconditionalontheaboveandSQEdiscretion.,

,"Note2:Grayshadedcellsareapplicablewhentheprocessisdeployed,andmaystillscorezeroiftheaboveconditionsarenotsatisfied.",

,"Forexample,AOIisnotrequiredforcomplexity5PCBA's,butitmaybedeployedbasedonsupplierpreference",

,"IfAOIisdeployed,AOIquestionsmustbescored1or0,notNA.",

,"Note3:Nootherquestions,otherthanthosethathavebeenpredeterminedbythegrayshading,canbeconsideredtobeNA.",

,,,

,"Therearecertainquestionsineachsection,(shadedinblue),thatareconsiderednonnegotiable(NN).Inotherwordsthequestionmustscorea1.",

,"Ifanyofthesequestionsscorea0,thentheprocesssectionunderreviewwillautomaticallyfail(NNFail),regardlessofoverallscore.",

,"Forexample,iftheoverallresultforasectionisequaltoorgreaterthan80%andifanyoneofthe""nonnegotiable""questionsscoredazero,thentheoverallresultforthatsectionwillbeFail,irrespectiveoftheoverallscore.",

,,,

,AUDITINGANEWSUPPLIERORANEWSUPPLIERFACILITY,

,Ifapotentialsupplierornewsupplierfacilityisrequiredtobeauditedthenthecategorytobecompletedintheauditdocumentshall,

,appropriatelyreflectthecomplexityoftheproducttobemanufactured.,

,"However,sincesuchasupplier/facilitywillnotbemanufacturingaDellproducttheSQEAuditorwillhavetoselectalinewithaproductwhich",

,mostcloselymatchestheproducttobemanufacturedandwhichisrepresentativeoftheproductionlinethatthesupplierintendstousetobuildDellproduct.,

,TheSQEwillnotconsiderauditinga'virtual'linebasedonsomefutureinstalledcapability.,

,,,

,TheLeadFreesectionisrequiredtobeauditedforallnewsuppliersforfacilities.,

,,,

,AUDITINGFORRMA/REPAIR,

,ThistoolmayalsobeusedtoassesscapabilityofRMA/Repairfacilities.,

,AllprocesshighlightedontheMenupagearerelevantforwhenitisnecessarytoconductaManufacturingProcessQPA,

,"However,onlythosemenubuttonshighlightedin'blue'anapplicablesectionsoftheLeadFreesection(3.8-3.14,4,6,7,8,9)maybeused",

,foraRepair/RMAQPAAudit.,

,,,

,TRAINING,

,ThePCBAProcessAuditisverytechnicalincontent.,

,SQE'swhousethistoolareconsideredwithinDellasbeingsufficientlyqualifiedtoconductthisaudit.,

,"Toobtainthisqualification,anSQEwillhaveparticipatedinatleastthreeauditsandleadafourthunderthesupervisionofaqualifiedauditor.",

,"SQE'swishingtousethistoolshouldcontacttheirregionalchampiontoarrangefortraining,qualificationandcertification.",

,,,

,SQE'sshouldreceivetrainingonDell'sLeadFreeimplementationstrategybeforeconductingtheLeadFreeaudit.,

,,,

,AUDITSCHEDULE,

,"TheAuditmaybeusedasandwhentheneedarises.However,Dellwillconductanofficialauditatleastannuallyforkeysuppliers.Beforeconducting",

,"anaudit,theauditormustensuretheDellcommoditymanagementteamresponsiblefortherelationshipareadvisedoftheauditschedule.",

,ItisalsointendedforsupplierstoconductinternalauditsbyselfassessmenteveryquartersoprogressmaybereportedtoDell.,

,,,

,ADDITIONALQUESTIONS,

,PleasecontactAlexXingatalex_xing@foradditionalinformationorifthereareanyspecificquestionswithregardtothetechnicalcontent.,

,PleasecontactWallaceAblesatwallace_ables@foradditionalinformationontheLeadFreesectionofthescorecardortoprovidecommentsor,

,corrections.,

,,,

,REVISIONHISTORY,

,A00InitialRelease.Oct1996(EMFControlledDocument).AuthoredbyWilliamRyan,

,A01Min