This study focuses on eliminating the lead pullback problem in an automotive quad flat no lead (QFN) package in order to meet the non-negotiable requirement to have a solder wettable or solderable lead sidewall. It involves using a non-traditional approach of Monte Carlo tolerance analysis to determine the final leadframe and singulation blade design solution. It was found out that the zero lead pullback could be achieved by reducing the leadframe lead to lead distance from 0.275 mm to 0.225 mm and increasing the blade thickness from 0.325 mm to 0.350 mm. Actual results from 10 line stressing lots all showed zero pullback validating the effectiveness of the final design and the use of Monte Carlo tolerance analysis technique. Costly investment for a lead pullback inspection system was avoided and the 100% manual inspection eliminated.

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This study aims to address the problem of machine saturation and low capacity at package singulation, caused by increasing product loading and new devices that requires frequent machine setups and conversions. With this evaluation, the process and equipment engineering group collaborated to improve the machine unit per hour (UPH) of package singulation machines at the manufacturing assembly.  Target improvements were divided into three phases, so that the team could focus more on each phase and was able to define robust parameters without compromising the product quality.  DMAIC methodology was used to improve the productivity of package singulation machines. With the help of our methodology, we identified the root cause and contributing factors to the problem. UPH improvements per machine were validated and assessed in terms of machine efficiency and product quality, because of characterization and standardization of every parameter in each phase of the project. The achieved total improvement was of 17.64%.

This paper will discuss how to reduce (IDM) Indirect Material consumption for derailing process by eliminating the manual derailing method as part of cost saving project. It involves the removal of cutter blade used for derail.Cost improvement was one of organizational goals of the company for 2019. This drive can be supported by analyzing Indirect Material spending and process simplification at assembly plant. At assembly End-Of-Line processes, derail cutter blade was one of the top Indirect Material spending at singulation and there is an opportunity to reduce if not eliminated the cost consumption of derail cutter blades through process simplification. Increasing volume in Quad-Flat-No lead (QFN) packages and new banner products being develop by New Product Integration NPI, Q1’20 means increase in IDM consumption per process. The challenge is to drive a process simplification that will reduce IDM to save cost by start of Q2’20. DMAIC methodology was used to improve the process of derailing process.