HOST COMPANYS VERIFICATION STATEMENT:

Host Company:
Address

Spansion (Penang) Sdn. Bhd.

Spansion (Penang) Sdn. Bhd.
Phase II, Free Industrial Zone, 11900, Bayan Lepas,
Penang, Malaysia.

Supervisor

Email

Namaswayan
karupanan.namas@spansion.com

Signature

: ______________________________

Name

: ______________________________
(Please endorsed with official stamp)

Date

: ______________________________

ABSTRACT
This industrial training report shows the responsibilities and routines of Incoming Quality Control
(IQC) department in Spansion. By working with Incoming Quality Control (IQC) department, the
incoming parts will be inspected to ensure that good quality products will be produced. The role of
IQC is to feedback the defects that found in supplies to the suppliers and make some arrangements
for compensation like parts replacement or refund or rework. In this report, initially, a brief
introduction to Spansion Sdn.Bhd. will be given, followed by the description of the job that I have
been assigned and experiences that I had gained from the my past 16-weeks industrial training
program at Spansion Penang.

During this past 16-weeks training program, I have met different kind of situations in the job that
being assigned to me which helped me gained a lot of meaningful experiences. This job had
sharpened my decision-making skill due to there were many times that I have came across a situation
which needed me to decide whether the condition of the incoming parts is acceptable by our
customers. Furthermore, whenever there were defects found in the parts, I need to find out the cause
for the defects whether its suppliers quality issue or product lines issue. Moreover, my
communication skill has improved due to my tasks which needed me to deal with different kind of
people from different departments. Skills that I have gained would help me in my future field work.

My weekly routine is to do particle counting inside KGD are and Sort, where my daily task is to
update EBR (Equipment buy off report) and Manual for every department in Spansion. I also do
some test and calibration there.

ACKNOWLEDGEMENT
I would like to express my gratitude towards Spansion for letting me to join this three months
Internship program. In the three months time that I worked at Incoming Quality Control (IQC)
department in Spansion, I have gained a lot of experience and knowledge. I also want to express my
appreciation to the people who have helped me accomplished the tasks.

First of all, I would like to thank Spansion for supporting this program. Spansion has provided a
good learning ground for internship students. Many thanks to my internship supervisor, Mr. Namas
for his willingness and patience throughout the whole internship in developing my skills and addedon a great deal knowledge and experience for me. Not to forget, all the staff in Spansion that I had
came in contact. They always gives me guidance, advice and opinion while I facing problem during
training. They are so dedicated and knowledge, the opinion and suggestion that they give me very
useful and valuable that help me a lot. Thanks also to everyone in Human Resource Department,
who organized an orientation session to introduce Plexus to us, and getting us familiarized with our
working environment.

TABLE OF CONTENT
Subject

Host company's verification statement

Abstract

Acknowledgements

Page Number

Chapter 1: Introduction to Company

1.1 Company Profile

7
8

1.2 Market Sectors

1.3 Training Scope

11

Chapter 2: Work Flow of IQC Department

2.1 Incoming Quality Department

2.2 Incoming Inspection Process flow chart

12

23

Chapter 3: Intra Project and main activities

3.1 Calibration

3.1.1 Digital Multimeter Calibration

3.2 Facilities Monitory

3.2.1 Smock and Jumpsuit

3.3 Document and Management

3.4 Measurement System Analysis

Discussion and Recommendations

Conclusion
Reference
Appendices

Appendix A: Example of 8D report

47

50

46

43
44

Appendix B: Example of Non-Conforming Material report

41

38

37

37

37

35

33

33

3.3.1 Non Confirmation Report (NCR)

Chapter 4: Training description

25
26

3.2.2 Shoe Verification

4.1 Problem Arises

3.1.2 Shoe Verification

25

CHAPTER 1: INTRODUCION TO COMPANY

In order to provide our customers and partners with rapid, high-quality services, Spansion has
established headquarters, sales support, and manufacturing locations in major cities around the
world.

(a)

Figure 1(a) & (b): Branches of Spansion in Penang, Malaysia

1.1

Company Profile
Spansion is a global leader in Flash memory-based embedded systems solutions. Spansions

Flash memory, microcontrollers, mixed-signal and analog products drive the development of faster,
more intelligent and energy efficient electronics. Spansion is at the heart of electronics systems,
connecting, controlling, storing and powering everything from automotive electronics and industrial
systems to the highly interactive and immersive consumer devices that are enriching people's daily

lives.

Spansion Penang Sdn. Bhd. was founded in 2003 after separation from AMD. Located in Bayan
Lepas, just about 15 minutes to the city center (Georgetown) and 5 minutes to Penang International
2
Airport. It has a build up area of 175k ft on 4 acres of land.
Spansion Penang provides global functions and shared services to Spansion globally with multiskilled, talented and experienced workforce to provide reliable and total flash solution to meet the
needs and expectations of Spansion's valued customers. It is also supported by the latest technology
such as state-of-the-art Failure Analysis, Reliability & Design Center.

Spansion Penang recently (June 2010) has been granted MSC (Malaysia Cybercentre) status and the
first among the Penang Industrial Zone companies.

Vision
Best-in-class business partner and shared service center.

Mission
To deliver excellent and value-added services through a collaborative unified way.

1.2

Market Sectors
Spansion is a Market Sector diversified organization whose strength is complex, high-tech

products. Spansion understands the unique requirements technology companies in each of our
Market Sectors have and are well positioned to fulfill these needs.

With its expertise in the products of Networking/Communications, Automotive, Industrial

and Consumer, Spansion provides its customers with a competitive advantage in the marketplace
through innovative global supply chain solutions, and agile/flexible manufacturing capabilities
supported with industry leading engineering capabilities.

Networking/Communications

Information is being consumed anytime, anywhere and any way. This

explosion in data traffic will continue to demand more equipment to support the Internet backbone
and the server farms that feed it. As the deployment of global mobile voice and data networks
continues globally so too does the need for reliable long life and secure components. Spansion
supports our communications and enterprise customers with a range of solutions to meet these and
many more diverse processing, Flash memory and analog needs.

Industrial

Industrial applications are rapidly adopting user interfaces that are more
typical of consumer electronics. Spansion has an innovative range of solutions to address the needs
of next generation users and applications. Integrating human machine interfaces (HMI) into our
industrial grade components, and applying the industrys highest bandwidth interfaces, we deliver
highly optimized solutions for products suited for aerospace/avionics, energy systems, factory
automation, telehealth and white goods.

Automotive

The automotive industry is rich in innovation as the car is morphing

into the most advanced consumer electronics device. Spansion provides the highest quality
automotive grade solutions. Our automotive portfolio enables customers to optimize their systems
performance with a unique blend of processing, graphics control and Flash memory solutions to
address a broad selection of automotive applications, ranging from the most advanced instrument
clusters and infotainment to safety and deeply embedded powertrain systems. Supplementing our
discrete component product line-up is an innovative selection of system-level solutions including
touch and voice recognition solutions designed specifically to enrich drivers safety and in-cabin user
experience. Spansion also offers seamless interoperability with our mixed signal and analog product
lines.

Consumer

Consumers appetite for instant access to data and applications anytime,

anywhere and on any device is rising. The home is becoming digital and smarter using a variety of
interfaces with more connected electronic devices from gaming and TVs to future appliances. The
devices of the future will give consumers more control over home entertainment, lighting and
heating environments, as well as security with features such as voice and gesture recognition.
Spansion supports the consumer segment with a broad array of memory, processing and analog
products. In addition, our touch and voice recognition solutions and power management ICs have
become an important component of the overall consumer electronics bill of materials.
1.3

Training Scope

Spansion (Penang) SDN BHD is a semiconductor company, dealing with printed circuit
board assembly. Spansion is unique because his company is divided into several sections which are
located around the world. Spansion in Malaysia is the part of the Design Center is known as the
Penang Design Center.

In Spansion, I have been placed in Incoming Quality Control (IQC) department during my 16
weeks industrial training. IQC department is set up by Spansion to ensure the incoming parts from
suppliers are good in quality. Besides that, IQC acts as the middleman between Spansion and
suppliers to feedback the problems facing in production line to both sides.

CHAPTER 2: INCOMING QUALITY CONTROL DEPARTMENT

2.1

ESD

Electrostatic Discharge (ESD): The transfer of electrostatic charge between bodies, or different regions of
same body, at different electrostatic potentials.
1. 3 major sources f ESD hazard

-people
-materials
-equipment
2. what cause static electricity
-friction between materials
-separation of materials
3. electrostatics charging:
i) Triboelectrification
The most common form of charge generation
-when two materials, at least one of which is an insulator, come in contact and then is
removed. Charges will be generated on both materials. Positive charge on one and negative
charge on the other.

ii) Triboboelectric Series

-as we can see, many materials are insulators that can generate and hold high static charges
for several days

Figure 2 (a) : Calibration equipment

ESD Measurement
4. What is ESD control important
ESD can cause yield loss
ESD can create walking wounded parts that cause reliability issues for our customers.
Customer requirements
An ESD occurrence requires all 3 events:
-Charge generation
-Charge accumulation
-Rapid discharge
5. ESD can effect up
Equipment structures and control cables make excellent antennas
Scrambled program instruction and data
Miroprocessor lockup
Confusing error messages
Software Errors
6. ESD damages
Fracture of gate oxide
Localized heating
Molten metal-silicon alloy
Short across the gate:

-gate to source
-gate to drain
7. types of ESD damage
a) human body model: discharge :
i) machine model : discharge fom machine members
ii) charge device model : device charge up and pins contact ground
8. Grounding conductors a method of electrostatic charge controls
Charge conductor

+++++++
When grounded, a conductor will go to ground
+ +potential
+ + at+all points
++
Charge insulators can and do stay charged for days in extreme cases. Insulator can have
areas with no charge, +ve charge and ve charge at the same time. The charge on
insulator does not/ cannot move. A charge cannot be grounded off an insulator by
conventional means.

+ + + + +
++
+ + + + +
9. Insulator vs Conductors
+ at+electrostatic charge occurs primarily on insulator and isolated
- the generation and storage
conductors. These materials are used throughout the work enviroment.
- Conventional grounding technique cannot remove charge from insulators and can be
compared to a bird on a high voltage power line.
- There are 2 posite methods for removing charges from insilators:

i) surface treatments to attract moisture to the surface

ii) relative humidity in excess of 30-40%
- the third option is to make the air more conductive by ionizing it.
0

10

10

Ionized air

10

resistance

10

10

Ambient air (outside)

Ambient air (inside)

Conductor Static dissipative range Insulative

10. ESD control for Personnel

Personnel Grounded
- Wrist Strap daily check or continues monitoring
- RTG = 1 mega ohm +25%
Footwear and flooring
-0.75 Meg < RTg < 100 Mega ohm

10

12

14

10

-wear wrist when sitting

ESD Proctive Garment
-conductive grid material
-sleeve to sleeve <1.0E + 9 ohms
11. Control methods
i) ground yourself before handling devices.
ii) Handle devices over ESD- safe station
iii) Keep work station clear of static generative materials
iiii) Use ionizers to minimize charge generation
v) Remove insulators from area
12. ESD control in factory
i) handle unprotected devices only when grounded
ii) transport devices in static shielding containers
iii) conductive containers must be closed
iiii) store sensivity items in shielding containers and on grounded surfaces
v) shielding in essentials when items are removed from protected areas
13. ESD Preventation procedures
Encourage good work habits
no prime charge source within 12 (some recommended > 3) of devices.
All paperwork and accessories must be keep away from devices.
Before doing paperwork, make sure that all devices are cleared from work surface
Minimize operator movement.
Always place covers on containers when moved.
Keep ESD shoes in contact with grounded surface it wrist strap is not worn.

14. Material Qualification Sequence

Corporate qualification manual based on

ESD assocation standards and company
requirements
Identification of products and services
vendor / product qualification sequence
Vendor specifications house testing third
party testing

Certification
Process
Electrical
properties

Physical
properties

Chemical
properties

Vendor / product
qualification list
Product qualified facility
tours trial runs
15. Packing Material Selection
Intimate Packing materials:
-anstatic if products slide
-static dissipative if intermittently touched
-conductive if leads are imbedded
Intermediate packing materials:
-exposed conductive layer is OK if not touching products
Outer Packing Material:
-non static generative
17. ESD foams

Antistatic Polyurethane (flexible polyether)

i) black conductive dipped foam
a) excessive carbon rub off
b) conductivity can vary from batch to batch
c) not chemicals resistant and does not accept components well
ii) Pink Surfactant Antistatic Foam
Conductive polyethylene (Closed Cell Cross linked Polyethylene)
a) Use in some clean rooms and little rub off
b) Very conductive grades and volume resistivity
c) Good chemical resistance and permanently conductive

18. Conclusion
Resistance measurements may be the most important test
Material should be tested of the claimed properties
Test must be done at standard 12% RH and temperature for correlation
Certification required from suppliers
Use ESD Association standardized test methods
19. ESD Paperboard (Boxes, Totes, Sheets) ESD Corrugated Board
Electrical testing
Material characteristic

 Mechanical results
Repulpability
Considerations
20. Verify Barrier Resistance
21. Consideration of paper
Verify product through testing
Low barrier resistance = better shielding
Surface resistance and relative humidity
Better mechanics = better performance
Rub resistance = no conductive particles
Repulbality considerations.
22. Extreme ESD : Class 0 Devices

ESD

= Extremely ESD Sensitivity Devices

No built in ESD protection devices

CDM failure level < 100V (even < 1V)
Spacing between conductors <1mm (internal or external)
Breakdown voltage < 100V
Damaged by electromagnetic interference (EMI)
ESD problems persist after applying all traditional ESD control measure
New devices / problems often require new ideas and solution
2

23. How do ESD devices really get damaged?

Current sensitive devices:
i) input of device with voltage touched by grounded conductor
ii) conductor with voltage touches input of devices

ESD Equation: V + M = ESD

Avoid the potential of spark!
V = voltage on device or tool
M = conductive contact to device input
24. Traditional ESD Control
try to control V and allow M

Assumption is that v is small enough so that M is safe

substantial focus is on environment around device

-grounded work surface, operator, tools

-ionizer insulator

grounding of devices / tools is good but not solution for 2 dilemmas

-way to get floating devices / tools to ground without ESD event

-how to take needed metal contact to device safely

focuses on limiting voltage (or Q, I) not eliminating ESD

25. Spark- free ESD Control

Futile to try to control voltage on device on floating device/ tool to low enough level
-let voltage on device vary
Need to prevent ESD no matter what voltage is on device, tool or environment
Spark-free design for device and process
-focus primarily on device and tools that touch device
limited time is spent on where it counts most
control of surrounding environment is secondary
26. Spark-free Approach to ESD control
1. prevent all unnecessary metal contact to device inputs
floating or grounded device
2. bring all tools to ground spark-free
ground through static dissipative material
then hard ground
3. Bring floating device to ground slowly, spark-free
static dissipative contact

Spark-free = NO ESD
27. Spark-free processing

Methods to prevent metal contact

design fixtures so that device inputs cannot touch metal surface of tools
use static dissipative materials on surface and tools

Device
input
Static
dissipative
metal
pinslayer
BAD
OOD
G
BEST
++++

++++

insulator

insulator

++++

insulator

Metal
Metal

29. Solution to floating Device dilemma

Metal

Bring floating device/ tool to ground slowly and safely

Use static dissipative material to limit current and prevent spark
1.0E + 0.6 ohms is ideal: ceramic are best
Them flow with grounded metal contact
Airplane Analogy

Height = V

Vertical dive to ground = metal contact

Land the airplane, dont crash it (control vertical velocity-control current)

30. Conclusion
ESD Control should be required in all manufacturing locations.

 Program maintenance and routine audits are important.

An ESD control program should focus and garments:
o Human grounding and garments
o Materials eliminate charge generating materials
o Equipments ground use ESD materials

2.2 Incoming Inspection Process Flow in Spansion

Suppliers
Incoming Lot
IQC Inspection

no

no
Feed
back
to
supplier
with
NMCR*

yes

Accept

F06-004 -Receiving Inspection

F03-001.X Approved Supplier List
F03-XXX General Requirement
F/04-XXX -Dimension

Acceptance into Store and

Release for production use

NCMR*

FIFO concept and shelf life control

for each type of material

MRB***Critical Reject?

yes
CAR***
Feedback to
Supplier

Lot Disposition upon MRB

Decision
no

* NMCR : Non Conforming Material Report

** MRB : Material Review Board <F01-131>
***CAR : Corrective Action Request

Accept Corrective Action

yes
Follow up Implementation
Diagram 1: Flow chart of the incoming process in Spansion.

According to Diagram 2, the incoming parts purchase by Spansion will ship to incoming
receiving department by suppliers. The operators of incoming receiving department have to verify
the correct quantity of parts is received and all the boxes or cartons are in good condition. If the
cartons are found to be in bad condition, forwarder would have to take responsibility and come to
Spansion to do sorting. For parts that are broken, forwarder has to make compensation. On the other
hand, if the cartons are in good condition, the engineer of incoming quality control (IQC) department
are need to inspect all the incoming parts those are required for receiving inspection (RI) based on
documentation part inspection instruction (PII). If the incoming parts are failed, it will on hold at
scrap hold. Otherwise, the technicians of Spansion Warehouse will receive the incoming parts and
store into the warehouse. They need to confirm the physical parts available in the warehouse are
matching to the quantity in the computer system with good condition.
Every time when production line technicians are need more parts to assembly the products,
they will request from kitting department. So the kitting area operators will kit the parts from
Spansion warehouse and send to production line. After receive the parts, all the production line
technicians and engineers will build up the products. If defect found in the parts, production will
purge the remaining parts in production line and it will on hold at scrap hold. After the product is
built up, it will pass to incoming quality contol (IQC) department for inspection. IQC engineers need
to confirm the outgoing products are in good quality. The products that are passing through IQC
engineers inspection will pack into boxes / cartons by operators of outgoing shipping department
before ship to customer.

INTRA PROJECT AND MAIN ACTIVITY

3.1 Calibration
Calibration Is the comparison of M&TE or Measurement Standards of unknown accuracy to a
Measurement Standard of known accuracy to detect, correlate, report, or eliminate by adjustment,
variation in the accuracy of the instrument being calibrated.
Measuring and Test Equipment [M&TE]
The measuring instruments, test equipment, standards, reference material, and auxiliary apparatus,
listed in the calibration procedure, or their equivalents necessary to measure a property. These
devices are used to measure, gauge, test, inspect, or otherwise determine compliance with prescribed
technical requirements.
Measurement Standards:
Are those devices, including reference materials, used to
calibrate M&TE, or other process Measurement Standards, which provide traceability
to a recognized National Standard.

3.1.1 Digital multimeter calibration

As part of the training I was showed why and how calibration was performed. On my first training
on calibration a Digital Multimeter (DMM) was used for demonstration.
A brief introduction on the definition of calibration, purpose calibration, appropriate calibration
standard used and actual calibration on unit under test (UUT) was shown.

Purpose
Calibrate Measuring and Test Equipment that are used to determine conformance to specifications, at
the relevant Departments (including Maintenance and Engineering) and Laboratories.

Multimeter:
Is an electronic tool used vastly in electronic industries for the measurement typically AC & DC
Voltages, Resistance/Ohms, AC & DC currents, Diode test , Frequency calibration & extra of
machines, electronic devices.

3.1.2 Shoe Verification test

Purpose
To describe a procedure to check the functionality of auto-door or daily shoe checker periodically per
requirements defined in <F00-016> & <F16-055>.

Scope
Apply to area where the ESD shoe checker or auto-door is installed to check the functionality of
ESD (Electro Static Discharge) safe shoe used in Penang Plant.

References
<F00-014>

Records Management

<F00-016>

Handling Procedure for Prevention of ESD Damage

<F01-033>

Procedure for The Use of Red Tags

<F01-039>

Procedure for Changing Entries in Company Records

<813-340>

Penang Calibration Plan

ESD Handling Procedures

<F16-055>

Equipment
1.PRS-801 Resistance System or Trek-152 Resistance Meter or equivalent
2.Self-made ESD verifier. See figure 1.

Procedure
The shoe checker / foot-wear tester shall be checked using self-made ESD verifier at least quarterly.
See figure 2.
Use the self-made ESD verifier to check the following :
1.Right foot-plate verification method:
Connect the banana plug of verifier to the ESD shoe checker. See figure 3.

Turn verifier knob to check on the following resistance ranges and the light on

the ESD Shoe Checker will be indicating the verification result. The
verification result as per defined in Table 1 (Right Foot-plate Indicator).
Ignore the light indicator for Wrist Strap.

2.Left foot-plate verification method:

Connect the banana plug of verifier to the ESD shoe checker. See figure 4.

Turn verifier knob to check on the following resistance ranges and the light on

the ESD Shoe Checker will be indicating the verification result. The
verification result as per defined in Table 1 (Left Foot-plate Indicator).
Ignore the light indicator for Wrist Strap.

Knob Position Right Foot Indicator Left Foot Indicator

700K (FAIL) ORANGE

ORANGE

800K

GREEN

GREEN

10M

GREEN

GREEN

20M

GREEN

GREEN

30M

GREEN

GREEN

40M

GREEN

GREEN

90M

GREEN

GREEN

100M (FAIL) RED

RED

110M (FAIL) RED

RED

Table 3.1: ESD Shoe Checker Verifiers Resistance Range vs. Verification result
If any of above fail, please put a DOWN tag on the checker and contact the Supervisor for repair.
See <F01-033> for the usage of down tag.
If pass, record verification date, the next due date and person doing the verification on the yellow
color of ESD Control sticker and stick it on the checker. See figure 5.
If any of above fail, open the casing and tune variable resistor until it is within the limit or replace
the faulty resistor. Inform ESD Coordinator and dispose the out of tolerance situation per <813340>.
Record result per Appendix A.

1.1

The Verifier shall be calibrated by using PRS-801 Resistance System or Trek-152

Resistance Meter in yearly basis. Below are the procedures :

1.1.1

Connect resistance probes to the two terminals of Verifier and measure

resistance of the following configuration. The readings obtained are
considered as initial reading.

KNOB POSITION MIN () NOMINAL () MAX ()

700K

665K

700K

735K

800K

760K

800K

840K

10M

9.5M

10M

10.5M

20M

19.0M

20M

21.0M

30M

28.5M

30M

31.5M

40M

38.0M

40M

42.0M

90M

85.5M

90M

94.5M

100M

95.0M

100M

105.0M

110M

104.5M 110M

115.5M

1.1.2 If initial reading fail

1.1.3 Record the final readings.
1.1.4

Record result of calibration using calibration record per <813-340>.

recording entries shall comply to <F01-039>.

1.1.5 Retain calibration record per <F00-014>.

1.1.6 Calibration frequency shall be yearly.

Figure 3 (a): Self built esd verifier

Figure 3 (b): Esd shoe checker foot wear teste

All

Figure 3 (c): Righr foot plate verification connection method

Figure 3 (d): Left- foot polate verification method

Figure 3 (e): Esd control sticker

3.2 Facilities Monitoring

In facilities monitoring, we ensure ESD Control Facilities, such as flooring and doors are in good
condition and functioning well. Below table shows items under the monitoring program.
Item

Criteria

Frequency Spec Status

ESD Floor at NVD area

Surface Resistance and Resistance To Monthly 16Ground

055

Good

Main Entrance to ESD Floor at Functionality

NVD area

Quarterly 16055

Good

ESD Shoes

Resistance

Half
Yearly

16055

Good

Smock

End to End Resistance & Surface Half

Resistivity
Yearly

16055

Good

ESD Checker

Functionality

16055

Good

Yearly

2.1.1 Smock and Jumpsuit

IQC / Manufacturing QE has the responsibility to check ( ESD Protective Garments) EPG or
commonly called smock/Jumpsuit are regularly tested on its electrical requirements to ensure the
ESD Garment have not lost theseconductivity and are within the electrical limits below.

i. Electrical Requirements
Surface Resistivity of EPG material shall be between 0.1 megohms/square
5

(1x10 ) and 1,000 (1x10 ) megohms/square when tested per requirements in

section 8.0.

Cuff to cuff resistance shall be between 0.1 megohm (1x10

ohms) and 1,000

megohms (1x10 ohms) when tested per requirements in section 8.0.

A simple method has been devised to perform this task. Tools required for the test are as follows: A
wooded hanger, Metal Clips, Resistance meter and Resistivity meter is used for this purpose.
Actual test method was illustrated with the above tools.
Construction of EPG or commonly known as Smock/Jump suit.
ESD Protective Garments are constructed from fabric material displaying
dissipative conductivity on both faces, in direction of both lengthwise
(warp) and horizontal (weft) as applicable, and among all constructed
panels. Such Conductivity are enhanced by rinsing in topical antistat, but
will be achieved with some permanence by the inclusion of conductive
yarn in the format of a square, rectangular, or diamond shaped grid of less
than 1.25 by 1.25 centimeters (0.50 by 0.50 inch) woven into the fabric.
EPGs are constructed from as few pieces of fabric as possible, and should have
double needle felled seams intended to maintain electrical conductivity
across the seam. The use of conductive thread is encouraged. Unplanned
seams such as one down the back of the smock are discouraged.
Lab coat type EPGs, for used in class 10,000 or more, are at least knee long
and are with left breast pocket with pencil slot, and two lower pockets.
Side slits for trouser pocket access are optional. The choice of side or
back slit is optional are not higher than waist level. All snaps are made of
stainless steel. There are conductive elastic cuffs, no more than 4 inches
wide for snug fit. A male snap for wrist strap attachment located in the
cuff area is optional. Construction of the EPGs are such that ESD
properties, color and fabric integrity are maintained through at least 50
industrial laundry

Example of smock esd verification

Title
Place

: Jumpsuit ESD measurement

: Spansion IQE

: PROSTAT PRS-812 Resistance Meter Version r2.0, Jumpsuit,

Equipment

invoices and Certificate of Conformance

: To test the material either follows the specification before using in

production.

Objectives

Procedure :

1. The Resistances meter clip clipped at the hands of jumpsuit.

2. The resistance meter switched on and mode was set in exponent.
3. Press test button.
4. The value recorded by size and based on drawing spec
Observation:
Lot No Size Resistance
8.55X 107

9.63 X 107
5.462 X 108

2.75 X 106
5. 584 X 108

9.82 X 107
XL 4.36 X 109
9.82 X 107
6.533 X 106
Table 3.2.1: ESD for jumpsuit

Conclusion:
9

A jumpsuit pass the test if the reading of resistance less than exponent 8 X 10 ). If not, the jumpsuit
fails to use in the production and it should return to the supplier.

3.2.2 Shoe Verification

Title
Place

: Shoes ESD measurement

: Spansion IQE

: PROSTAT PRS-812 Resistance Meter Version r2.0, test plat,

Equipment

Productions booties, invoices and Certificate of Conformance

: To test the material either follows the specification before using in

production.

Objectives

Procedure:

1. The shoes was wear by the tester.

2. The Resistance meters clip clipped at the test plat and at the shoes.
3. The resistance meter switched on and mode was set in exponent.
4. Then the tester stands with a single foot that wear boot.
5. Press test.
6. The value recorded by size and based on drawing spec.

Figure 3.2.2 (a) and (b): Shoes testing procedure

Observation:
Drawing No Size Resistance ()
29309/B

3.12 X 106
6 X 108

7.352 X 107
2.5 X 108

5.75 X 106
6.82 X 108

XL 9.33 X 107
8.98 X 106
6.5 X 106

Table 3.2.2: ESD for shoes

Conclusion:
8

A boot pass the test if the reading of resistance less than exponent 8 (10 ). If not, the boot fails to use
in the production and it should return to the supplier.

3.3 Document Management

Document Management is the minimum set of business processes that must be in place in order to
ensure the appropriate use of documents.
Documentation Services at major Spansion sites, is available to provide service and support for
document management and record management needs. As a minimum, Documentation Services
provide document management support for policy and system level documents, in addition to
meeting site document management needs.
Equipment Manual:
Are manuals used for operating a specific equipment. In Spansion PNG the QE department controls
document and endorses the manuals with a stamp and date & captures all relevant manual in the
Access data base.
Although the manuals are kept by the equipment owners , regular verifications are done by QE to
ensure all documents available in the database are also available in the owners filing cabinet.
Equipment buyoff report (EBR):
Where a new equipment is bought off before put in use. The buy off entails details checks by en-user
on the functionality of the equipment . Followed by Safety personnel checking the safety aspects of
the equipment to ensure there is no potential safety hazard in using the equipment. And finally the
QE dept will conduct a Electro Static Discharge (ESD) check any charge generated by the machine is
within Spansion spec limits .
Similar procedure as used for Manual is used to ensure availability of EBR documents.

3.3.1 Non-Confirming Material (NCM)

NCM form is used to note down the information and the defect description of defective parts.
Normally, NCM form will be raised once the engineers or technicians found out the parts had defect.
Every NCM form will have different NCM number. The sample of this form is show at APPENDIX
B page 50.
The person who raised the NCM form needs to fill in the NCM information, which is
including part number, part description, quantity, defect code, and detail of the rejection. After that,
department supervisor and engineer need to write their comment on the defective parts, then approve
and sign at NCM Source Area Review column on the NCM form. The defective parts will quarantine
or on-hold at a quarantine area with the NCM form attached on it.
In the daily morning meeting, the QA engineers, process engineers, test engineers, product
engineers, production supervisors, program management and SQE engineers are needed to be
involved and discussed these defective problems. The defective parts are needed to be investigated
and judged the root cause of the defect is come from suppliers or from the company production line.
If the defects are caused by suppliers, SQE need to follow up these cases, otherwise, the defective
parts need to pass back to production department to make decision on it.
After the meeting, all the people who involved in the meeting will need to agree the final
decision and sign on the corresponding decision column at NCM disposition in the NCM form,
which are production scrap, return to supplier, third party scrap, use as is, rework and others.

3.4 Measurement System Analysis (MSA)

The MSA material posted on this site originates from MSA reference manual developed by a
Measurement Systems Analysis (MSA) Work Group, sanctioned by the DaimlerChrysler
Corporation/Ford Motor Company/General Motors Corporation Supplier Quality Requirements Task
Force, and under the auspices of the American Society for Quality (ASQ) and the Automotive
Industry Action Group (AIAG). The manual was developed to meet the specific needs of the
automotive industry and its one of QS9000/TS16949 requirements
The purpose of this study is to assess the quality of a measurement system used to measure product
parameters defined in control plan.
The study include

i. Stability, bias, linearity, gauge repeatability and reproducibility for variable data
ii. Attribute MSA for pass/fail data
iii. Inspection Capability Study for operator pass/fail data.

TRAINING DESCRIPTION
During the 16-weeks of industrial training, I have exposed to the real working environment
and gaining a lot of experiences which include theory and real production applications, quality
control and improvements and other hands on approach. As a result, I had been trained to be familiar
with working environment and had been widen my knowledge both in knowledge that are related to
my fields of study and general knowledge.
Besides that, I have improved my soft skills such as communication and negotiation skills.
Most of the working time, we need to communicate with staff from different kinds of levels. We used
email to contact and deal with our customer, supplier and also colleagues at company. Other than
email, we also will meet up with them to discuss and negotiate with them. From here, I learned to
handle problems and work as teamwork. It also provides me a very good chance to brush up my
English as well.
Besides working on the mentioned task which is usually requested from supervisor
previously, there are other tasks done as well. Those tasks are such as helping engineers to do
sorting. Sorting is done when production detects some defective parts and IQC will be responsible to
screen through the available part in store and to sort out the good part and the defective part. These
jobs are not included in previous chapters as it is more to complicate daily tasks that sometimes
require some technical skill. They are all about study on the given vendor drawing, rework and
measure by using the tooling, assist on some data collecting and entry jobs.
Others than that, in IQC, photo taking is part of my job whenever there is complaint from
customer, production, or IQC engineers of defective part received for future reference. Furthermore,
there are defects that will be photographed in order to obtain disposition from supplier to whether
RMA back to supplier or scrap the part. During my internship training, I have photographed various
types of defect on various items.

Problem Arises
Incoming Quality Control engineer is not an easy job as we always need to deal with
strangers. We might upset them unintentionally, thus we have to be careful when dealing with
someone that we do not know. Our job is to try to keep a good relationship with all the suppliers and
avoid any unnecessary arguments. This job is mainly requiring us to have strong interpersonal skills.
However, I did discover my shortcomings as well through this industrial. Lacking of
experience and knowledge about the job had made me an acquaintance. It was my major
shortcoming. I was having dilemma when trying to make some critical decisions and I had always
had to consult with my supervisor. I do tend to make silly mistakes when doing the paperwork as

well.
Besides, challenges and obstacles are faced during the moments dealing to people who is
controlled and take care for parts in company ware house. Sometimes, sorting and screening was
suspended half way and couldnt be fully completed due to unavailability of tool and unsteady
physical quantity as shown in system. Task cannot be done as planned even though raise to purge
notice has been out for few days due to others who played the role on it proceed over the expected
time. This has seriously delayed the task timeline and causes a lot of time wasted. Therefore, it is
important for all employees to plan ahead for the managements on tasks and to meet each others
commitments.

DISCUSSION AND RECOMMENDATIONS

IQC Department plays a very important role in Spansion as they can affect the process speed of the
factory. When there is a supply quality issue, if IQC couldnt solve it efficiently, the production
would have to be halted due to the shortage of supply. To speed up the process of IQC, there are a
few things needed.

1. Communication skill
Good communication skill would aid in communicate with other staff from different kinds of
levels. Good communication would lead to good understanding which could speed up the
process when seeking approval for certain action.

2. Good understanding of customer specifications

Good understanding of customer specification allows IQC to perform sorting more
efficiently. Furthermore, it eases IQC in making decision whether the quality of parts reached
the customer requirement. By that, it prevents a lot of unwanted delay in the process.

3. Apply 5S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke)

5S helps to organize a work place for efficiency. Through it, the process of preparing
documents can be speed up.
For recommendations, undergoing 16-weeks industrial training is not a wise decision because the
knowledge and engineering skills cannot be fully implements in 16-weeks. I think the industrial
training should be extended for other 16-weeks. For the first 4-weeks, we are just in learning process
and there will be a lot of mistaken occurred. We need to keep on learning from the mistake and try
our best to make it perfect. After practicing, we will be able to master all the skills that needed in

working and start to perform well in coming 4-weeks. Besides that, although it is time consuming
because other than working, we also need to write log book and prepare for the final report, but this
will be a good opportunity for students to learn on the ways to manage their time wisely.

CONCLUSIONS
The purpose of the industrial training is to provide students an opportunity so that they could
expose themselves to a real working environment. Instead of studying theories without putting them
into practical, industrial training gives students a chance to use the knowledge that they learnt in
university and use it in their tasks. From that, students could compare and get a clear picture of the
difference between theories and practical. Besides letting students to use knowledge that they have,
industrial training is also good for students to gain extra knowledge and experience. Furthermore,
industry is more than a just a place for interns to gain technical knowledge, it is also a place for
interns to learn how to be independent and work in a group. It helps interns to sharpen their
communication skills as to keep an organisation moving, communication between departments is
needed, and this provides interns an environment to practise while completing their tasks.
As a globalised compony, Spansion provides a good environment for interns to utilize their
skills. Spansion is an assembly site, due to its varies supplies from all around the world, interns are
able to expose themselves to different types of technologies.
For the past 3 months being assigned to IQC department, I have gained a lot of working
experience under the guidance of my supervisor, Namaswayan. IQC department plays a very
important role in Spansion, IQC engineer act as the middle person between Spansion and vendors. If
there is a quality issue, IQC needs to feedback the problem to both Plexus and vendors. IQC
engineers needs to be familiar with the customer specifications so that they could differentiate parts
that can be accepted and parts that cant be accepted. From that, I had gained a lot of knowledge in
checking the quality of the parts.

Furthermore, the most important thing that I had gained from this internship is my
communication skill. As a IQC engineer, when there is an issue, it is necessary to have a good
communication with staff from other departments like KGD department, financial department so that
the quality and quantity issue can be solved in a much efficient way. Moreover, it trained me to adapt
to working under pressure so that when there is a lot of issues, I could complete my tasks
accordingly to their importance.
In a nutshell, industrial training is good for students as it could expose them to a real working life,
giving them extra practical knowledge and the responsibility while working. This would prepare
them in their future career.

REFERENCES
The following report provides information on a variety of topic.

1. INTERNET
http://pearlnet/
http://pearlnet/10aboutus/About_pg.htm
http://www.spansion.com/About/Pages/About.aspx
2. BOOKS
WS Foo & WW Yau (2004). Do you know we are using Flash everyday?. Magazine of

Dialog AMD, 21, 20-21

KS YAM (2003). FASL Penang Wafer Sort Operation. Magazine of Dialog AMD, 13,
18
Tan Shin Yi (2005). Quality Management System. Magazine of Dialog AMD,37, 18

Logbook

3. RESPONDANCE
Namaswayan (Spansion Quality engineer)

APPENDICES
JCI NO. AMD 08-16-01

CORRECTIVE ACTION REPORT

8D REPORT

Customers name SPANSION PENANG

Concern
Title

Ref No.
Bad mark contamination on Bond Lead

8D Reporting date

Plant

Feb/05/2008

JCI main plant

Feb/26/2008

Issue Date
3663

Apr/14/2008

Part
Name

FTM115 Substrate (13.0mm x

11.0mm)

Part No

30210 Rev.1

JCI No

1602

Sep/09/2008
1 Use of team
approach
H.UMEDA

MFG.

2 Problem
Description
NCMR#C3663, JCI shipment
information:

M.SHIMIZU

MFG.

Inv# SPAN-P-96-1190 (ship date: 2008/03/18), Shipped Qty: 143,307pcs,

O.ISHIKAWA MFG
K.OGUSHI

QA

T.INOUE

QA

JCI Lot# 0508-1009, 0708-1641, 0808-1943, -1944

Spansion-Penang found the bad mark ink contamination on Bond lead.

TCI-C:
Fang

Mfg Dep. Manager

Ricky

QA Dep. Manager

Qiu hai xia

QA Engineer

Yang xiu gui

QA Engineer

3 Containment /Short
term

%
Effect

Implementation
Date

100%

Apr/17/2008

100%

Apr/17/2008

- JCI will sort RTS balance lot for the above defect reported.

100%

Pending RTS

Lot # 0708-1641 qty 19,692.

- JCI had the below shipment for this part after the effected
invoice#:

100%

Apr/28/2008

Corrective Action

- Defect information was reported to the related process operators for their
awareness. (Please refer to the attached below.)
- Inspected JCI retained sample form the delivered lot but did not found
the mention defect.

4 Define Root Cause

JCI did not receive actual defect samples. Hence, we conjecture the below rot cause

% Contribution

JCI did not receive actual defect samples. Hence, we conjecture the below rot cause
based

100%

on sample photos and information.

These bad ink contaminations are UV ink that was occurred on defect unit marking
process. These lots were shipped and inspected on TCI-C.
TCI-C found the machine trouble during affected lot loading. The printing screen fixed
on
frame of the printer had mechanical vibration due to wearing of bearing and loosen
timing
belt. UV ink on the screen may have scattered on to the Bond lead of good unit due to
above machine abnormality.

Bearing
Timing belt

Machine trouble happened during lot # 0808-1944 processing, machine was repaired
mid way of loading but operator did not suspect that the trouble will leads to this
defect. Lot was release as per normal production.

5 Permanent Corrective Action

Implementation

To add the conditions check of the printing machine in daily check sheet.

To standardize the above check item on the work procedure. (Please check the

Date
Apr/17/2008

attached.)
- Any affected WIP to be put on MRB for confirmation before release to
production
when machine of such trouble occur again.

6 Define methods to verify effectiveness of corrective action

Implementation

- TCI-C will monitor the defects in FQA data (LRR & DPM) in order to confirm the
effectiveness of the corrective action for 1 month (by end May).

Date
May/2008

TCIC-C did not observed any FQA reject of UV ink contamination during Apr to Jun.
Hence, JCI consider that the above corrective action is effective.
TCI-C FQA data:

7 Prevent Recurrence

April/28/2008

- To check the bond lead surface of good unit after UV ink printing process also of
possible
ink contamination on Line and FQA.

8 Approval
Prepared by T. Inoue

Close Date

Reported
by

Checked by T. Sawada

Apr/28/2008

T. Inoue

Approved by Y. Kuboshiki
JCR-20020108

Quality one point education record:

(X-OUT Marking)

(FQA)

Revised daily check sheet for X-OUT printing:

X-OUT printing machine daily PM check list.

Any mechanical vibration of frame and printing screen.

Bearing and timing belt condition.

pansion Limited
NCMR No. 3663

Appendix B
NCM report
Non-Conforming Material Report
Creation Date: 2008-4-23 9:46:42

PART ONE: TRACEABILITY

Supplier: JCI
Spansion Site: PNG
Spansion Spec.: F04-0X30210
Rev: 1
Spec Description: FTM115 Substrate (13 X 11)

Commodity: SUBSTRATE
Supplier Lot Number: 0708-1641,
Spansion/QC Lot No.: P-96-1190
P.O. No: 7100015847
Pack Slip/Invoice No.: SP-P-96-1190

Quantity Received: 143307

Quantity Accepted: 123615
Quantity Rejected: 19692
Date Received: 21-March-2008
SAP ID: 31006730

PART TWO: DISCREPANCY

Supplier Quality

__ Supplier Admin

__ Spansion Internal Admin

Description:
Bad mark contamination on Bond Lead

__ Spansion Internal Quality

__ Blanket

PART THREE: MATERIAL REVIEW BOARD/DISCREPANT PARTY RESPONSE

Action:

Supplier to investigate and provide corrective action report

Debit No.: 0

CAR No.:

Date:

PART FOUR: DISPOSITION

Return to supplier Retain by Spansion Approvals:
Qty: 19692
__ Correction
__ Replacement
Credit
Sample:

Qty:
__ Use As Is - Prod.
__ Use As Is - Engr
__ Use As Is - Insp
Deviation
__ Testing/Eval.
__ Screen/Rework
__ Scrap

Date

DM Mgr.

karupanan namas ________________ 2008-4-23 15:27:40

ENG Mgr.

royce yeoh

________________ 2008-4-23 17:55:02

MAC Mgr.

no mak

________________ 2008-4-23 19:07:03

PRO Mgr.

sk ong

________________ 2008-4-24 14:21:24

SQE

karupanan namas ________________ 2008-4-24 16:22:49

Buyer

50