FUSHAN TECHNOLOGY (VIETNAM) 1 (5)

Confidential

Title: BA FIRST PIECE INSPECTION INSTRUCTION

Document Type: Working Instruction
Effective Date: 01-Jun-2019
Creator: Vuong Thanh Hieu
Owner: Pham Thanh Trang
Doc. ID: QA-3009
Doc. location: Doc Share
Distribution: BA Production/Quality/BA Maintenance/MTE/ENG
Function: Quality

Approvals:

Department Name / Title

Quality Nguyen Huu Can/ Quality Manager
BA Engineering Jerome Ayag Pecana/Process Engineering Manager
BA Production Nguyen Quang Binh/Program Manager
BA Maintenance Ngo Quang Thao/Maintenance Manager

CHANGE HISTORY

Version Status Effective Date Handled by Approved by Comments

6.0 Add process
flow chart
7.2.2 Add
5.0 Approved 12-Aug-2014 Vu Tien Anh Mai Huu Luat
classification table
for change-over
level
6.0 Change process
flow chart.
6.0 Approved 10-Sep-2014 Vu Tien Anh Mai Huu Luat 7.2.2 Make clear
scope of each
change-over level
Change template to
7.0 Approved 21/02/2017
new company
Change BA first
piece definition,
Re-index Doc ID.
Restructure the
Vuong Dau Thi Tuyet document, define
8.0 Approved 28/8/2017
Thanh Hieu Anh FPI when repair /
maintenance
/restart line in
section 6.2

-Clarify items check

FPI when line re
Pham Thanh Nguyen Huu
9.0 Approved 01-Jun-2019 start after 24 hour
Trang Can
-Adding FPI after
Inventory

This document contains confidential and proprietary information and duplication is not allowed for external use. Only controlled copy issued or Intranet location
controlled by Document Control can be used for activities that impact product or service quality. The printed copy for internal use is uncontrolled and only valid at
the time of print.
FUSHAN TECHNOLOGY (VIETNAM)
Ver/Status: 9.0/Approved 2 (5)
Confidential Effective Date: 01-June-2019 Doc ID: QA3009

1. PURPOSE
- The document details step for verifying the product/process for Product Changeover and
after machine maintenance/repair (Including Production Recovery, Stencil Change), New
Program change.
- The document details samples size for frequency sample check in BA

2. SCOPE
- This instruction process defines how to verify and perform First Piece Verification
Process utilizing the BA First Piece Inspection Report. This document shall be applied
for all products producing in Hanoi Operations.

3. DEFINITIONS
BOM : Bill of Material.
PWB : Printed Wire Board
PWBA : Printed Wire Board Assembly
BGA : Ball Grid Array
IPQE : In Process Quality Engineer
SMT : Surface Mount Technology.
PE : Product Engineer.
FPV : First Piece Verification.
BA : Board Assembly.

4. RESPONSIBILITIES
 BA operators shall be responsible for carrying out the first piece verification accordingly
to this document and inform Quality for supervise process.
 BA Engineer, PE, In Process Quality Engineer, Maintenance Shift Leader are
responsible to required processes for first verification, to check and confirm if the
existing status of process, machine, tools, material, document, operator, control program
and parameter etc. are suitable to run the production and determine final approval and
keep the checklist as record.
 Quality Leader/ Group Leader/ IPQE is responsible to approve all product changeover
by approving the First Piece Inspection Report. Production Group Leader/Line Leader
initiates the First Piece Verification Report.
5. PROCESS DESCRIPTION
5.1 Before proceeding FPI process, Production shall make sure:

 Production Line is cleaned up from previous material/semi-production. No

WIP is pending in every single machine; all WIP (if any) is moved to defined
location.
 WIP which is available for new PON shall be prioritized and defined in FPV
record.
Above points shall be verified and confirmed by Process Quality audit.
5.2 The first piece verification must consider to be
executed whenever product changeover, new program launching as below definition:

QA-3009-BOARD ASSEMBLY FIRST PIECE INSPECTION INSTRUCTION

FUSHAN TECHNOLOGY (VIETNAM)
Ver/Status: 9.0/Approved 3 (5)
Confidential Effective Date: 01-June-2019 Doc ID: QA3009

• Line changeover level 2, 3, 4. Line changeover definition as followed:

Do first piece
Changeover
Definition verification and
level
clean up
1. Same product, different module code
Level 1 No
2. Product run at the line before
1. Same product, different module code
Level 2 Yes
2. First time run at the line
1. Different product
Level 3 Yes
2. Product run at the line before
1. Different product
Level 4 Yes
2. First time run at the line
• New program: New program launching at any machine (program update, brand
new or ECN change), require to perform test from that machine to backend.
• New line: a new line launching for first running following ENG-2001. New BA line
setup
• Maintenance/ Repair Machine: Line stop for Maintenance/ Repair activities in 4
hour or longer
• Line restart after weekly holiday (machine no turn off power supply)
• Line restart after long holiday (> 24h or Machine turn off power supply)
• Line restart after Inventory
5.3 In case Pick and Placement program change or
new line launching, BA engineer will do polarities test for tape board. Then tape board will
be transferred to PE for LCR test. LCR test must be performed by PE, the test result should
be available in 3 hours, if not, PE shall inform Production and relative teams for
acknowledge. The results shall be attached to FPI Report.

5.4 While the first pieces/panels are under

inspection (AOI, Rafla, BUI/Primus), production can run with the risk, but shall be stopped
immediately if any failure reported.

5.5 SMT PWBA Inspection

QA-3009-BOARD ASSEMBLY FIRST PIECE INSPECTION INSTRUCTION

FUSHAN TECHNOLOGY (VIETNAM)
Ver/Status: 9.0/Approved 4 (5)
Confidential Effective Date: 01-June-2019 Doc ID: QA3009

5.5.1 If SPI online, BA Operator shall firstly check printing quality through verifying
SPI result (solder paste height, volume, position) for first two panels then
passing to Process Quality. Process Quality shall confirm and record result in
FPI Report. Otherwise, QA Operator will take 2 panels for SPI off-line test
and record accordingly in FPI Report.
5.5.2 Line leader will sign-off on the Report after feeder setup is completed by
scanning. The confirmation 100% by Process Quality audit will be only
provided if all signatures on feeder lists are fulfilled.
5.5.3 If an AOI program is available; check Y (Yes) on the report then select the
correct program and revision per their MIS for the 1st Piece Assembly and
run the first panel through AOI process. AOI process will inspect for
presence/absence, polarity and offset/skew. IPQE/Quality Group Leader
reviews all defects called out by AOI program.
5.5.4 Maintenance Technician shall measure the reflow oven profile against the
parameters; result shall be recorded and confirmed by Maintenance
Technician/ Quality Operator in the report.
5.5.5 BA Operator shall perform the inspection on the first 2 panels after Reflow to
ensure the good alignment and there is no missing component and wrong
orientation by as required in MIS. This inspection must be confirmed again by
Process Quality audit and recorded in Report.
5.5.6 In case BA Operator shall do visual check after ACF final bonding to ensure
the good alignment, proper bonding.
5.5.7 BA Operator shall do visual check modules (8 modules of 2 panels) after
Router, the result must be confirmed by Process Quality audit.
5.5.8 Once finish BA process, test boards shall be moved to FA for BUI/Primus
test. The report is only completed after BUI/Primus test completion.
5.6 The panels inspecting as the 1st Piece will be
segregated and maintained its status as the 1st piece panel built. These panels will be used
as the 1st piece when running the opposite side in production of a two sided assembly (if
any).

5.7 If the verification process fails, one of the

following will be notified; IPQE/ Production Group Leader/BA Engineer/Line Leader/ to
resolve the issue. Note any discrepancies on the Report in the Comments section, including
driving resolution of the failure then sign off prior to continuing the run.

5.8 If there is no discrepancy during the process, the

panel will be pulled for testing. In the event, there is a Test Failure; Failure Analysis is to be
done by DT, PE.

5.8.1 If it is confirmed that there is missing components, wrong components/value

and wrong orientation that caused the failure, Corrective Action should be
taken immediately and recorded into First Piece Inspection Report.
5.8.2 If it is confirmed that it is a tester problem or some other minor defects like
insufficient/open etc., the board is deemed as 'pass' the first article build.

6. RECORDS
Name Doc ID Index by Retention Location

QA-3009-BOARD ASSEMBLY FIRST PIECE INSPECTION INSTRUCTION

FUSHAN TECHNOLOGY (VIETNAM)
Ver/Status: 9.0/Approved 5 (5)
Confidential Effective Date: 01-June-2019 Doc ID: QA3009

Period
BA First Piece QA-3009- Date/line 2 years \\hvfsp01\PUBLIC\DocShare\17.
Inspection FM01 no/Prod name
QUALITY\QA-General Quality
check list

7. REFERENCES
QA-2032. Process Audit Procedure
ENG-2001.New BA line Setup Procedure

QA-3009-BOARD ASSEMBLY FIRST PIECE INSPECTION INSTRUCTION