Author: Phone Number: QR#

Problem Solving Report Julia. Fan

Problem in Shift: Problem found by:
Safety QualityX Responsiveness People Cost Other 1 REC: CSA: EOL: OTHER:
Report: 10-30-09 Part number 8A8T-19G461-AA 2 Maintenance: Production:
Problem Description: Sketch:

Ford EMC lab is having an issue with the part 8A8T-19G461-AA that Harada
produced.

Problem Definition (Real Problem):

Ford EMC lab complained that they had to use high transmitted power to pass
the reception test. EMC did replace the base antenna on the vehicle and the
problem went away.
Not determined
Quality Productivity
Standard: x Downtime Duration: x 1- Identified 2- Implemented
Deviation: x Scrap Quantity: x
Eng Chg: x Scrap Cost: x 4- Closed 3- Feedback
Defect: 1 Safety Impact: x
Containment: Breakpoint Who Date Status
Picked up the part at Ford. Part Number: 8A8T-19G461-AA. Manufacturing Date:
04/14/2007. SN: 00071 N/A Julia Fan 10/21/2009 Done

Harada RF Lab did preliminary testing, and found AM transistor shorted. Please see the Ervin
third tab. N/A Larashi 10/23/2009 Done
Mike
Sent damaged transistor to vendor for detail analysis N/A Merrick 10/30/2009 Done
Received Sanyo "Returned Product Analysis Report". The report will be attached to the Mike
email. N/A Merrick 11/30/2009 Done

Process/Part Check (similar to "7 Diamond Process" Steps 1-6): Y or N

1 Is the process being followed? Y 4 Has the operator been trained? Y
2 Is correct tool being used? Y 5 Do the parts support quality? Y
3 Is correct part being used? Y 6 Has EOL data been verified Y
Direct Cause Analysis: (see other side for 5 Why Analysis)
1) Indicate possible direct causes on diagram. 2) Circle most likely direct causes.

Man Machine

PROBLEM

AM transistor was
shorted due to
EMC test overload overload
Physical handling damaged Defect transistor from supplier

Method Material
Test each ( ) (?) ( crossed out)
direct
cause
and Direct Cause of the Problem Possible Direct Cause Not a cause of the problem
decide

PAGE 1 OF 2
 Report Number:
Problem Solving Report
Root Cause Analysis: In the first WHY write down the Direct Causes from the front.
(If more than one possible or direct cause is found, use additional sheets)
WHY? EMC lab complained that they had to use high transmitted power to pass the reception test
WHY? AM Gain lower than spec.
WHY? AM transistor shorted
WHY? Internal damage to the tramsistor
WHY? An overvoltage applied to the transistor
Root Cause: An overvoltage applied to the transistor
Transfer to Champion: (if necessary)
Harada US Harada China
Mike Merrick RF Assistant Manager

Team Takehito ONUKI RF Engineer

Member Julia Fan Quality Engineer Harada Japen
Ogawa Yasumasa Quality Engineer

Intermediate Action Plans (not containment) Who Due Date Status

Sent damaged transistor to ventor for detail analysis Mike Merrick 10/30/2009

Long-Term Corrective Actions Breakpoint Who Due Date Status

ESD protection device for AM/FM amplifer was

already changed for MY11&MY12 designs (B299,
U38X, C346, U502.) ESD testing performed at DV
and PV levels with no failures. See "ESD Test" tab, MY11
also attached report from Panasonic. programs Mike Merrick May-09 closed

Lessons Learned: Could the communication of this problem and its fixes
possibly prevent other departments from incurring the same problem? If yes, 1 1- Identified2 2- Implemented
which area?
Verification & Resolution Questions: Y N
4
N/A Problem Escalation:
4- Closed
3 3- Feedback
What level is the problem
Has this reoccurred? X currently being supported?
Have the Process Sheets been updated? X Author
Has the DFMEA/PFMEA been updated? X Line Supervisor
Has the Control Plan/Process Flow been updated? X Manager
VP
CEO
Have other forms been updated? X

PAGE 2 OF 2
 Two Warranty Parts 8A8T-19G461-AA Testing Results
AM FM

Mang. Current Detail

Part SN Draw(mA) Detail Analysis
Date AM Gain (Spec. -6+/-2 dB) (Spec. 30- Result FM Gain (Spec. 6+/-2dB) Analysis
90mA) Result
Max (dB) Min (dB) 1MHz (dB) Max (dB) Min (dB) 1MHz (dB)

5/14/2008 1611 -5.9 -6.2 -6 42 Good 6.5 5.6 6.0 Good

Shorted Q3
7/15/2008 814 -23 -18 -22 46 (AM Amp) 6.4 5.5 5.8 Good
AA Testing Results
SDARS

Current
Draw(mA) Detail Analysis
SDARS Gain (Spec. 34+/-2.5dB) (Spec. 55- Result
160mA)
2.320GHz 2.32625GHz 2.3325GHz
Shorted Q1
0.7 -1.3 -2.4 130.0 (SDARS LNA)
Shorted Q1
2.2 1.9 1.3 138.0 (SDARS LNA)