Incoming Raw Material Inspection Format

Quality Cover.
QXD 5/24/00 5:26 PM Page 1
A M E R I C A N M I C R O S Y S T E M S , I N C .
GA00028 Quality.qxd 5/24/00 5:29 PM Page 1
AMI CORPORATE QUALITY MANUAL
AMERICAN MICROSYSTEMS, INC.

2300 Buckskin Road
Pocatello, Id. 83201
Spec. #5500011
Date: 2000
Rev. S
C o r p o r a t e Q u a l i t y M a n u a l
The controlled copy of the Quality Manual shall reside in the Document Center under the document
number #5500011.
Many documents referenced in this manual exist in a controlled form in the Document Center. The
Quality Manual shall be maintained and controlled in accordance with the AMI Document Control
System as referenced in AMI #5501004, Guidelines for Generating 7-digit Documents.
This document is reviewed and updated annually and is considered current if the revision/date on the
first page of the manual is concurrent with the latest revision/date on the file in the Document Center.
Prepared By:
_____________________________________________
Paula Lee/Date
Quality Programs Manager
AMI Management Representative:
_____________________________________________
Jim Young/Date
Director of Reliability and Quality Assurance
Approved By:
_____________________________________________
Gene Patterson/Date
President
ii AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

INTRODUCTION
It is fitting that today’s application-specific integrated circuits, or ASICs, have become complex systems
on a chip, or microsystems, because American Microsystems, Inc. pioneered the development of ASICs
since 1966. Today AMI is realizing its full potential as an ASIC company. AMI is a company that saw the
future in terms of microsystems, and made that part of its name.
AMI provides its customers with the full range of capabilities: products, design service, value-added
packaging and assembly, and a variety of manufacturing technologies that help shorten development
cycles, reduce design costs, increase integration, and improve reliability. Most importantly, AMI
emphasizes a service and a product. AMI satisfies its customers by tailoring its services and products to
fit customer needs. AMI’s products and services are aimed at faster cycle times, lower costs, world-class
reliability, and designs specific to each customer’s needs.
AMI’s Vision: “To Be a Profitable, Growing, and Self-funded Integrated Circuit Company.”
Mission: Provide customers the best total solution, employing AMI’s Digital and Mixed-Signal
capabilities coupled with extraordinary service in our Target Markets. We will:
Develop and Grow Our Targeted Markets and Customers.
Acquire and/or Develop Appropriate Technologies and Competencies.
Profitably Diversify Into New and Emerging Markets.
AMI Values:
RESPECT for ourselves and others.
ETHICAL business behavior.
ACCOUNTABILITY for all we do.
COMMITMENT to do our best.
HONESTY and INTEGRITY in every interaction.
The values identified above are the driving force for continuously building trust among ourselves, our
suppliers, and our company.
AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 iii

QUALITY MANUAL GENERAL INFORMATION

This document is a statement of the management philosophy at AMI. It was organized and reviewed by
Gene Patterson, AMI President, Jim Young, Director of Quality, along with support from the Quality
Department. Any employee may propose changes to the Quality Manual, or any quality system
document, through the use of the controlled documentation system. These changes shall be reviewed by
the Quality Department to ensure that the Quality Manual adheres to customer quality system
requirements.
The quality activities described in this manual meet, but are not limited to:
ISO9001/1994 + QSA Semiconductor Supplement which defines fundamental quality systems

expectations of many worldwide companies and QS9000 Third Edition (March, 1998)
(ZERTIFIKAT Nr. E-1261), which defines the fundamental quality system expectations of Chrysler,
Ford, General Motors, truck manufacturers, and other subscribing companies.
ISO9001/1994, an international set of Guidelines for Managing a Quality System.
Mil-PRF-38535 for Level Q (EQC-92-320 and EISC-94-081), a performance specification which

provides an acceptable established baseline to support Government (military) microcircuit
applications.
Paragraph 1.2.1 of Mil-STD-883 that establish uniform methods, controls, and procedures for
testing microelectronics devices suitable for use within Military and Aerospace electronic
systems.
AMI has chosen to focus on increasing first-pass yields and reducing cycle time in all of its operations,
instead of typical cost of quality analysis, to make the quality of its products and services competitive.
To support this objective AMI has formed a department, Integrated Yield Engineering. The charter of this
department is to analyze product and process sort yields and identify sources of in-line particulate and
wafer handling defects. This department works to identify yield limiting defects, establish Quality Control
methodologies, and facilitate the implementation of Corrective Action Plans. The QS9000 Potential
Failure Mode and Effects Analysis along with the Control Plan Program will be used as part of this
analysis.
Programs outlined in this Quality Manual are implemented through the issuance of AMI process
specifications, functional procedures, and company procedures. These proprietary procedures are found
in actual working documents which are available for review by customers.
The Quality Manual itself is non-proprietary and is available for distribution to employees, customers,
government representatives, vendors, subcontractors, and assessment organizations.
Individual working documents are updated to represent current practices as soon as changes are
properly approved, without change to this Quality Manual.
The contents of the Quality Manual are reviewed and approved by the President of AMI, Director of
Quality and the Quality Department, in conjunction with approval of AMI’s Technology Review Board,
before publication of each annual revision. The responsibility to integrate AMI’s quality principles into
the organizational structures resides with the President and his staff.
iv AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

TABLE OF CONTENTS
1.0 Management Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2.0 Quality System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
3.0 Contract Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
4.0 Design Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
5.0 Document and Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
6.0 Purchasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
7.0 Control of Customer Supplied Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
8.0 Product Identification and Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
9.0 Process Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15
10.0 Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17
11.0 Control of Inspection, Measuring, and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . Page 19
12.0 Inspection and Test Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20
13.0 Control of Non-conforming Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 21
14.0 Corrective and Preventive Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 22
15.0 Handling, Storage, Packaging, Preservation, and Delivery. . . . . . . . . . . . . . . . . . . . . . . Page 23
16.0 Control of Quality Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25
17.0 Internal Quality Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26
18.0 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27
19.0 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 28
20.0 Statistical Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 29
* Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 30
AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 v

1.0 MANAGEMENT RESPONSIBILITY
QUALITY POLICY STATEMENT:
It is the policy of American Microsystems, Inc. to satisfy our customers by producing products that meet
or surpass their quality, reliability, cost, and delivery standards.
No defects are acceptable.
The President of AMI has the executive responsibility to define and document the Quality Policy
Statement. This Policy is implemented through the Quality System which provides direction, in the quest
for continuous improvement of process, product, policy, and procedure. The outcome of this quest has
been defined by the management of AMI in the Quality Policy Statement. AMI is committed to this policy
and requires that it is understood, implemented, and maintained at all levels in the company.
ORGANIZATION
The President of AMI is responsible for structuring the Quality System and assigning the activities
described in this manual. The AMI organization was established to insure management of appropriate
activities including: business development, technology planning, product concept, development,
prototype, and production of our products.
The Quality Organization specifies the groups within AMI which have a major role in accomplishing
activities defined in the Quality Manual. This includes the reporting structure as well as descriptions of
the charters and capability of each department. Reference AMI #5510000, Executive Staff General
Reference Document.
The Product Design and/or development Business Units, in conjunction with the Manufacturing groups,
have the responsibility for end-product quality. These groups are chartered to select critical steps in the
process and monitor the product quality at these points. The Business Units are also responsible for
identifying in-house verification requirements, providing adequate resources, and assigning trained
personnel for verification activities. AMI has established a multidisciplinary approach for decision
making and support of this system. See the attached organizational chart for functional structure and
Section 4.0, Design Control, for further information.
Departments within the quality organization are structured to ensure, through monitoring, that only
quality products are received by AMI’s customers. This is accomplished by organizational freedom and
authority to identify and record quality problems, initiate action to prevent the occurrence of product
nonconformity, and verify the implementation of solutions.
The Director of Quality has the primary responsibility and authority for assuring that quality systems are
in place, documented, and functioning. In addition, the Quality Organization provides plans, education,
and motivation for company-wide improvement in quality.
The Quality organization reports directly to the Site Manager of AMI Pocatello. The Quality organization
has the freedom to audit throughout the company and the opportunity to guide improvement by
identifying problems and suggesting solutions.
1 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

Quality Assurance tasks within AMI organizations serve the management function of maintaining
conformance of processed materials (product), and documented systems to specified requirements.
Personnel performing QA tasks have sufficiently well-defined responsibility, authority, and organizational
freedom to identify and evaluate quality problems, control further processing or delivery of non-
conforming product and to initiate, recommend, and provide solutions. The Corporate Quality
organization, at AMI-Pocatello, is responsible for affecting the Quality Programs Plan. Separate
Reliability and Quality organizations, reporting functionally to the corporate Director of Quality, affect
the plan at other AMI sites.
Executive-Level Organization
Staff and Services
AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 2

QUALITY
The Document Center (DC) is responsible for maintenance and controlled dissemination of official
AMI documents, paper forms or electronic media. Authorization of new documents or changes to
existing ones is governed by uniform adherence to a defined control procedure. Reference AMI
#7500051, Document and Data Control System Requirements. Because of the evolution to electronic (or
paperless) documentation, the corporate DC is an entity within the corporate Information Systems (IS)
Organization. Nevertheless, it remains responsible for assuring that all AMI document sets are current
and accurate, as well as complete in the aggregate.
The Failure Analysis (FA) organizations perform in-depth analysis of AMI products from design
development to customer returns as well as engineering support services.. The AMI-Philippines FA lab is
responsible for package-related failure analysis and support of the product testing operations in that
facility. The AMI-Pocatello organization is divided into two laboratories - the Scanning Electron
Microscope (SEM) Lab, specializing in supporting wafer manufacturing, and the FA Lab, that specializes
in tracing electrical behavior to the root cause defects in die-related failures. Analysis outcomes are
documented in formats that are suitable for informing AMI engineering, manufacturing, and/or
customers of the findings and, measures that could be taken to prevent recurrences (Reference AMI
#5351023, Failure Analysis Department’s Areas of Responsibilities).
Reliability (REL) continuously evaluates the capability of AMI’s manufacturing processes and materials
to produce products suitable for any prospective application. The overall program, administrated by the
corporate REL group in Pocatello, uses Standard Evaluation Circuits (SECs) for ongoing packaged-device
testing and Technology Characterization Vehicles (TCVs) for wafer level reliability testing of the
fabrication processes. The production REL group in AMI-Philippines, in addition to executing all
packaged-device testing, is specifically responsible for packaged-related reliability appraisal and
containment of manufacturing problems with bearing on reliability. Reference AMI #5150050, Training
Requirements for Reliability and Statistics.

The Statistical Methods (SM) Department facilitates the use of industrial statistics at AMI, including
the use of control charts, the computation of process capability (Cpk) indices, and directing engineers
and other employees in the use of designed experiments and other statistical techniques.
The Quality Programs Management Department (QPMD) performs the necessary auditing of all
internal systems, documented flows, processes, and vendors to assure management and customers that
adequate quality systems are defined and functioning. QPMD administers the following programs: Self-
Audit, Supplier Control, Customer Returns, Corrective Action, Technology Review Board (TRB), ISO9001
and QS9000. Associated responsibilities are listed in AMI #7500096, Quality Programs Management
Department General Index.
AMI #5500013, AMI Supplier Management System, which includes the process for the qualification and
certification requirements of suppliers, is administrated under the direction of QPMD and the Supplier
Management Team (SMT). See Section 6.0 of this manual.
The Technology Review Board (TRB) is responsible for maintenance of all certified and qualified
processes, and process change control. Reference AMI #7500127, TRB Organization and Responsibilities.

MANAGEMENT REVIEW
The President of AMI has ultimate authority for quality at AMI.
The President has appointed a Management Representative, the Director of Quality, who has the
responsibility and authorization to ensure that a quality system, the Quality Program Plan (QPP), is
established, implemented, and maintained in accordance with ISO9001/1994 + QSA Semiconductor
Supplement and QS9000 Third Edition (March 1998) Semiconductor Supplement. Reporting on the
performance of the Quality System is accomplished through presentations at the Corporate Management
Review. These presentations focus on Quality and Departmental support of the Business Objectives.
It is the responsibility of the Executive Management Staff to ensure that they are providing direction,
giving support, and providing adequate resources for these programs.
The Executive Management Staff at AMI is a team under the direction of the Company President.
Periodically this team, using a multidisciplinary approach, reviews a set of indices which reflect their
efforts towards meeting the Key Business Objectives and improving Quality Systems within the
company. This Corporate Management Review (CMR) ensures continuing suitability and effectiveness of
our systems to meet these principles. The CMR is an effective tool used to support decision making and
long-term planning. This review is under the administration of the Quality Department. Records of the
meeting and assigned activities generated during the meeting are maintained by the Quality Department.
The guideline for this review is documented in AMI #5500030, Corporate Management Review.
BUSINESS PLANNING
Short-term (1 year) and long-term (3-5 years) business planning is a tenet of AMI business operation.
AMI’s business planning cycle is an ongoing process that produces a controlled working document,
(Long Range Plan and Five Year Financial Projections), that is updated annually. Updating the AMI One
Year Business Plan document is the responsibility of the Finance Department. Updating the AMI Five
Year Business Plan is the responsibility of the New Business Development Department. This document is
located in the QSI System 9000 located in Lotus Notes.
The Five Year Plan includes financial, technical, quality, and long-term business goals. The data in the
plan is in the form of financial tables, timelines, roadmaps, and descriptive language. The Five Year Plan
is developed and reviewed by each Business Unit and is based on data from at least these sources:
yearly review of critical Customer’s long-term needs and roadmaps, product and competitor market
trends as determined from yearly benchmarks and published analysis, fundamental technology trends as
identified from research activities, conferences, partnerships, and technology transfers. The long-term
plan is updated annually in concert with review and completion of the One Year Plan.
The One Year Plan is driven from current company financial conditions. The One Year Plan and
short-term goals are based on financial projections of the current business climate. The Financial
Department drives the development of each yearly plan beginning at the start of the company’s third
quarter and finalized by the end of the fourth quarter. The One Year Plan consists of financial projections
and goals by Business Unit and individual Business Unit and Manufacturing Key Business Objectives
(KBOs). The One Year Plan is reviewed at each CMR.

2.0 QUALITY SYSTEM

The Quality Program Plan (QPP), as defined in this manual, is inherent in AMI’s controlled document
system. It is defined by comprehensive and individual process flow diagrams and procedures as well as
device related documents.
Review of the Quality Program Plan is accomplished by the Corporate Management Review (CMR), as
stipulated in AMI #5500030, Corporate Management Review.
Corporate programs are periodically audited and occasionally revised to ensure compliance to the
documented QPP, which is designed to conform to the current revision in effect of ISO9001/1994 + QSA
Semiconductor Supplement and QS9000, Mil-PRF-38535, and Mil-Std-883. Our product and process
control plans are developed at the system, subsystem, and component level as required on individual
products. The Control Plans for individual Business Units and Manufacturing Areas will be incorporated
into the area procedures as necessary based on the QS9000 Advanced Product Quality Planning and
Control Plan (APQP) manual requirements. Control Plans are also discussed in Section 4.0, Design
Control and in Section 9.0, Process Control.
Implementation of the QPP is the responsibility of AMI’s Executive Staff Members. Maintenance and
control of the QPP is the responsibility of the Quality Department. Documents listed in this manual and
the procedures associated with them are the responsibilities of each and every department that performs
these functions at AMI.
AMI has a comprehensive continuous improvement philosophy throughout its organization, including
business processes and support services. A continuous improvement effort is in place for quality, service,
and price. This is evident in the Business Objectives, and the plans to meet these objectives discussed at
all quarterly CMRs. Weekly status reports from all departments within the company document on-going
improvement activities.
Opportunities for quality and productivity improvement are in place for the following: unscheduled
machine downtime, excessive cycle time, scrap, excessive variation, less than 100% first run capability,
process averages not centered on target, testing requirements not justified by accumulated results,
excessive cost of non-quality, excessive handling, and storage and customer satisfaction. Facilities and
tooling management are discussed in Section 9.0, Process Control.

AMI is fully capable of compliance with all requirements set forth in the Production Part Approval
Process (PPAP) manual required by QS9000, when required by the customer. This production part
approval is granted for a part number, engineering change level, manufacturing location, material
subcontractors, and production process. Any changes to these requirements will require customer
notification and written customer approval. All changes will be validated before being implemented. The
Production Part Approval Process requirements may be stipulated, by contract, to our subcontractors.
Some of the techniques for continuous improvement used at AMI include the following:
Control charts, are used on all key characteristics and key process parameters. Control chart procedures
are documented by AMI #5351006, Control Chart Procedure.
Capability indices, or Cpk’s are calculated for all key characteristics as documented in AMI #5351025,
Process Capability Indices. The results are published in the quarterly Reliability Update.
Design of Experiments (DOE), is used extensively by the Process and Design Engineers.
Parts Per Million (PPM) analysis, is used to determine appropriate sampling plans and estimate an
average outgoing quality.
Problem solving classes are also on-going.
Other techniques such as studies on equipment effectiveness, cost of quality, benchmarking, and
mistake proofing can be found actively being used throughout the company.
Further explanation of the continuous improvement program is in Section 20.0, Statistical Techniques.

3.0 CONTRACT REVIEW

The main purpose of Specification and Purchase Order Review is to ensure that all product requirements
are adequately defined and documented in order to complete a product feasibility review. This review is
the first step in converting the customer specifications and purchase orders into internal processing
documents. During this review the following are identified: processing, controls, pricing, delivery, test
equipment, fixtures, tooling, or skills required to assure that customer-specific requirements are met.
Purchase Orders (POs) and applicable customer specifications are reviewed to assure that the customer’s
contractual requirements can be met by AMI internal standard processing flows. If any contract states
specifically that QS9000 certification is a requirement, then the requirements of QS9000 specific to these
customers, requires review for compliance. If not, then either special characteristics or processing
instructions will be created to AMI’s device specification or exception will be taken to the customer’s
specification. Special characteristics as defined in QS9000, will be evaluated for implementation at this
time. If exception is taken to the customer’s specification, AMI shall work together with the customer to
attain a mutually acceptable agreement. Manufacturing work instructions are converted from the
customers’ requirements in accordance with applicable Business Unit documentation and in AMI
#7500051, Document and Data Control System Requirements.
It is the applicable Business Unit’s responsibility to review specifications and purchase orders to
determine whether AMI has the capability to support the customers’ initial and subsequent requests.
This procedure is documented in AMI #5502008, Customer Contract Review Procedure. The Customer
Specification Conversion function is deployed to the Business Units of AMI for the express purpose of
enhancing customer satisfaction. Certified individuals within each of these units, including
Manufacturing, are responsible for assuring that customer specifications are mutually consistent with
AMI’s designing and manufacturing documents and comply with AMI’s quality systems and standards.
Any amendment or contract change is handled through this same documented system and
communicated to the responsible area. If additional review is required, Customer Service shall route the
review request to appropriate departments. Records of such reviews shall be maintained per Section
16.0, Quality Records.
Customer support and satisfaction is a major focus at AMI. The central CSR organization, located in the
Worldwide Planning & Test Operations organization, has the responsibility of gathering and reporting
how AMI is satisfying the Customer needs. (See AMI #5502026, Customer Satisfaction, Determination
and Improvement.) AMI ensures customer confidentiality of contracted product and related product
information.

4.0 DESIGN CONTROL

AMI has documented procedures to assign, plan, control, and verify the design of products, ensuring that the
specified requirements are met. Cross-functional teams are often required and used to ensure that all areas of
Design Control Plan elements are met. Organizational interfaces are defined within Business Operations
Development specifications, AMI 440XXXX, listed below. Each Business Unit uses the referenced product
development workflow applicable for the type of product being designed. This interface assures that the
necessary information being documented is transmitted and regularly reviewed. The development work flows
and procedures, when completed are considered the product control plan. Further explanation of the Design
Control is documented in AMI #5500058, Design Control.
The product development flow provides customers with a flexible interface, depending on such factors as
experience, capital expenditures, timing, loading, etc. The interface points tend to be product specific. Each
Business Unit has documented its own unique development flow, which demonstrates how it establishes and
maintains procedures to plan, control, and verify its system in design of the product. These flows also
document how each area identifies and assigns qualified personnel, equipped with adequate resources to
perform their job functions. Compliance to these flows ensures that the necessary information is documented,
transmitted, and regularly reviewed. Any update to these flows will be performed as required. A Design Failure
Mode and Effects Analysis, (DFMEA) when required, is part of the product control plan.
Design verifications are held at numerous points in the design flow to ensure that outputs meet the design
input requirements as well as the requirements of the next development flow block. Design input shall also
consider the results of any contract review activities.
Design reviews are documented and maintained at appropriate stages of the design per the Business Unit’s
Development Workflow documentation. A review of the design output ensures that all input requirements have
been met. Design validations are performed and documented prior to release to production. Any changes or
modifications to the design or design documentation are identified, documented, and reviewed under the
guidelines of AMI #7500051, Document and Data Control System Requirements. These changes may require
internal or customer approval.
AMI has a comprehensive prototype program. When possible, the same process, tooling, and subcontractors
that are in place for production are used in the manufacturing of prototypes. Reliability data, on production
processes, is published on a quarterly basis.
Advanced Product Quality Planning is documented within the development specification and contained within
the project start packet and the product control plan. These plans include all data necessary to ensure product
quality during the prototype, pre-production, and production phases. Also, refer to Section 5.0, Document and
Data Control, paragraph two for further explanation.
Development Type AMI SPECIFICATION #
Standard Product 4401040 - Timing Generator Products Workflow and Procedures
Mixed-Signal ASIC 4401023 - Mixed-Signal Project Engineering Development Workflow

and Procedure
Digital ASIC 4401005 - Digital Project Engineering Development Workflow
Foundry 4402001 - Foundry Development Workflow and Procedure

Product Development and Production Process Flow

5.0 DOCUMENT AND DATA CONTROL

Documents and data are maintained in a controlled environment. These materials are used to control
the quality of the characteristics of AMI’s products and services, including: Customer
Specifications/contract review, design, development, purchasing, manufacturing, product services,
assembly, test and inspection, storage, shipments to customers, and equipment calibration and
maintenance.
Such documentation and data include, but are not limited to: Design Control Plans, which include
Customer-required Special Characteristics; process flows and procedures; quality control instructions
and monitoring guidelines; product specifications; product travelers; drawings; test tapes; database
tapes; and Customer Specifications.
The issue and amendment of AMI documents shall be authorized, controlled, and recorded in a timely
manner in accordance with AMI document #7500051, Document and Data Control System
Requirements. The current AMI document revision can be determined from the document Master
Database.
It is the responsibility of AMI personnel originating, obtaining, or amending any process or

documentation of material requirements within the scope of AMI’s documentation system to ensure that
such activities are recorded and appropriate background data is available in accordance with AMI
documentation procedures. These procedures are identified in AMI #7500051, Document and Data
System Requirements, AMI #5501000, Document Approval Matrix, and AMI #5501003, Inactivation,
Reactivation, Obsoletion Procedures which ensure that document changes, approvals, and activation or
obsoletion procedures are met.
The affected area and device/document owners in the respective Business Units, Manufacturing, and
Support Groups are responsible for reviewing and approving documentation releases and amendments
to ensure that they meet or exceed system and quality requirements outlined in this Quality Manual.

6.0 PURCHASING
AMI has established and documented a purchasing system to ensure that purchased products conform
to specified requirements. This system includes the review of purchasing documents by the QA Systems
Technician, who is part of the Quality Organization, for adequacy of the specified requirements.
Supplier selection, evaluation, qualification, and control are part of the AMI #5500013, AMI Supplier
Management System. This system promotes the purchase of reliable commodities and subcontract
services that meet or exceed AMI’s requirements as well as those of our customers.
AMI considers management of suppliers, both vendors and subcontractors, to be critical in assuring the quality
and reliability of AMI products. Strong emphasis is placed on controlling the quality of purchased items to
ensure that selected suppliers produce quality materials and services on time. This emphasis is evident in the
selection, qualification, and evaluation process that AMI uses to govern third party subcontractors, e.g.,
assembly houses, and test facilities providing services beyond internal capabilities. Subcontractor and Supplier
audits are carried out by AMI to ensure Quality Systems are in place and practiced.
To support the philosophy of eliminating mass incoming inspection, AMI strongly encourages suppliers
to utilize statistical methods to demonstrate process control and to share the data thus obtained. Where
suppliers demonstrate acceptable process control and correlation, dock-to-stock procedures may be
used, i.e. no incoming inspection is required.
The Business Unit, Manufacturing Area, or Support Group in need of materials or services in conjunction
with the Supplier Engineer is responsible for initiating the creation of a Supplier Management Team
(SMT). The SMT is responsible for the evaluation of new suppliers, completion of an Evaluation Survey,
and the development of a continuing evaluation plan. Purchasing is responsible for keeping records of
supplier communications and for the issuance of purchase orders only to suppliers documented in AMI
#5500013, AMI Supplier Management System. Purchasing documents shall contain data clearly
describing the product and applicable issues of specifications, drawings, inspection instructions, and
relevant technical data including quality requirements, when applicable. The SMT and Purchase Order
Review System also ensure that materials used in the manufacturing system satisfy current
governmental and safety constraints on restricted and hazardous material, as well as environmental,
electrical and electromagnetic considerations, as applicable.
When specified in contracts, AMI’s customers shall be afforded the right to verify at source, or upon
receipt, that purchased products conform to specified requirements. This verification shall not be used by
the supplier as evidence of an effective control of their quality system.
AMI encourages our subcontractors, as part of our subcontractor control and development, to meet the
compliance requirements of the Quality Standards listed in this manual. This effort is documented in our
Supplier Survey, which is issued on an annual basis and in AMI#5500013, AMI Supplier Management System.

7.0 CONTROL OF CUSTOMER SUPPLIED PRODUCT

AMI develops and ensures that there are procedures for the identification, verification, storage, and
maintenance of customer property, both at AMI and our supplier sites. Any such property that is lost,
damaged or unsuitable for use shall be recorded and reported to the customer. Guidelines are supplied
for the protection of product while in the possession of subcontractor.
Customer-supplied documentation and software is maintained in restricted access files within the Document
Center to protect proprietary information, reference AMI #5501020, Customer Specification Handling.

8.0 PRODUCT IDENTIFICATION AND TRACEABILITY

All Product developed and manufactured is traceable within AMI systems from purchase order review to
shipment of the product. Every manufacturing lot has a unique number that is traceable from the starting
raw material through every step in the manufacturing process. The rule set for Product Identification and
Traceability defined in AMI #5500045, Product Identification and Traceability is implemented by various
process control procedures referenced in that specification. The wafer fabrication lot is the
manufacturing lot. The same lot number with a suffix is used to identify all sublots of the original
manufacturing lot. Once a manufacturing lot has been defined, only sublots of the same manufacturing
lot can be combined into a single lot. Every lot is documented by electronic and/or paper travelers that
record the processing date, measured values, the machine I.D. and revision of the control software/test
program, and the batch of raw materials that was used at each manufacturing step.
AMI uses PROMIS, an application software package, as part of the control system for product identification.
This system provides shop floor control in the manufacturing areas. Use of this system is also mentioned
in Section 9.0, Process Control. This system enables AMI to trace material and associated test data in a
timely manner while it is being processed and after it is shipped.
Product identity is inherently obvious through all manufacturing steps except module assembly. Every
wafer is marked with a wafer number, the fabrication lot number, and the AMI product number.
Individual die generally do not have any product identity marking. Maintenance of product identity and
traceability in the assembly process and for plated die is assured by assembly procedures. See the AMI
#7020037, Plastic Baseline Assembly Requirements for an example. After assembly, product identification
is again inherent because every assembled module is marked with a date-trace code that is uniquely
associated with the AMI manufacturing lot and product numbers.

9.0 PROCESS CONTROL

Processes are identified, planned, installed, and controlled in a suitable environment to meet our quality
requirements. The guidelines and requirements for shop floor control include lot tracking, statistical
control, and equipment maintenance documented in AMI #7619090, Shop Floor Control (SFC)-Lot
Tracking and Statistical Process Control (SPC).
All of the processing operations are controlled by a documented work instruction or procedure. AMI
ensures that a documented process is accessible to all operators, at any step where the absence of such
a procedure could adversely affect quality. This control includes documented flows and special
environmental working requirements:
AMI #7450000, SASS Manufacturing Capability Index

AMI #7019027, Fab Master/Flow Chart
Electrostatic Discharge (ESD) controls are governed by:

DOD-Std-1686
EIA-Std-541
AMI #5503001, Directions for the Handling of (ESD) Sensitive Devices & P.C. Boards
The Process Control of subcontracted items is documented in the AMI Baseline Specifications. Reference
documents: AMI #702XXXX and #705XXXX.
Quality Control activities, within manufacturing are not performed by a separate organization.
In-process inspections carried out by qualified manufacturing technologists. In-process inspections and
monitoring results are logged into an interactive SPC database, AMI #7619090, Shop Floor Control (SFC)-
Lot Tracking and Statistical Process Control (SPC). Real-time control charts facilitate process control with
these measurement results. AMI’s SPC philosophy is explained further in Section 20.0, Statistical
Techniques. Special or key characteristics are defined and controlled by SPC. This data is available in
AMI’s Reliability Update.
The internal and customer-specified lot acceptance testing, sampling and monitoring after final test, and
environmental screening is performed by Manufacturing. This places the responsibility on manufacturing
to assure that the lot acceptance procedures being used do not compromise the quality of the product.
Having quality activities report to manufacturing reinforces the concept that every department is
responsible for quality.
Suitable maintenance, including a preventive maintenance (PM) system, is a fundamental activity within
manufacturing. Preventive maintenance of our facility and equipment, with an emphasis on uptime,
directly supports our continuing process capability and continuous operations. Maintenance operations
and PM requirements are documented in AMI #3339061, General Line Maintenance Requirements and
Controls. New production equipment installation and qualification will be performed according to AMI
#3339053, Fab Equipment Installation Checklist and AMI #7500122, Process Change Approval.
Process development and transfer shall be coordinated through the Manufacturing R/D Engineering
Group according to AMI #4150066, Process Development and Transfer Procedure.
Release of any process or piece of equipment to production, after any maintenance or engineering activity has
been performed shall require qualification or validation as defined suitable in the process specification.

Control of the appropriate identified manufacturing environmental requirements is provided by the

Integrated Yield Engineering Department. This includes the clean room temperature and humidity,
(which are computer controlled), clean room particle counts, deionized (DI) water quality measures, N2
(nitrogen), O2 (oxygen), and Clean Dry Air monitors. The specifications for this testing meet the
requirements of Federal STD. 209 and the current AMI process requirements. Workmanship and product
requirements are defined in applicable specifications.
The Plant layout is evaluated by a cross functional team to minimize material and handling of the
product, along with maximizing usage of value-added floor space. The effectiveness of existing
operations and processes are continually reviewed for the overall work plans, appropriate automation,
tooling management, ergonomics, operator and line balance, cycle time, and inventory levels. To
support these studies appropriate technical resources, which include cross-functional teams, are
available during all phases of the process from design through shipment of product. This data is
available in the weekly Manufacturing Status Reports and is summarized in the data presented at the
Quarterly Corporate Management Review.
When non-conforming product is identified through the use of an FMEA, root cause analysis, mistake
proofing, and a problem tracking system are used in problem resolution as well as to prevent the
manufacture of non-conforming product. See Section 2.0, Continuous Improvement.
Several reliability test chips are used to acquire long-term data. Examples of these are:
TCVs: Arrays of simple circuit structures that are used to characterize fundamental failure phenomena.
The characterization of things such as metal electromigration, transistor life times due to hot carrier
effects, and time-dependent dielectric breakdown are factored into design rules and manufacturing
process controls.
SECs: Packaged ASICs that typify the design-fabrication technology. The Reliability Department tests
SECs with the intention of creating failures to accurately predict the reliability of AMI’s products in
various application environments.
Both SEC and TCV test data are summarized in the Quarterly Reliability Update for AMI’s customers.
Beyond the obvious function of continual improvement, the Reliability Department’s purpose is to save
AMI customers the added cost and time-to-market delay of an ASIC product qualification.
AMI has prepared a documented contingency plan, titled “The Business Resumption Plan.” This
procedure exists to protect and restore vital business processes in the event of a disruption. The AMI
business philosophy is to pro-actively insure that business disruptions affecting our customers be
minimized.
Advanced Product Quality Planning and Control Plans are mentioned in Section 4.0, Design Control.
Special Processes. At the present time no production processes are considered “special” as defined in
section 9.2 of ISO9001 or QS9000, March 1998, section 4.9.2.

10.0 INSPECTION AND TESTING

AMI has established documented procedures for inspection and testing activities to ensure specified
requirements are met on raw materials, subcontracted activities, and product. Acceptance criteria for
attribute data sampling plans are zero defects.
The Design layout inspection and product functional verification procedures are described in Section 4.0,
Design Control.
Receiving inspection of purchased or subcontracted items is performed in accordance with procedures

set forth by the Engineering Contingent of the Supplier Management Team (See Section 6.0, Supplier
Management System).
Incoming inspection may be done by a sample inspection, but the use of supplier SPC data is preferred.
The methodology used depends upon the length of the relationship with the supplier, the results of
earlier 100% inspections, and the results of supplier audits and surveys. Reference AMI #7619172,
Approved Vendors Incoming Silicon "Ship to Stock" Procedure; and AMI #7601101, Process Chemical
Control Plan.
AMI product or raw material, without exception, shall not be dispatched until required inspections and
tests have been completed or necessary reports have been received and verified.
In the event that a batch of incoming raw material is found to be non-conforming, AMI’s measurements
are correlated with the supplier’s to verify nonconformance and involve the Supplier early in the process.
If the material is still considered non-conforming, the material is immediately identified and is
quarantined in an area physically isolated from acceptable material. For information on non-conforming
material refer to Section 13.0, Control of Non-conforming Product.
Materials and products are stored such that deterioration is minimized. Age control of time-limited
materials is maintained from the date of manufacture through the point of use. An example of this is in
AMI #7601101, Process Chemical Control Plan.
Manufacturing subcontractors submit a required summary of generic process control indices and
example charts from which the control indices shall be independently confirmed. This data is submitted
to QPMD and is available for review. Reference AMI #5500013, Supplier Management System.

AMI uses an internally generated procedure to evaluate finished products for acceptance or rejection
when they are submitted for inventory or shipment. Specifications exist for each product which indicate
the sampling and quality levels of specific parameters. Final inspections and test data for each product
are documented and reviewed for compliance. A lot rejected at test is submitted for 100% screening of
the failing parameter before shipment. Reference AMI #7020044, Electrical/Environmental Baseline
Requirements. Further explanation of AMI's inspection and testing procedures are available.
The continuance of processing for discrepant materials is permitted only with approval of a Material
Review Board (MRB) after a full review of AMI and customer requirements. Whenever applicable, AMI
shall report nonconformance to a government or customer source representative and assure they are
represented on the MRB. AMI is continually evaluating this system to ensure that product does not ship
until all required procedures have been completed and all of the associated data is available.
Records are maintained which give evidence that the product has passed inspection and test with defined
acceptance criteria. Record retention is addressed in Section 16.0, Quality Records, of this manual.

11.0 CONTROL OF INSPECTION, MEASURING, AND TEST EQUIPMENT

The responsibility for performing calibration is under the control of our internal in-house qualified
laboratory as well as commercial independent qualified laboratories. Control of inspection, measuring
and test equipment, and methods used during processing are documented to assure measuring and test
equipment systems are capable of measuring device characteristics within tolerances as prescribed by
customer or industry standards, as applicable.
Measuring and test equipment utilized in design and manufacturing areas are part of an established
calibration system. This system is in compliance with ANSI/NCSL Z540-1-1994 and other quality system
requirements listed in the Quality Manual General Information. Measurement capability and
uncertainties are recorded under this system. The specifications, scheduling, subcontracting,
performance, and record keeping of calibrations are the responsibility of Manufacturing. The calibration
system shall be developed and maintained by AMI’s Calibration Lab. Calibrations of product measuring
and test equipment meet the requirements of AMI #5380042, Calibration Operational Procedure.
AMI #5380110, Test Maintenance PM Procedure and AMI #3339061, General Line Maintenance
Requirements and Controls, provides detailed guidelines for preventive maintenance activities.
The extent of the calibration and the maintenance service intervals of equipment are established based
on stability, purpose and degree of usage, and by equipment manufacturer’s recommendation. Approved
calibration procedures are used on equipment used in final acceptance of AMI’s product. Equipment and
standards required to perform the calibrations are documented within the equipment manuals. All
calibration procedures have been written in a measure and record format.
Supplier Laboratories that performs testing for AMI must meet the requirements of AMI #5500013, AMI
Supplier Management System.
Calibration histories, including calibration reports from outside laboratories, and calibration forms used
for internal calibrations, are kept on file in the Calibration Lab and are available for review.

12.0 INSPECTION AND TEST STATUS

The inspection and test status of a product is identified through one or more electronic location, code, or
text systems. The primary method utilized is the Shop Floor Control system referred to as PROMIS.
Reference AMI #7619090, Shop Floor Control (SFC) - Lot Tracking and Statistical Process Control (SPC).
Other examples are Design checklists, Fab masters, Assembly travelers, and Product Operations Lot
Acceptance Test (LAT) sheets. These methods of product recording support traceability of processing at
AMI. The Manufacturing Technologists contain and label, with text or color coding, discrepant products
for immediate disposition Reference Documents: AMI #702XXXX, AMI #705XXXX, AMI #4402XXX, AMI
#4401XXX, AMI #7450000, and AMI #7019027. The PROMIS system contains the documented evidence
that the product has received the required processing throughout production to meet the requirements of
the Manufacturing Control Plan. These records shall identify the inspection authority responsible for the
release of conforming product.
Further explanation of this element can be found in Section 8.0, Product Identification and Traceability.

13.0 CONTROL OF NON-CONFORMING PRODUCT

AMI’s practices comply with the MIL-STD-1520 Corrective Action and Disposition System for Non-
conforming Material. Non-conforming material is separated from acceptable material at the earliest
possible point in the manufacturing process (see AMI #7619134, Discrepant Material procedure and AMI
#7455067, Final Test operation: Test Procedure). When minimum quality standards are not met,
regardless of end usage, non-conforming material is immediately segregated or placed in distinctly
marked containers for the accumulation of scrap or reclaim.
AMI has established documented procedures to ensure that product that does not visually conform to
specified requirements are identified, segregated, evaluated, and dispositioned.
A Material Review Board (MRB) has the responsibility to review and the authority to disposition non-
conforming or suspect material (refer to AMI #7510004, Material Review Procedure). AMI Reliability is
the final authority for all MRB decisions. Non-conforming material is never shipped without the
customer’s written acceptance. This includes QS9000 product manufactured with deviations from the
product’s PPAP documented process.
Suspect material is any material deemed suspect by an AMI employee. This material may have been
manufactured as an experiment or manufactured at a time when either of the two following
requirements, which would govern normal production were not met, (Device-spec was not released or
there was no purchase order at the time). As required by AMI #5500045, Product Identification and
Traceability, a suspect or "Experiment" lot is not shippable until a MRB establishes that it does indeed
meet all of the requirements of a normal, shippable production lot. If the lot history is not traceable, all
test results and measurements of the lot were not within the acceptable ranges, the lot doesn’t meet all
quality requirements, or the lot doesn’t meet the purchase order requirements, it is non-conforming and
not shippable.
Permissible reprocessing of product, as defined in AMI #7619134, Discrepant Material Procedure, is part
of our normal manufacturing process. The IYE Department has established a prioritized reduction plan
that is tracked and evaluated on a regular basis through the Corporate Management Review system.
First-pass yield, or the percentage of lots manufactured without any reprocessing, is continually
reviewed and documented.

14.0 CORRECTIVE AND PREVENTIVE ACTION

The Corrective Action Request system (CAR) documents discrepancies and ensures that corrective and
preventive action is taken to inhibit subsequent deficiencies. Appropriate action is determined based on
the root cause to prevent a recurrence of the discrepancy. Although AMI strives for prevention of errors
on a continual basis, formal corrective action is occasionally required.
The Corrective Action System is structured in such a manner to ensure the effective handling of Quality
Audit System discrepancies, customer complaints, and reports of product and process nonconformities.
The Quality Department reviews and performs a follow up on CAR activity, when applicable, to ensure
that effective corrective actions are taken. The effectiveness of the CAR system is documented and
reviewed, on a regular basis by the Director of Quality. A summary of the CAR data and cycle time are
reviewed quarterly at the Corporate Management Review.
The CAR system requires problem solving methods, mistake proofing, and preventive action be initiated
and documented while dealing with problems to a level corresponding to the risk encountered. Some of
the additional internal systems used in the problem resolution and corrective action process include:
DFMEA - AMI#7500129, Design FMEA Procedure, PFMEA - AMI #5500040, FMEA Specification, SPC, and
root cause analysis.
As part of the internal audit activity, performed by QPMD, a verification of the implementation and
effectiveness of previously issued corrective actions is performed. Further explanation of the Corrective
Action system can be found in AMI #7500115, Corrective Action Request.
The Return Material System documents when and why products are returned to AMI. Through the use of
this system AMI strives to eliminate internal deficiencies and returned product. The review of this
returned product includes an initial review by Product Engineering as well as FA and stimulates process
change when appropriate. The Corrective Action System is used in conjunction with the Return Material
System to prevent the recurrence of problems.
Reference: AMI#5370002, Returned Material (RMA) Procedure. CAR and RMA data is reviewed during the
Quarterly Corporate Management Review by Senior Staff. See Section 1.0, Management Responsibility.

15.0 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

The purpose of the internal packing, storage, and shipping system is to protect the quality of the product
and ensure safe arrival at the appropriate customer location. Reference AMI #7020044,
Electrical/Environmental Baseline Requirements.
Parts moving into Finished Goods Inventory must have passed AMI’s internal finished product
acceptance. In general, this inventory contains parts that are uncommitted to any particular customer.
Parts in Finished Goods Inventory may be classified into several categories, each of which is saleable in
a given market. Reference AMI #7000004, Packaging Procedure.
Boxstock is a designated storage area. The inventory, in this area, consists of marked and packaged
devices ready for delivery to a customer. The acceptance of parts into Boxstock Inventory is dictated by
customer requirements and standards for mechanical and cosmetic criteria. Parts are shipped per
customer requirements, which may include the specific transportation mode, routing, and containers.
Parts may be shipped directly from this inventory after agreement is determined between the Customers’
purchase order and AMI documentation. Reference AMI #7450000, SASS Manufacturing Capability
Index, and AMI #7500025, Quality Control Plant Clearance Procedure.
Areas handling conforming and deliverable product to be shipped to a customer have defined and
documented procedures and environmental controls. An inventory management system is in place
which optimize turns, assures stock rotation and low inventory levels. Our supplier delivery performance
system has been established to support 100% on-time delivery. A system has been developed to evaluate
and monitor adherence to established lead time requirements. This data is continually monitored
throughout the Company and reported on a regular basis. The documented Work instructions provide
methods for the handling of product to prevent damage and deterioration. Specific Electro-Static
Discharge (ESD) and clean room controls are designated where appropriate. ESD, handling, and clean
room controls are governed by best industry practice and the requirements of current processes at AMI.
Reference AMI #7440000, Facilities General Index, and AMI #5503001, Directions for the Handling of
Electro-Static Discharge (ESD) Sensitive Devices & P.C. Boards.
Each area handling products is responsible for defining, documenting and enforcing appropriate
handling, and storage controls. Examples of these are found in the AMI #7619042, FAB Cleanroom
Specification, AMI #7610000, Fab 10 Cleanroom Specification, AMI #7455109, Wafer Handling Procedure,
and AMI #7619177, Wafer Handling/Barcode Specification.

EXPORT REGULATORY COMPLIANCE
It is the policy of AMI to comply with both the letter and spirit of the laws and regulations restricting the
transfer, export, sale, or disposal of any product or technical data from the United States. The AMI
Export Control Corporate Policy has been established to accomplish this goal. Under no circumstances
will an export be made contrary to the applicable laws of the United States or contrary to the policies
mandated under the AMI #5502001, AMI Export Control Corporate Policy.
The AMI Export Control Corporate Policy is specifically implemented to meet the requirements of the
Export Administration Regulations, the International Traffic in Arms Regulations, the Nuclear Regulatory
Commission Regulations, and the Foreign Assets Control Regulations. The persons responsible for
administering this program will be provided the necessary support from all employees to maintain
compliance to changing export regulations.
Export of AMI products for assembly, testing, and international sales is key to AMI’s success. A violation
of any export provisions may jeopardize those exports. Furthermore, violations may subject AMI to
substantial fines and penalties.
Employees violating the policies set forth in the AMI Export Control Corporate Policy and the export laws
of the United States may be subject to dismissal from AMI. Hence, any questions concerning these
policies or any export regulations should be directed to the Export Control Manager.

16.0 CONTROL OF QUALITY RECORDS

Record Management at AMI archives information that has been recorded in any format, on any type of
media from its creation to its final disposition. This documented program provides for the optimal
retention of records vital to the operation of AMI and for their destruction when they are no longer
required. Quality Records are determined per area and require a minimum retention of five years. This
includes, but is not limited to, obligations concerning its employees, customers, vendors, and state and
federal regulatory agencies.
It is the responsibility of each major functional area to establish, document, and maintain an efficient system
for quality records, which includes: identification, collection, filing, storage, access and maintenance from
creation until obsolete, superseded or scheduled for transfer to the Records Retention facility. These records are
also maintained to demonstrate conformance to specified requirements and the effective operation of the
Quality System. Specific customer retention schedules that exceed AMI’s standard will be documented in the
customer’s specification. These records are to be legible and stored in a suitable environment that ensures the
prevention of damage, deterioration or loss. This system includes AMI and subcontractor’s Quality Records and
is controlled by the AMI #5501021, AMI Records Management System, and AMI-P #411007, Records
Management and Retention Guidelines and Procedures.
All documentation shall be maintained in the work area during active use. All inactive files are to be
transferred to the Record Retention Facility for the remaining period of required retention until disposal. The
records, which remain readily retrievable, are stored in a suitable environment in order to prevent damage,
deterioration and loss. This system is controlled by AMI #5501024, General Records Retention Schedule.

17.0 INTERNAL QUALITY AUDITS

QPMD, which is an independent group within the company, plans and implements, on an annual basis,
internal audits of the quality activities outlined in this manual. This Self-Audit is done to assure
management and customers that AMI has an effective Quality Assurance program in action.
Audits are performed on internal systems, documented flows, procedures, processes, incoming
materials, and suppliers. Suitable work environment requirements are considered during the audit
process. Audits are scheduled based on the status of program requirements and the importance of the
activity in the processing of a quality product. Audits are scheduled on all shifts in all areas of the
company. This system is defined by AMI #7500116, AMI Quality Audit Procedure.
When performing an audit, QPMD checks for a documented flow and the documentation being utilized
to perform each operation.
In-process auditing is performed at each critical point in the process to evaluate effectiveness of the
system or procedure, and to establish the training needs of each operation. The findings of the audits are
documented and the discrepancies are forwarded to the management personnel responsible for the area
of corrective action. The results of the internal quality audits form an integral part of the input to
management review activities. Follow-up activities, when required, record and verify the effectiveness of
the corrective actions taken. The Corrective Action System is explained in Section 14.0 of this manual.

18.0 TRAINING
AMI is committed to the continuous improvement and professional development of its employees. AMI
provides training for its employees by reimbursing them for tuition, books, and laboratory fees at
recognized institutions for education relating to their jobs or careers within the company. Employees
attend technical, management, and professional conferences and seminars relating to their job function.
AMI sponsors training with vendors for newly purchased or updated equipment. AMI provides in-house
training such as management; environmental, health, and safety; computer software; and on-the-job
training. AMI adjusts the employee’s work schedule, whenever possible, to allow class attendance.
AMI continually evaluates the knowledge and skills of its employees by comparing their abilities to the
job requirements and then identifies the areas requiring knowledge and skill improvements. Accordingly,
AMI provides training programs by utilizing the expertise of in-house experts and outside professionals.
Training in all areas of the company is evaluated for effectiveness on a periodic basis.
By providing its employees with on-the-job training by a certified trainer, AMI ensures that they have
hands-on experience with a qualified trainer until they can demonstrate the ability to perform each task
satisfactorily. After completion of training, each manager qualifies his/her employees for the job on the
basis of education, training and experience, as required.
Each department, and the Training Administrator, are responsible for establishing, documenting, and
controlling the required training data for the employees. AMI documents the general training
requirements for its employees in AMI #5500000, General Training Requirements.

19.0 SERVICING
This ISO9001/QS9000 section requirement does not apply to any of the systems in place at AMI at the present
time. Should we implement "Servicing" as a part of the charter, it will be defined and documented.
AMI Customer concerns are documented through the use of our Return Material and Corrective Action
System. See Section 14.0, Corrective and Preventive Action.

20.0 STATISTICAL TECHNIQUES

The Statistical Methods (SM) Department is responsible for assisting in training and guiding the use of
statistical techniques at AMI. Reference AMI #5351024, Statistical Process Control at AMI.
The SM department provides training and assistance to engineers in the Design of Experiments (DOE)
and assists management in the interpretation of experimental results. The SM department also helps
determine appropriate sampling plans and provides assistance in the application of regression analysis
and other statistical techniques.
SPC is used as an integral part of our Quality Plan and Process Control Plan. AMI uses SPC and other
statistical techniques to improve quality by continuously reducing variation in processing to improve
yields, and reduce variation in the final product. The use of SPC is subject to review by SM personnel.
AMI’s SPC plan focuses on key characteristics, which are defined to be the pass/fail MAP parameters
(electrical measurements of finished wafers) of major processes. Control charts are maintained for each
key characteristic, from which the Cpk is calculated. The key characteristic Cpk values are reported
quarterly in the Reliability Update. Any key characteristic with a Cpk of less than 1.5 must have a Low
Cpk Action Plan. A summary of these action plans is also included in the Reliability Update. Reference
AMI # 5351025, Process Capability Indices.
In addition to the key characteristics, measurements in the wafer fabrication process are identified that
contribute to the variation of the key characteristics. These measurements are called Key Process
Parameters (KPPs). Once the key process parameters are selected, control charts are established for each
parameter. The control charts are then used to achieve and maintain control about the targeted value.
Each of these control charts has an Out-of-Control Response Plan that provides instructions for actions
to be taken when out of control situations occur.

DEFINITIONS:
Acceptance Criteria:
Standards or criteria that characteristics, materials, products, and services must meet.
ASIC:
Application Specific Integrated Circuits.
Audit:
An evaluation to determine if present activities conform to specified requirements and whether
products conform to acceptance criteria.
Boxstock:
Inventory that consists of completely marked and packaged devices ready for delivery to a
Customer.
Business Unit:
A group that designs, develops, and markets a specific group of AMI’s products.
Calibration:
Comparison and adjustment to a standard of known accuracy.
CMR: Corporate Management Review

A formal evaluation, by Senior Management, of the Quality System in relation to the Quality
Policy and Business Objectives.
Conformance:
Compliance with specified requirements.
Control:
An activity to ensure conformance with acceptance criteria.
Corrective Action:
Action taken to correct the conditions adverse to quality.
Defect:
A product which does not meet acceptance criteria.
Documentation:
Recorded information.
ESD:
Electro-Static Discharge.
Failure:
Any condition that prevents the product or service from performing its specified function.
Inspection:
Activities such as measuring, examining, or testing one or more characteristics of a product, and
comparing these with specified requirements to determine conformity.

MAP:
Measurement After Processing, parametric testing.
Nonconformity:
The non-fulfillment of specified requirements.
Objective Evidence:
Facts which are observed and documented.
Operating Procedure:
A document that specifies or describes how an activity is to be performed to manufacture a
product, including methods, equipment to be used, and a sequence of operations.
Quality:
Conformance to specified requirements.
Quality Organization:
An organization within AMI, which has major roles in accomplishing the activities, defined in the
Quality Manual.
Quality Control:
The operational techniques and activities used to fulfill requirements for quality.
Quality System:
The organizational structure, responsibility, procedures, processes, and resources for
implementing total quality management.
Supplier:
Vendors and subcontractors who furnish materials, products, or services to AMI.
Specification:
The document that prescribes the acceptance criteria with which a product or service has to
conform.
Traceability:
The ability to trace the history, application, or location of an item or activity by means of
recorded identification.

Quality Cover.QXD 5/24/00 5:26 PM Page 2
American Microsystems, Inc.

2300 Buckskin Road
Pocatello, ID 83201
Telephone: (208) 233-4690
FAX: (208) 234-6795
Printed on Recycled Paper http://www.amis.com
QUALMAN00
GA00028PP(2.5K)5/00

Incoming Raw Material Inspection Format

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Incoming Raw Material Inspection Format

Uploaded by

Copyright:

Available Formats

Quality Cover.

QXD 5/24/00 5:26 PM Page 1

AMI CORPORATE QUALITY MANUAL

AMERICAN MICROSYSTEMS, INC.

AMI Management Representative:

ii AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 iii

QUALITY MANUAL GENERAL INFORMATION

ISO9001/1994 + QSA Semiconductor Supplement which defines fundamental quality systems

ISO9001/1994, an international set of Guidelines for Managing a Quality System.

Mil-PRF-38535 for Level Q (EQC-92-320 and EISC-94-081), a performance specification which

iv AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

2.0 Quality System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

3.0 Contract Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8

4.0 Design Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

5.0 Document and Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11

6.0 Purchasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

7.0 Control of Customer Supplied Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13

8.0 Product Identification and Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

9.0 Process Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15

10.0 Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

11.0 Control of Inspection, Measuring, and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . Page 19

12.0 Inspection and Test Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20

13.0 Control of Non-conforming Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 21

14.0 Corrective and Preventive Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 22

15.0 Handling, Storage, Packaging, Preservation, and Delivery. . . . . . . . . . . . . . . . . . . . . . . Page 23

16.0 Control of Quality Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25

17.0 Internal Quality Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26

18.0 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27

19.0 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 28

20.0 Statistical Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 29

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 v

1.0 MANAGEMENT RESPONSIBILITY

QUALITY POLICY STATEMENT:

No defects are acceptable.

1 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

Staff and Services

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 2

3 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 4

The President of AMI has ultimate authority for quality at AMI.

5 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

2.0 QUALITY SYSTEM

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 6

Problem solving classes are also on-going.

7 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

3.0 CONTRACT REVIEW

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 8

4.0 DESIGN CONTROL

Development Type AMI SPECIFICATION #

Standard Product 4401040 - Timing Generator Products Workflow and Procedures

Mixed-Signal ASIC 4401023 - Mixed-Signal Project Engineering Development Workflow

Digital ASIC 4401005 - Digital Project Engineering Development Workflow

Foundry 4402001 - Foundry Development Workflow and Procedure

9 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

Product Development and Production Process Flow

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 10

5.0 DOCUMENT AND DATA CONTROL

It is the responsibility of AMI personnel originating, obtaining, or amending any process or

11 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201

AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201 12

7.0 CONTROL OF CUSTOMER SUPPLIED PRODUCT

13 AMERICAN MICROSYSTEMS, INC. • 2300 Buckskin Road • Pocatello, ID 83201