5M CHANGE TRAINING in manufacturing .pptx

change training

1. 5M CHANGE TRAINING 2022.12.02 This material constitutes confidential information of Toshiba TEC Singapore Do not disclose or reproduce it without permission

2. Engineering / Process Manager Production Manager Quality Manager Window Person to TSE/TIE Who Should attend this training : Supplier Key Personnel

3. Objectives : To explain TSE/TIE requirement on the 5M Change Request To increase supplier awareness on the importance of 5M change and potential penalty To inform supplier need to conduct self evaluation on changes before propose To introduce 5M Change Request Form Eliminate of silent change from suppliers After training : Supplier to share the requirement of 5M change request to their internal working person. Supplier will submit 5M change request form to TSE/TIE for approval when there is a need of change. TSE/TIE and supplier can eliminate incidents, disruption and rework process due to supplier silent 5M change.

4. What is the most Terrifying Words NOT WANTED TO be hear AS manufacturer? $ Market Claim $ Manufacturer Pain Customer satisfaction Company Reputation Profit Customer

5. Example of Market Recall (Safety): Samsung says bad battery design and rush to release an updated version of the Galaxy Note 7 caused some of the devices to overheat and explode. Samsung manufactured the phone with a battery from a different supplier . But Samsung was in a rush to get the new phones out, and the new battery produced by the supplier had a defect that also caused it to overheat. ( Steve, K. (2016, Nov). Samsung announces what caused the Galaxy Note 7 to overheat and explode. Retrieved from http://www.businessinsider.com/samsung-issues-galaxy-note-7-battery-report-2017-1/?IR=T )

6. Supplier Silent Change (1) TSE received feedback from end customer that found plastic shaft holder crack. When received RMA printer, QA found oil on the thread hole which tighten with plastic shaft. TSE found supplier had silently changed the “Degreasing process” from machine degreasing to manual degreasing and operator had failed to remove oil trapped in thread hole of stamping part. After assembled with plastic part, Esters (oil attack) take place and causing plastic crack! Supplier paid USD XX,XXX to perform rework for all the shipped FG at customer premises. Case 1 Stamping Case 2 Stamping TIE incoming inspector detected part welding drop off and found no nugget at welding area. TIE found supplier had silently changed the welding parameter in order to improve the productivity of powder coating process. Supplier have to scrap all the quantity of same affected lot and run new lot to support production.

7. Supplier Silent Change (2) TSE received feedback from end customer that found plastic cover crack after sometime. After investigation, TSE found supplier had silently changed the barrel melting temperature during molding process . Due to the change of parameter , material start to degrade after certain period and result of plastic crack. Supplier silent change had incurred USD X,XXX to perform field rework. Case 3 Molding Case 4 Molding TIE production detected driving gear fitting loose during printing process. Later found that it was due to the Gear inner hole dimension bigger and reduced interference fit between gear and shaft. Supplier had conducted drilling to rework the inner diameter without TSE/TIE acknowledgement and approval. TIE production incurred USD XXX loss to perform rework for all the FG.

8. Why Supplier not Inform 5M Changes ? Don’t tell Customer won’t know Part within spec after changed , does not need to alert customer Change due to support urgent production (one time case only) Changed done by internal other division Window person and QA not aware of the change ( Information Breakdown ) Not aware need to submit 5M change request

9. Why 5M Change Request and Approval are important? Silent 5M Change is Submit 5M Change Request for approval ; Doing silent change , supplier may facing below problems : Indirect dimension out of specification but failed to detect. (Only focus on IPQC/OQC dimensions) High volume of nonconformance parts been produced and need to scrap Caused customer to rework, production loss time and market claim To review and reduce potential problem due to 5M change Some change may need to get TSE/TIE customer approval before proceed. Customer may have more consideration based on the function of part and advise on the evaluation of change.

10. Common Silent Change Among Suppliers Changes can be good , but changes can also create Risk !

11. INTRODUCTION of 5M What is 5M? Quality Problem Material Machine Measurement Change of 5M may lead to Quality Problem Transfer /shift plant Machine major repair Tooling modification Maker Country of origin Grade Mixing ratio of raw material RoHS Equipment to jig measurement Quality control system OQC point Man direct labor working day Staff Method Machine parameter Rework Packaging

12. Category : Machine Example 1: Transfer secondary process to/between subcontractors including shifting of subcontractor's plant. Plating process (b) Powder coating/ (c)Heat treatment Spray Paint Process Example 2: Add or modify jig and fixture Stamping a) Inspection Jig b) Welding holding Jig c) Rework Jig Molding a) Cooling Jig b) Degating Jig c) Inspection Jig Each supplier have different capability on secondary process. For every time change, part produced need to be requalify to ensure the part meet drawing specification. Modification of jig might affect the datum for part placement. It may cause: Wrong positioning Inaccurate measurement result

13. Example 3: Change and repair of molding machine Example 4: Major repair / modification on tooling Stamping a) Plugging insert b) Change of die plate / punches c) Change of guide pin Molding a) Change of gate (Block or unblock for gate point) b) Block or unblock a cavity c) Add or remove part material for appearance improvement Change of machine model/brand (no change of tonnage) Change of machine tonnage Change of molding machine barrel size Change, repair or modification of tooling may affect part dimension and appearance . Category : Machine Molding parameter will change due to machine change. Mechanical strength of part may change.

14. Category : Machine Example 5: Change / shift of production plant to new production plant Transfer tooling/secondary process from HQ to subsidiary Transfer tooling to/between subcontractors including shifting of subcontractor's plant Example 6: Fabricate tooling due to : (a) New tooling (old tooling wear off) (b) Spare Tooling A A B (new tool) A A B (Spare) Category : Machine New Tooling : Different condition with tooling used in previous FA submission  Need to resubmit FA for TSE approval

15. Category : Method Example 1: Packing Method is important to ensure part is well protector during transportation. Any change on the TSE/TIE approved packing method should submit 5M change request form. Packing quantity Part Placement Packing Material External Carton Packing Method Example 2: Change of production process (different with manufacturing process flow chart) Manufacturing process Rework process Secondary process. Eg: Spray paint pattern or jigging process Automatic process to manual process Note!! Silent rework is forbidden!! X ID Rework X Gear tooth flashing rework X Part curve profile rework

16. Category : Method Example 3: Change of machine parameter Machine parameter (Out Of Control Limit) is different compared to the master parameter submitted during FPA. Important!! Molding Process a) Preheat Parameter b) Mold Temperature. c) Cycle Time. d) Holding Pressure e) Injection Speed f) Injection Pressure g) Back Pressure & Screw Speed Welding Process a) Weld Time b) Squeeze Time c) Current d) Holding Time Moisture level too high, caused Silver Streak Difference of mold temp will affect part texture glossiness Pressure too low Short shot Current too low Welding Drop off Change of parameter will affect part dimension, appearance or welding strength.

17. Change of Material Raw material type Maker Grade Country of origin (COO) Change of mixing ratio of master batch : Pigment grade (molding) Use recycle material (molding) Chemical Substance Stamping a) Tapping oil b) Degreasing agent c) Stamping oil d) Plating chemical　 Raw Material Category : Material

18. Category : Man (b) Change of Staff TSE/TIE Window Person for quality communication and Quality Management Quality Organization chart Production Setter (Turnover rate > 40% within 3-month rolling period) (c) Factory working day less than 5 days per week (a) Change of Direct Labor Production Operator (Turnover rate > 40% within 3-month rolling period) IQC / IPQC / OQC Inspector (Turnover rate > 40% within 3-month rolling period) TSE/TIE Qualified Inspector (QIS) (Resign / add) 40% Important!! New staff well trained? Lack of experience?

19. Measurement Method Quality System Control Plan Outgoing inspection point Any change of the quality control will directly affect the accuracy of measurement result and detectability of inspector. Change from Jig Checking to Equipment Measurement method. Inspection Interval Period Inspection Sampling Size Change of outgoing inspection point (unable to cover TSE/TIE incoming inspection point.) AQL 0.65 0.40 Every 2 hours Every 4 hours Category : Measurement

20. 5M Classification Table (Stamping) 5M Classification Table (Molding) 5M Change Application Form There are different 5M category classification in market , including but not limited to listed example in TSE/TIE 5M Category Classification table. TSE/TIE may change or update above classification content from time to time. Supplier require to submit 5M Change request form when there is a need of change. >> Supplier can use your company 5M change request form format and send to TSE/TIE >> TSE/TIE to advise the need of the FPA sample submission after reviewed 5M Changed Request from supplier. TSE/TIE 5M Change Control Requirement Example :

21. 5M Change Request Form Fill up by supplier * Attach Evaluation Report Fill up by TSE

22. EVALUATION METHOD OF 5M Change Sufficient evaluation need to be done before submit for approval. Example of evaluation: Part dimension (cover IPQC, OQC and customer IQC dimensions) Additional dimension which relate to the change Part Appearance Part Structure Mechanical Properties of part Degradation of material Consider environmental compliance Always compare Apple to Apple Find out what is the difference of part before and after change Different kind of changes will require different type of evaluation method

23. Whether will the part will have weld shifted, weld line easy broken after change ? Whether will the part mechanical strength weaken after change ? Have compare the old and new part most tighter tolerance dimension after change ? Example : molding parameter change Some of the considerations you should take: Whether newly change on parameter , look normal for use in mass production ? Whether this part (material) have big post shrinkage ratio ? Whether the measurement to be taken after post shrinkage ? Whether will the part dimension will out of specs after change ? Whether will the part structure easy to have post warpage after change ? Whether will the part degraded (material) after change ? 1

24. Example : molding parameter change Comparison of Molding Parameter 2 Part photo before and after 3

25. Example : molding parameter change Measurement report on part dimension and appearance 4 Measurement cover: TSE/TIE IQC Supplier IPQC/OQC Affected dimension Related dimension Others Supplier need to provide own judgement on any difference on part dimension/appearance after the 5M change

26. Advance Notice period Criteria TSE/TIE Primary contact Notice Period Example Change related to Process PQE/ PQA One month Change of machine parameter Change of production process Change of quality control plan Change related to Cost / Material / / Manufacturing location change / Tool shift Sourcing/ SCM Six Months Change of Production Plant Change of raw material Reduce of number of working days Tooling location change Kindly put attention to TSE/TIE window person and cc for below four groups to avoid any missing information sharing. PQE/ PQA [email protected] ; [email protected] Sourcing/ SCM [email protected] ; [email protected] Please call to window person to ensure they had received your email request.

27. summary 5M : Machine, Material, Man , Method and Measurement Refer to TSE/TIE 5M Classification Table Most common silent 5M Change : Do not repeat in future Machine parameter change Change of quality control plan Change of production process Unauthorized rework process Sufficient evaluation to be done before submit for approval. For example: Part dimension (cover IPQC, OQC and customer IQC dimensions) Additional dimension which relate to the change Part Appearance Part Structure Mechanical Properties of part Degradation of material Supplier need to submit 5M change request form with evaluation result when there is a need of change.

28. Thank you