SOP-42Q-MES0069 Statistical Process Control

42Q Home > Quality > Statistical Process Control

 

 

 

Quality Statistical Process Control Version MES15.71 Revision K1  

 

   

Introduction

SPC is an industry-standard methodology for measuring and controlling quality during the manufacturing process. It is a method for monitoring, controlling, and, ideally, improving a process through statistical analysis.

Based on statistical theories, SPC (Statistical Process Control) is applied to Sanmina’s manufacturing and production line for the purpose of quality control. SPC enables users to continuously monitor, analyze, and control the production process in real-time to reduce possible waste and improve process capability. Key tools used in SPC include control charts, monitor maintenance, email notifications, system configuration, line stoppage, etc. On the client-side, the SPC system includes tree components: SPC portlet , SPC TV portlet and SPC Dashboard portlet. 

Using the SPC, the Company can dramatically reduce variability and scrap, statistically improve productivity, reduce costs, uncover hidden process characteristics, instantly react to process changes, and make real-time decisions on the shop floor.

See below the main features for SPC:

• Support BATCH units calculation for Yield and Pareto charts.
• Display Affected Serials for all charts displayed.
• Change chart background color for Out-of-Control condition.
• E-mail Notification sent to specific recipients for Out-of-Control condition.
• Ability to export DPMO reports.
• Control on production process route (MFG hold) base on Pareto chart,P chart, NP chart, C chart, U chart, FPY chart, Xbar-R chart and I-MR chart.
• SPC Dashboard displays multiple monitors on TV in real-time.
• Support multiple data collection strartegies: Automatic Collection data from MDS or MESWeb,Manual Collection data vis SPC UI, and Automatic Collection data via SPC API.

 

SPC also provides some charts that help to see graphically some statistics: 

1. Attribute Control Charts – Process CONTROL (defects and defective units)

• Monitors Grouping data by Piece: P and NP charts.
• Monitors Grouping data by Defect Points: C and U charts.
• Monitors by BATCH: Yield (pie) and Pareto charts.
• Others: FPY and DPMO (DPMO, DPMO-P, DPMO-A, DPMO-T, DPMO-C) charts.

2. Variables Control Charts – Process CAPABILITY control (attribute values)

If the combination of Monitor setup (Part Number + Process/Workstation) has attribute setup on Shop Floor Configuration (Attribute Maintenance) the attribute charts will be displayed on Monitor Maintenance screen with: X-Bar/R chart; I/MR chart; Cpk/Ppk.

To get more information, see the next topics of this document.

 

 

 

Server Information Configuration

After SPC is deployed to the users' web server, users need to set up a server and configure the server information from the Server Information page.

To access the Server Information page in the MES Portal, navigate to: Administration > Server Information.

Figure 1: Server Information Page

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Create SPC Server

To create an SPC server:

1. Select Add from the Server Information page.

 

Figure 2: Add SPC Server

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2.  In the Add Server Information page, select SPC from the Program drop-down box.
3. Complete all the fields and select Add to save the configuration to the database.

Fields, as seen in the above screenshot, are explained in the following:

Name: The name of the SPC server.

IP: The SPC server IP address.

AppServer Port: The port that the SPC server deploys within the Tomcat server.

Context Path: The patch that the SPC server deployed on the Tomcat server. After the system is refactored, the system should have only one program that supports all sites/plants so the context path of server information for each site/plant should be /SPC-server.

Token: Safe Palindrome authentication to call the API.This is used to connect to the services for collecting data via SPC API.

Key: Safe Palindrome authentication to call the API.This is used to connect to the services for collecting data via SPC API.

Status: After you have completed all the fields above, select a status from this drop-down box, and click the check button to verify that the SPC server connection is working.

 

 

Edit SPC Server

To edit an existing server:

1. From the Server Information page, check the box of a server and click Edit.
2. In the Edit Server Information page, update the values of any field as needed.
3. Select Save to save the updates to the database; otherwise, click the Cancel button if users want to quit the action without saving changes to the server.

 

Figure 3: Edit Server Information Fields

 

 

Delete SPC Server

To delete an existing server:

1. Select the server and click Delete in the toolbar.

 

Figure 4: Delete Server

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Monitor Group Maintenance

MES 15 Quality SPC 1.2.28 uses the Monitor Group to maintain the SPC monitors that collect data from different sources, such as DotLine Source, MDS, and SPI. However, MES 15 Quality SPC does not actually collect data from SPI, it collects data from the SFDC archive as an associated database schema and support is not fully ready yet. The Dot Line Source was added in Monitor Group Maintenance to support the Dot Line chart, and the difference between the Dot Line chart and other charts is that the user transmits the data to the SPC through an API, and this data has been calculated, and the SPC directly uses the data for display.

 

 

 

 

View Monitor Group

To view existing monitor groups:

1. In the MES portal, navigate to: Quality > SPC. The SPC Welcome page will display. Select Enter.

 

Figure 5: SPC Welcome Page

Figure - SPC Welcome Page.png

 

2. In the Monitor Group List page, select an SPC engine from the drop-down box. By default, the first SPC engine will be selected.
3. Once an SPC engine has been selected, the existing monitor groups that were created under the selected SPC engine will be displayed on the Monitor Group List page.

 

Figure 6: Monitor Group List

MG list 1.1.png

 

 

Create Monitor Group

Every monitor is created under a monitor group. So before creating a monitor, a monitor group must be created first. To create a monitor group:

1. From the SPC Monitor Group List page, select the button in the toolbar.SPC opens the Add Monitor Group page.
2. Enter the monitor group name in the Name field.

 

Figure 7: Add Monitor Group

SPC_Add Monitor Group

3. Select MDS, SPI, or DotLine Source from the Data Source Type drop-down box.
4. Enter a Shop Floor ID,  and Description. 

Figure 8: New Monitor Group Page - MDS

  SPC_Selecting Data Source Type  

5. If you need to send an MFG Hold to stop the production line, you can enable the Send MFG Hold request to the checkbox.

The fields in the above figures are explained as follows: 

Shop Floor ID: Defines which SFDC that SPC should collect data from. 

MDS 

Note: Now, the SPC program is deployed on the Amazon cloud server (in the USA). Users scan SNs on their local  PC. So there will be a time zone difference between the SPC server and MDS if they are not in the same time zone. SPC uses the value of this field to calculate the timezone of local MDS, compares it with the Amazon cloud server time zone, calculates the time offset, and determines the right time for SPC monitor to retrieve data (create time + time offset) so that the scanned SNs data can display on monitor charts. 

Beginning with version MES 15.70,the time zone is defined at the Plant Maintenance module by the administrator. 

Figure 9: Plant Timezone

  SPC_Selecting Data Source Type

 

Send MFG Hold request to: This checkbox is not selected by default. It is optional. Users wanting SPC to send an MFG Hold to stop the manufacturing line must check the Send MFG Hold to request a box and select radio button: MDS. The MFG Hold will be sent to MDS, and then, MDS will send the MFG Hold to local SFDCs. 

From MES 15.69, SPC calls the new MES APIS to create/release Hold. The system will get the right MDS service from the Server info module.  Click the to test the web service connection.

Figure 10: New Monitor Group Page - SPI

 

Figure 11: New Monitor Group Page - DotLine Source

Note: Since some data is manually collected by users, and this kind of data could not be extracted from 42Q, this data has been calculated, and an API was provided to collect the data and present it to users in the Dot Line Chart. Below see a sample Dot line chart. See below some rules to get the DotLine Chart:

 

1. First users need to create a new monitor with the below info specified:

 Specify which process, parts... will be used for this monitor to collect data.

 Select Chart Type: Dot Line.

When the Dot Line Chart is selected,  Application & Data Column is enabled to let users select which Application & Data Column will be used to display this chart.

• Group By: Disabled.
• Interval: Disabled.
• Rules & Actions: Enable.

2. External Program will periodically pick data from Source Record by certain frequency, and put it into SPC by publishing it; 

API interface.

3. SPC TV will select Monitor to display. 
4. Draw Chart: just like the current u/p chart done in SPC. 

X axis: time collected(Import Datetime), Format: MMDDmm

Y axis: Data, UCL (Upper Control Limit), LCL Lower Control Limit(), Target.

See the sequence below:

 

Figure 18: New Monitor DotLine Chart Monitor Tab

 

Figure 13: Data Collection Strategy Tab

It is not allowed to update the Data Collection Strategy if the DotLine source type is selected because the Dot Line chart is not a control chart, so these rules cannot be applied to the Dot line chart. In order to achieve the feature of sending an alert e-mail or changing the background color to red, a rule must be set.

A new rule according to the characteristics of the Dot line chart was added: Consecutive points above or lower than UCL or LCL.

 

Figure 20: New Monitor DotLine Chart Standard Control Chart Tab

 

Figure 21: New Monitor DotLine Chart Available Charts Tab

Select Data in the Drop Down List, select both: Data1 and Data2 at the same time.

Data1 or Data2 can be understood as a group of data. Users can choose to display the two groups of data together in the dot line chart, or just display one group of data.

 

Figure 22: New Monitor DotLine Chart Actions Tab

And finally, users can select the following actions:

Send an alert email: This action sends an alert email to a specific person. Users can specify who would receive these alert emails in the Email Maintenance module.
Change the background color to red: If the exception was triggered, the background of an associated data record in this monitor will turn red. 

 See below a sample of DotLine Chart generated: 

Figure 23: New Monitor Group Page - Sample of Dot Line Chart

  

 

 

Edit Monitor Group

To edit a monitor group:

1. From the Monitor Group List page, check the box of a monitor group that users need to edit, and select Edit. The Edit Monitor Group page will display.
2. Edit any field as needed, and select Save to save the change, or Cancel to abort.

Figure 18: Edit Monitor Group Fields

 

 

 

Delete Monitor Group

To delete a monitor group:

1. From the Monitor Group List page, check the box of the monitor group to be deleted, and click  Del.

 

Figure 19: Delete Monitor Group

Note: It is not allowed to delete the monitor group which contains one or more SPC Monitor.

 

 

Monitor Maintenance

Brief Introduction and Preparation Work

SPC portlet provides users plenty of parameters to maintain SPC monitors. An SPC monitor is a platform for the setup of such processes as object monitoring, data collection strategy, rules, control charts, and actions. With monitor maintenance function, you can create a new monitor, edit the existing monitor, disable or enable monitor, show monitor data or control charts, lock monitor, and so on. So monitor maintenance is a key function to SPC.

 

 

 

 

Preparation Work: Associate Part Number With a Route

MES SPC retrieves data from MDS via database view. To make the part number data configured in MDS to be displayed in the SPC monitor creation page, the part number must be manually assigned to a route. To do so, you can follow the steps below. Users may skip instructions 1 and 2 below if a part number has already been created and the part number has been assigned to a route. 

1. Create Part Number

To create a part number:

1. 1 Navigate to: Shop Floor Control > Configuration > Shop Floor Configuration, and select the Part Number module.

 

Figure 20: Shop Floor Configuration Part Number Module

 

2. From the Part Number List page, select Add Part Number to proceed.

 

Figure 21: Part Number Main Page

3. In the Part Number Form float window, input some parameters to create the part number, and click the Save button.

 

Figure 22: Part Number Form

 

3. Associate part number with a route

 

1. From the Shop Floor Configuration portlet, select Product Route to proceed.
2. In the List Route window, select the icon on the right of the menu bar.

 

Figure 31: Product Route Main Page with Icon Highlighted

 

3. In the Part x Route Assignment List undefined window, select Add.
4. In the Part x Route Assignment Form undefined float window, select ashop floor ID, input thepart number, and select a route.

 

Figure 33: Part x Route Assignment Form

5. Select Save to define the Part and Route assignment.

 

 

 

 

Create a New Monitor

SPC monitors should be created under an existing monitor group. 

Users are able to set up monitors one by one part number for different production lines for one location/process, so there are too many monitors to be maintained, causing workload for them to maintain these monitors in 42Q SPC. From one plant estimate, there are about 30,000 monitors to be created to support 42Q SPC’s rolling out to the whole plant. 

To solve this workload, users are able to do the following operations:

• Create  Monitors in Batch
  • Support creates multi-part numbers/Family id with one location/process/location family or multi-location/process/location family with one part numbers/Family id.
  • Allow users to export all the related attributes when creating a monitor.
  • If selected part numbers have attributes, the attribute selection box in the new monitor>Data Collection Strategy page will only allow the common attributes.
  • To create monitors in batch, users should fill a batch id. This batch id will help users to do the operation of search or edit monitors.
• Edit  Monitors in Batch
• Delete  Monitors in Batch

1.  From the Monitor Group List page, select the  icon for a monitor group.

 

Figure 25: Monitor Group List Page with Go Icon Highlighted

 

The Functional List page is displayed: 

2. From the Function List page, select  (Monitor Maintenance).

 

Figure 26: SPC Function List Page

 

3. On the Monitor List page, select the icon.

 

Figure 27: SPC Monitor List Page

The user now enters the New Monitor form. This page provides all parameters to set up a customized single monitor or monitors in batch in SPC. 

Figure 28: New Monitor Form

The user needs to fill in the necessary information in the available tabs to create monitors. See step by step in the next topic.

 

 

Monitor

The first section is the Monitor.

 

Figure 29: Monitor Section

Batch ID: The name of the monitor or batch of monitors. This field cannot be edited as it is automatically set after the Part Number, Family ID, and Location,  Process, and Location Family. If monitor data is automatically collected from MDS, the monitor name consists of two parts separated by a hyphen: The first part is Part Number / Family ID, the second part is Location / Process / Location Family. If monitor data is collected manually via SPC UI, the monitor name will also contain the third part: the attribute name. 

 

Collect Data From: Enable SPC to collect data from Now or from a past date. 

Note: Historical data that contains exceptions could stop the present production line. If a previous date is selected here and the option Send MFG Hold request to was checked when creating the server, then a user attempting to save the monitor at this point will be prompted by a warning that asks the user to confirm the decision to save.

 

Part Number: The part number to be monitored by SPC. The part number is created and configured in MDS before being created in the SPC monitor. The Part Number option is selected by default. Users must enter a specific part number or select one from the associated drop-down box. 

TIP: When users enter four characters into the field, the portlet will automatically begin searching and listing any part numbers that match the input. To date, the Part Number, Family ID, Location, Process, and Location Family fields support this search-as-you-type feature. 

Family ID: The Family ID to be monitored by SPC. Family ID is created and configured in MDS before being created in the SPC monitor. Users must select the Family ID option manually and either enter the family ID or select one from the drop-down box.

 

Figure 30: Family ID

Location: The location to be monitored by SPC. Location is created and configured in MDS before being created in the SPC monitor. The Location option is selected by default. Users must enter or choose a location from the associated drop-down box. 

Note: Attribute is associated with part number + location or part number + process.  If a  monitor is created with part number A + location B and part number A + process B, some attributes will be associated, then the user can create Continuous control charts. The associated attributes can be viewed at the Data Collection Strategy tab.

 

Figure 31: Location

Process: The process to be monitored by SPC. The process is created and configured in MDS before being created in the SPC monitor. Users must select the Process option manually and then enter or choose a process from the drop-down box.

 

Note: If the "Route by Process" option is enabled in SFDC when a new monitor is being created, the user may select either Part Number and Location or Part Number and Process.  However, if the Mfg Hold submodule is to be used to perform a hold on a serial number for a certain part number, the respective monitor should be created by selecting Part Number and Process, not Part Number and Location.

 

 

Figure 32: Process

Location Family: The location family to be monitored by SPC. Location Family is created and configured in MDS before being created in the SPC monitor. Users must select the Location Family option manually, and then enter by choosing a location family from the drop-down box.

 

Figure 33:Location Family

Note: Some plans have more part number records but don’t have a relation with the route. The system will create a monitor with Part Numbers that should be relative to shop orders. Part Number/Family ID needs to set up relation with shop order which status is Release.

 

 

 

 

 

 

 

Data Collection Strategy

The second section is the Data collection strategy. According to the data chosen (Part Number and Location) at the Monitor tab, the user can create continuous control charts.

 

Figure 34: Data Collection Strategy for Non Continuous control Charts

Automatic Collection from Unit: Allows SPC monitor to automatically collect data from MDS service. This option is selected by default.

Manual collection via SPC UI:  Allow end users to manualy collection continuous data vis SPC ui(Input feature in SPC).

Automatic Collection via SPC API: With this option the users can create a monitor with Automatic Collection Via SPC API type and clients (such as PWB), which can push the data to SPC via its monitor API as long as the characteristics in the parameters of the API endpoint exist and match this monitor, the continuous data control charts (such as X bar-R chart, I-MR chart, and CPK/PPK report) will plot.

Subgrouping Method: This field defines the rules of how data should be organized to form a series of points plotted on control charts. It consists of the following components: Unit Quantity, Time, Subgroup Size textbox (if Unit Quantity is selected), and Time Range drop-down box (if Time is selected).

• Unit Quantity:  The data will be grouped by quantity. The quantity is defined in the Sample Size textbox. For example, if a data source contains 100 data items and the sample size value is 2, then this data source will be divided into 50 groups (100 / 2 = 50). This radio button is chosen by default. 

• Time: The data will be grouped by time range. For example, if a sampling period is 60 minutes and the time range is 10 minutes, then this sample period will contain 6 groups of data (60 / 10 = 6). Users must manually select the By Time option.

 

The sampling rules are customized by the user. The sampling method is divided into by time period sampling and by quantity sampling. The time and quantity can be set in SPC (The default sampling is the first serial number). 

Note: If there is no data in this sampling range, no new points will be created in X bar - R chart).

 

Figure 35: Data Collection Strategy for Continuous control charts

SPC supports continuous data(e.g. the thickness or humidity) and discrete data (e.g. pass or fail) control  charts in one monitor. Users can choose one of them or the two control charts.

Figure 35a: Data Collection Strategy for Continuous Control Charts - Continuous data

Figure 35b: Data Collection Strategy for Continuous Control Charts - Discrete data

Sampling Method: The sampling method belongs only to continuous charts. This field defines the rules on how data should be organized to form a series of points plotted on control charts. It consists of the following components:

• Full (Full Inspection). 
• Every X Units: Users can input the numbers of units. For example 5, that means the system will select one unit from every 5 units.
• Every X Time: Users can select the time from the drop-down list. Options: 10 minutes, 15 minutes, 20 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 6 hours,8 hours, 12 hours, 24 hours.

The original system is defaulted to FULL inspection, without configuration. Every Unit and Every time sampling, the system defaults to extract the first serial number of this time period/quantity for statistics.

Before SPC 1.2.25, only the attributes with the same prefix would be recognized as a group. Now, according to the Attribute Maintenance Configuration, it is possible to check whether the attribute is in the same group. 

The current SPC  has an attribute grouping control logic. Only the same type of attribute can be monitored in a monitor, otherwise, it will prompt a warning message. To turn the SPC attribute grouping logic consistent with the actual SFDC attribute grouping rules, new rules were created for the attributes. According to the Attribute Maintenance Configuration, it is possible to check whether the attribute is in the same group.

Note: Only the attributes in the same attribute group can be monitored together in one monitor.

 

Figure 36: Shop Order Configuration - Attribute Configuration

 

• Single Unit, Multiple Characteristics: This is the default method. This method is the subgroup method before SPC V1.2.30. Single Unit, Multiple Characteristics, that means Xbar-R Chart supports calculation of more than one attribute but for one SN (Serial Number).
• Multiple Units, Single Characteristics: This subgroup method is the enhancement from SPC V1.2.30. Multi-Units, a single characteristic that means Xbar-R Chart supports the calculation of one attribute but for different SNs. The SNs are in subgroups, and users can define the subgroup size. 
• Summary:  After all settings are defined, users can select Summary to view the data collection strategy summary.

Figure 37: Data Collection Strategy Summary

 

 

 

Standard Control Chart

The following section is the Standard Control Chart, which contains two sub-sections: Interval and Rules.

 

Figure 38: Standard Control Chart

 

Interval

This sub-section has a checkbox and a textbox that defines the frequency that SPC recalculates the center line value of a control chart. Here valid groups are used as the frequency unit.

 

Figure 39: Interval Section

1. No grouping and without recalculate bar values
2. Allow user set the number of groups, calculate new BAR value used for the next data analysis
3. Allow user to set the number of groups, use the same BAR value used for the next data analysis

See below a sample of the chart:

 

Figure 40: Chart Sample for Valid Group

 

 

 

Rules

This sub-section lists all seven rules which are considered to be out-of-control exceptions. Users can select one or more rules in this checkbox group.

 

Figure 41: Rules Section

Consecutive Points above or lower than UCL or LCL option will be available if the selected data source is DotLine Source.

 

 

Available charts

This tab displays all available control charts, DPMO, and Other Charts in the current context. The SPC Control Chart is generated based on the data source that is configured in the Monitor section so that different configurations in the Monitor section may have different available charts. Users can choose one or more control charts in this checkbox group.

 

Figure 42: Available Charts (non Continuous control charts)

The textbox on the right of the chart name is used for defining the centerline value of the control chart. For example, if a user chooses the C Chart checkbox, the C-Bar textbox becomes available. Users can then manually enter a number in the textbox, which becomes the centerline value of the chart.

 

Figure 43: C-Chart Fields

Note: Be careful with the values entered in the textbox for control charts if the line stoppage function is enabled. If the Send MFG Hold Request to MDS checkbox was selected when creating an SPC server, SPC may stop the production line if a user defines unreasonable values for the control chart based on the rules selected.

For FPY Chart, selecting the Display checkbox enables SPC to display FPY chart on the monitor. The Trigger checkbox enables an out-of-control warning.

Before SPC 3.2, SPC Cpk / Ppk Chart data had only one revision that contained all data. This is inconvenient particularly when a user wants to generate a Cpk / Ppk Chart once a month for their clients. Beginning with SPC 3.2, Cpk / Ppk Chart adds a date range setting function enabling the user to set a date range for Cpk / Ppk chart data. 

 

Figure 44: Choose Specific Version

 

Note: The Current SPC allows the user to choose a specific version to display FPY chart.

 

 

 

 

 

Other Chart

The fourth section is the Other Chart. The components of this section are as follows:

 

Figure 45: Other Chart

DPMO Chart: Enables SPC to monitor a manufacturing line with a DPMO chart. Defect opportunity and UCL represent the two parameters used for defining DPMO charts.

Note: The other 4 charts are custom made by the company according to the specific defect code. For example:
DPMO-Placement Chart: Placement is a defect code name. The chart is only for this defect code. The other 3 charts are the same.

 

Figure 46: DPMO Chart Types

 

Yield Chart: Enables SPC to monitor the manufacturing line with the Yield chart. The Limit' is a parameter used for defining the Yield chart.

Pareto Chart: Enables SPC to monitor the manufacturing line with a Pareto chart. Users can define a Pareto chart exception rule by selecting the Create exception when checkbox and entering, for example, 3 defect code of the same type within 10 minutes. 

 

Figure 47: Create Exception When Fields

 

For Continuous control charts, the available control charts are described below: 

 

Figure 48: Available Control Charts for Continuous control charts

The Calculation by field in the Cpk / Ppk chart settings has two available options: All Data and Month. By default, All Data is selected. 

All Data: SPC generates only one revision with all Cpk / Ppk chart attribute data.  

Month: The Cpk / Ppk chart data collection duration for this monitor will be based on a natural full month. 

The Method of Std Dev(within)  in the cpk/ppk chart has three available options: Pool standard deviation, Rbar, and Average moving range.

The method used to Std Dev(within) depends on the subgroup size.

When subgroup size > 1, SPC estimates Std Dev(within) using one of the following two methods: Pooled standard deviation and Average of subgroup ranges (Rbar), SPC select Pooled standard deviation method by default.

When subgroup size = 1, SPC estimates Std Dev(within) using the Average moving range method.

Xbar-R Chart: X-bar and R (range) chart is a pair of control charts used with processes that have a subgroup size of two or more. 

I-MR Chart I-MR chart is a combination of two charts (Individual and Moving Range) is to track the process variability based on the samples taken from a process over the period of time. An Individual moving range (I-MR ) chart is used when data is continuous and not collected in subgroups.

 

See below description and samples of the main available charts at SPC:

 

Pareto Chart

Preto chart indicates which problem to tackle first by showing the proportion of the total problem that each of the

smaller problems comprises. It is a type of chart that contains both bars and a line graph, where individual values

are represented in descending order by bars, and the cumulative total is represented by the line.

 

Figure 49: Pareto Chart

 

C-Chart

C-chart is an attribute control chart used with data collected in subgroups that are the same size. 

It shows how the process, measured by the number of nonconformities per item or group of items, changes over time. Nonconformities are defects or occurrences found in the sampled subgroup.

 

Figure 50: C Chart

 

P-Chart

P-chart is an attribute control chart used with data collected in subgroups of varying sizes. Because the subgroup size can vary, it shows a proportion on nonconforming items rather than the actual count. P-charts show how the process changes over time.

 

Figure 51: P Chart

 

NP-Chart

NP-chart is an attribute control chart used with data collected in subgroups that are the same size. NP-charts shows how the process, measured by the number of nonconforming items it produces, changes over time.

Figure 52: NP Chart

 

U-Chart

U-chart is an attribute control chart used with data collected in subgroups of varying sizes. U-charts shows how the process, measured by the number of nonconformities per item or group of items, changes over time.

 

Figure 53: U Chart

XBar-Chart

X-bar and R (range) chart is a pair of control charts used with processes that have a subgroup size of two or more. 

The standard chart for variables data, X-bar, and R charts help determine if a process is stable and predictable. The X-bar chart shows how the mean or average changes over time and the R chart shows how the range of the subgroups changes over time.

 

Figure 54: XBar Chart

 

R-Chart

The X-bar chart shows how the mean or average changes over time and the R chart shows how the range of the subgroups changes over time.

Note: LCL can’t be negative. Both S (Standard Deviation) and R (Range) can't be negative, due to their nature. All the points that the user scans are displayed on the chart and when expanding chart details, all the information in the chart page is collected such as SPC Collection time, Average, LCL, UCL, OCAP, attributes, etc. There are no negative numbers on the Y-axis.

 

Figure 55: R Chart

Yield -Chart

This chart shows the Yield value for a selected or retrieved process, one at a time, and a list of the N last products passed on this process.

 

Figure 56: Yield Chart

 

FPY-Chart

FPY is a First Pass Yield: 

• Capable of plotting the First Pass Yield of a product at a particular process step over a period of time or number of boards.
• Capable of manual configuration the upper control limit and lower control limit.
• Can displays the target (Goal) line.
• Capable to use the 7 Rule alarms for triggering.
• Capable to trigger the alarm when FPY falls below the Target Line.

 

Figure 57: FPY Chart

 

CPK/PPK-Chart

CPK/PPK shows if the real process capability meets the specification

Definitions

 Cp= Process Capability. A simple and straightforward indicator of process capability.

 Cpk= Process Capability Index. Adjustment of Cp for the effect of non-centered distribution.

 Pp= Process Performance. A simple and straightforward indicator of process performance.

 Ppk= Process Performance Index. Adjustment of Pp for the effect of non-centered distribution.

Cpk is for the short term, Ppk is for the long term.

Cp and Cpk

It is common to express process capability in terms of:

• How well can we meet the customer’s specifications?
• Voice of Customer / Voice of the process
• It is a potential capability index - Cp is defined as:

             Cp = USL – LSL/6σst

The minimum acceptable value for Cp is normally considered to be 1

Cpk = Min (USL- x, x – LSL)/3σst

When there is no shift or drift, Cpk and Cp are equal. As the process drifts, Cpk gets smaller. 

 

Pp and Ppk Chart

Over time, the drift in the process will have the effect of ‘flattening out’ the distribution, and the standard deviation of the process will increase.  To reflect this effect properly, we define two long term capability indices, Pp and Ppk.

These indices have the same formulas as their short term counterparts, but use the long term standard deviation in their denominators, σlt

Pp = USL – LSL/ 6σlt               Ppk = Min (USL- x, x – LSL)/3σlt

Figure 58: CPK/PPK Chart

 

 

Available Charts

 

The following section is the Available Charts, which contains three sub-sections: Available Control Charts, DPMO, and Other charts. 

 

 

 

 

Actions  

The fifth section is the Actions. This section defines what actions should be taken after the out-of-control exception is triggered.

 

Figure 59: Actions

Send alert e-mail: This action sends an alert email to a specific person. Users can specify who would receive these alert emails in the Email Maintenance module.

Change the background color to red: If the exception was triggered, the background of the associated data record in this monitor will turn to red.

Send MFG hold request after n minutes: This action is an SPC line stopper function. To enable this action, the following options must first be enabled:

1. Send MFG Hold request to MDS checkbox in Add/Edit Monitor group page.
2. Pareto Chart checkBox in Other Control Charts section.
3. Create an Exception when n1 defect code of the same type within n2 minutes checkbox in the Other Control Charts section.

 

If Send MFG hold request after n minutes checkbox is enabled and if n1 defect code of the same type were scanned via NetDC within n2 minutes, SPC will send an MFG hold request to SFDC / MDS after n minutes. If the input minutes is 0, SPC will send the MFG hold immediately.

Note: This checkbox is not selected by default. Line stopper in SPC supports hold by part number + Location/process based on monitor selection. 

 

Lastly, remember to click  to save all the configurations before you leave the page, or click button if you want to give up the configuration and return to the Monitor List page.

 

 

 

 

Search Monitor

The Search Monitor portlet makes it very convenient to find a specific monitor from the monitor's list. You can find this function in the toolbar on the Monitor List page.

 

Figure 60:Search Monitor

Users can search monitor by keyword and monitor status.

By keyword: Users can search existing monitors according to a keyword by first clicking the keyword drop-down box (the green framed area in Figure 43 and selecting a category. A corresponding can then enter a keyword in the adjacent textbox.

By monitor status: Users can search monitor by monitor status. Users must select a monitor status from the status categories drop-down list.

 

Once search criteria have been selected and entered, select   to execute the search action.

 

 

Hide Inactive Monitors

It allows you to filter out those monitors that have no new data coming in during the past settable hours. You can define the settable hours in the SPC System Parameter Maintenance module, and view active monitors on the Monitor List page. Besides, you can turn off the filtering inactive monitors function.

 

View Active Monitors by Default Hours

In the Monitor List page, the checkbox Hide monitors with no data in chart in the past(hours) are selected by default along with a textbox displaying the hours defined in the SPC System Parameter Maintenance module. The SPC system filters out those inactive monitors that meet the condition.

 

Figure 61: "Hide monitors with no data in the chart..." Checkbox

 

 

Edit Settable Hours

Edit the hours' textbox value and select Input to view corresponding monitors. The value allowed in this textbox is a positive integer between 1 to 168. Modification of the value here does not affect the value defined in the SPC System Parameter Maintenance module.

 

Figure 62: Edit Settable Hours

 

Disable Hide Inactive Monitors Function

Unchecking the Hide monitors with no data in the chart in the past (hours) box deactivates the monitor filtering function so that SPC system shows all existing monitors.

 

Figure 63: "Hide monitors with no data in the chart..." Checkbox Unselected

 

 

 

 

 

 

Edit Monitor (Edit Monitor in Batch)

SPC allows users to modify the parameters of an existing monitor according to their needs. Users can modify sections including Interval, Rules, Available charts, Other control charts and Actions. To edit monitors, they must be stopped.

 

1. Select a monitor from the monitor list in the ‘Monitor List’ page, then hit the icon in the toolbar.

 

Figure 64: Monitor List - Edit Monitor Page

 

2. From the Edit Monitor page, modify the preferred available information. 

Note that the Monitor tab is not allowed to be modified. Update the other tabs' information accordingly.

 

Figure 65: Edit Monitor Page

  Figure 65a: Edit Monitor Page Data Collection Strategy

 

3. Select to save all modifications before you leave the page.

 

Note: If the Data Collection Strategy selected is Manual Collection via SPC UI, a user can also modify the Attribute values.

 

 

 

Edit Monitor  in Batch

1. Search for the Batch ID and select the monitors in the batch to edit and then hit the in the toolbar.

 

Figure 66: Monitor List - Edit Monitors in Batch

 

Figure 67: Batch Edit Monitor page

 

2. From the Edit Monitor page, modify the preferred available information. 

Note that the Monitor tab and Data Collection Strategy tab are not allowed to be modified. Update the other tabs information accordingly.

 

Figure 68: Edit Monitor Page

3. Select  to save all modifications before leaving the page. 

 

Note: If the Data Collection Strategy selected is Manual Collection via SPC UI, the user can also modify the Attribute values. 

 

 

Manually Input Data to Monitor

To date, the SPC monitor supports three data collection strategies: Automic Collection From Unit Attributes, Manual Collection Via SPC UI, and Automic Collection via SPC API, which can be configured in the Data Collection Strategy section. If ‘manual collection via SPC UI’ is selected as a data collection strategy, data must be manually entered after the monitor is created. 

 

 

Input Data for Only One Monitor

To enter data for one monitor:

From the Monitor List screen, select the monitor that needs to be manually input data (the ‘Collection Type’ value of this monitor is ‘Manual’), and then click the  icon.

 

Figure 69: Monitor List - Input

 

In the Collect New Data page, input attributes data to correspondent fields.

 

Figure 70: Input - Collect New Data Page

 

 

 

Input Data for Multiple Monitors At Once

Users can select and input data to multiple monitors at once, as long as all of the selected monitors' Collection Type is Manual.

 

Figure 71: Monitor List - Collection Type Column

Note: If users have selected monitors that contain at least one monitor whose Data Collection Type is not Manual and clicks Input, users will be prompted by an alert window saying 'You have selected at least one monitor that is not for manually data collecting. Please check and try again.' Close the alert window by clicking Ok. 

 

Input Attributes for The Current Monitor

On the Collect New Data page, users can enter attributes for multiple monitors at once. The Monitor drop-down list will display the currently selected monitor to be input data. Users can view Line, Monitor name, and Location of the current monitor on the top left corner. Note that the allowed input of attributes is number only.

 

Note: If users have input values in at least one of the fields and select Reset, an alert window will display with the warning message, 'You are about to reset all values. This action will delete all values of the current monitor. Are you sure you want to proceed?' Selecting Yes resets all entries for the current monitor to the default value.

 

Figure 72: Collect New Data Page Reset - Alert Window

Note: If users have input values set to at least one of the fields, and select another monitor from the Monitor drop-down list, an alert window will display with the warning message, 'The data for the current monitor has not been saved yet. Are you sure you want to go to another monitor?' Selecting Yes will redirect the user to another monitor without the current monitor's data stored in the SPC system.

 

Figure 73: Collect New Data - Selecting a Different Monitor Alert Window

Note: If users have input values to at least one of the fields and select the New Record button, an alert window displays with a warning message, 'You are about to cancel the attribute data entering. The current monitor will have no attributes recorded. Are you sure you want to proceed?' Selecting Yes will move a user to the Monitor List page without the current monitor's data stored in the SPC system.

 

Figure 74: Collect New Data - New Record Alert Window

 

 

Save current monitor's attributes data

On the Collect New Data page, if a user has finished inputting data to the current monitor, and selects Save, all the current monitor fields turn grey except the Monitor drop-down list and the user cannot edit any data. The current monitor name in the Monitor drop-down box changes to 'monitor_name (Saved)' where monitor_name is the name of the current monitor. Now the user can switch to another monitor to input attributes data to that monitor.

 

Figure 75: Save Monitor Attributes

 

 

Switch to Another Monitor

To switch to another monitor to input attributes, click the Monitor drop-down box and select another monitor from the list

 

Figure 76: Selecting Another Monitor

 

 

Back to the 'Monitor List' page

To go back to the Monitor List page, select the button.

 

Figure 77: Monitor List - New Record

 

 

 

 

 

 

Automatic Collection via SPC API

The Automatic Collection via SPC API method allows the users to create a monitor with Automatic Collection Via SPC API type, the clients (such as PWB) or other third-party applications to push the data to SPC via its monitor API as long as the characteristics in the parameters of the API endpoint exist and match this monitor, the continuous data control charts (such as X bar-R chart, I-MR chart, and CPK/PPK report) will plot with SPC.

Scenario

One plant needs to measure the thickness of their products multiple times during a process that can take days. They measure the thickness every 1/2 to 1 hour. They need to collect the thickness using Production Workbench as this is the interface the Operators use for the entire manufacturing process.Every thickness measurement collected via Production Workbench should be displayed on the SPC chart in near real time not only when the unit (non-serialized batch) moves from the location via terminator command.   SPC shall display all records collected via PWB attributes in “near real time”. This shall occur upon submission without regard to if we are in the middle of the process or at the end of the process moving to the next location.

 

The following will take the Production Workbench sending attributes values to SPC via SPC API as an example to explain the work process step by step.  

 

 

 

Work process step by step

 

In order to transmit data through the API, the SPC Token , Key and the Generic attribute need to be set.

Step 1: Define the SPC Server information at the Server information.

Navigate to: the Administration > Server Information; add one SPC server information. Note: Please select the SPC for the Program field.

Figure 78: SPC Server Information

   

 

Step 2: Define the generic attribute form at the Generic Attribute Maintenance(MDS) module that allows the production workbench to call the SPC API to send attribute data to SPC.

Navigate to: Administration > Generic Attribute Maintenance(MDS); add one Generic Attribute information.

Figure 79: Generic Attribute for SPC API

 

 

 

Note: Please select spc_service_host for the Attribute Name field and project for the Table field. And the Value is the SPC Host: SPC AppServer Port (The SPC Server defined at the server information).

Step 3: Create a Monitor, select the Automatic Collection via SPC API at the Data Collection Strategy tab.

And add the attributes at the Characteristics list.

Note: The Characteristics must be the same as the attributes used/scanned at Production Workbench.

Figure 80: Create a Monitor Automatic Collection via SPC API

 

 

Step 4: Input/Scan the Serial number at the Production Workbench application.

To transmit the attributes values to SPC via the SPC API, the users select the command. e.g. Record Monitored Measurement.

After input the command, some fields will show:

SPC Monitor Name? : Input the SPC monitor name. The Monitor Name must be the monitor that is created at step 3 (See Figure 81 above).

Attribute Name?: Input the Attribute name. The Attribute Name must be the Characteristics that is defined at the Data Collection Strategy tab (See Figure 80 above). 

Attribute Value?: Input the attribute value. The value will be transmitted to SPC via SPC API even if the user doesn’t input the terminator/end command. The user can view the chat on the monitor in real-time. e.g. The input value 99 will show on the monitor chart(See Figure 84 below).

Figure 82: Production Workbench

 

 

 

Step 5: The users can view the charts (attribute values) at the monitor charts.

Select the monitor, then select the Chart to view the chart.

Figure 83: Monitor Chart menu.

 

 

 

Figure 84: Attribute value on the Chart

 

Disable, Enable, Delete Monitor

From SPC V1.2.30, it supports automatic start monitors to simplify the application use process, this will greatly reduce maintenance costs. Engineers only need to create monitors when they have a new product or disable/delete monitors after the product has been EOL. Even keeping a large number of Enabled monitors will not affect SPC performance.

 

Disable monitor

After a new monitor is created, its status is Started by default. The monitor's data is automatically collected from MDS.

If a user does not need a monitor to operate, the user can disable the monitor.

1. To disable a monitor, check the box of the monitor.
2. Select the icon to disable the monitor.

 

Figure 90: Function List - Disable

Users can search disabled monitors using the search function by selecting Disabled from the monitor status drop-down box and clicking the icon.

 

Figure 95: Monitor Name with Disabled Status Selected

 

 

Enable disabled monitor

To enable a disabled monitor

1. Find the disabled monitor in the list and check the box for that monitor.
2. Click the icon in the toolbar.

 

Figure 92: Function List - Enable

Users can search enabled monitors using the search function by selecting Enabled from the monitor status drop-down list and clicking the icon.

 

Figure 93: Monitor Name with Enabled Status Selected

 

 

 

 

Delete Monitor/Delete Monitor in Batch

If a user no longer needs a monitor or monitor in batch and wants to remove it, the monitor can be deleted. Note that once a monitor is deleted from SPC, it cannot be restored, and this is permanent. 

To delete a monitor:

1. Check the box of the monitor to be deleted, and select Disable to disable the monitor first.
2. Once the monitor is disabled, locate the monitor in the disabled monitor list, and check the box of the monitor to select it.
3. Click the icon in the toolbar.

 

Figure 98: Function List - Delete

 

4. Then choose Yes in the pop-up window.

 

Figure 99: Delete Pop-up

To delete a monitor in batch:

1. Search for the Batch ID and select the monitors in the batch to be deleted.

2. Check the box of the monitors to be deleted and select Disable to disable the monitors first.

2. Once the monitors are disabled, check the box of the monitors to select them.

4. Click the  in the toolbar.

5. Then choose Yes in the pop-up window

Beginning with SPC 1.2.30 the start and stop buttons are removed. Some images may also have these two buttons, that doesn't matter, because the system has an enhancement, with the newly created monitor in start status by default.

 

 

View Control Chart, Data & Write OCAP

Control Chart is a very important tool for SPC to monitor the manufacturing line. Through the analysis of control charts, users can learn whether a manufacturing line or process is under control and determine the reasons for an out-of-control exception, so that they can take appropriate measures. To date, our SPC system supports 6 control charts: C chart, U chart, P chart, NP chart, X Bar-R chart, I-MR chart, and also support 5 other charts: DPMO chart,FPY chart, Yield chart, Pareto chart, and Cpk / Ppk chart.

Beginning with SPC 3.2, the SPC development team applies Ext JS technology, other than the old Jfreechart technology to all of the 11 charts. The Ext JS technology enables SPC to represent more interactions with the user from the UI perspective. For instance, a user can view more information about a chart point by hovering their cursor over the point. Also, users can view both SPC charts and data on the same page without having to open them on different pages.

 

View Control Chart

Here take the C chart as an example to demonstrate how to view the control chart with the Ext JS technology enhancement. The operation of other control charts is similar to the C chart below.

1. To SPC view the control chart, from the Monitor List page, select a monitor and click the icon in the toolbar. This displays the chart page.

 

Figure 100: Function List - Chart

Note: On the top of the page users will see a few brief information on the control chart, such as monitor name, part number and location. The family ID can also be displayed here if the Display Family ID is checked in the SPC Portal System Parameter module.

To view the C chart, users need to choose the 'C' chart from the chart drop-down list, select a revision from the revisions drop-down list, and click Retrieve, then SPC will generate a C Chart according to the parameters users submitted and will display the C Chart and its data in the current page.

 

Figure 101: C-Chart Retrieve

Tips:

1. On the Chart, blue points are normal points, red points are exception points, green points are exception points that have been written OCAP.
2. If you move the cursor over a point in the chart, a pop-up window will be prompted showing more information on the selected point, including SPC Collection Time, Inspected, Defects and Cause. Note that control charts vary in more information on a selected point.
3. If you click a point on the chart, the corresponding data line in the data list will be highlighted; if you select a data line from a data list, the corresponding point on the chart will be highlighted as well.
4. The red background of a data line means that this data item has violated the rules you defined in the Rules section, and the OCAP of this data record has not been processed yet; the green background of a data line indicates that OCAP of this data record has been processed.
5. This data list table structure consists of 9 columns: SPC Collection Time, Inspected, Defects, UCL, LCL, OCAP, OCAP History, Cause and Affected S/Ns.

 

Figure 102: C-Chart Information Points

 

 

Write OCAP

To write OCAP, means to write something about the fix to the exception. To do this:

1. Click the icon, then input the description of this OCAP in the pop-up OCAP windows.
2. Click  to save the change to SPC.

 

Figure 103: OCAP Window

If there are more than one unprocessed OCAPs after entering a description of the current OCAP, enable the Apply to previous OCAPs checkbox to apply the change to all the unprocessed OCAPs.

After the OCAP is processed, the background of the associated data record will turn green.

 

View OCAP History

Select  to view the OCAP history of a data record in the pop-up OCAP history window.

 

Figure 104: OCAP History

 

View Cause

Select  to view the rules that the current point has violated.

 

Figure 105: Cause

 

 

View Affected S/Ns

Users can view the affected serial numbers and export them to an Excel file.

1. Select  to activate a pop-up window that displays the affected S/Ns list.

 

Figure 106: Affected Serial Numbers

 

2. To export the affected S/Ns to an Excel file, click the icon at the bottom of the Affected S/Ns window.
3. Select Yes to confirm the action.

 

Figure 107: Confirm Export Alert

 

 

4. Choose whether to open the XLS file or save it to the hard drive.

 

Figure 108: Open or Save XLS

There is a reference link at the Defects, that will show the Defect Code.

Figure 106a: Defect Message

   

 

 

 

View and Edit Data

View Data List

Users can view detailed data of a monitor. To do this:

1. Select a monitor and click the icon in the toolbar in the Monitor List page. 

 

Figure 110: Data List

 

On the ‘Data List’ page, set the time frame for the search by selecting the beginning date and ending date in the toolbar.

Select a status from the data status drop-down list (the red frame area in Figure 83) and click the icon to view the matching data.

 

Figure 111: Data List Page - Search Fields

.

Figure 112 shows data records of a monitor whose data is automatically collected by MDS. 

 

Figure 112: Data List - Automatically Collected Records

The user can click the Export icon to export the records to an excel file.
Figure 123 shows data records of a monitor whose data is manually collected via SPC U.

 

Figure 113: Data List - Manually Collected Records

 

 

Disable Data

A data record in the data list stands for a single point in a control chart. Disabling a data record will remove the associated point from the control chart. To disable a data item:

Check the box of a data record, then click the icon in the toolbar.

 

Figure 114: Data List - Disable

Users can search disabled data records by setting the time frame for the data record by selecting the beginning date and ending date, and selecting Disabled from the data status drop-down box (the red frame area in Figure 84). Then click the icon to execute the search action.

 

Figure 115: Data List - Search Fields

 

 

Enable Data

Enabling data, restores a data record from disabled status. To do this:

1. Select the data record from the disabled data list, then click the icon in the toolbar.

 

Figure 116: Data List - Enable

 

 

Edit Data

This function is limited to the monitor whose data is manually collected by SPC UI. To edit data record:

1. From the Monitor List page, select a monitor whose Collection Type value is Manual, and click the icon.
2. In the Data List page which lists the enabled data, go to the last page of the list, select the last line and click  in the toolbar (only the last data record is allowed to be modified). The user will be redirected to the Edit Data page where any data fields may be edited.
3. Select Save to complete the changes.

 

Figure 117: Data List - Edit

 

Figure 118: Edit Data Page

 

 

Maintain Lock

SPC offers a full set of functions to manage MFG hold. When creating a new monitor, users can define the minutes of delay before MFG hold was sent. Users may view lock records and unlock existing locks as well.

 

 

View Lock

1. To view lock, from the Monitor List, select a monitor and click the icon in the toolbar. The Lock List page displays.

 

Figure 119: Monitor List - Lock

 

Figure 120: Lock List Page

The Pareto chart, C chart, U chart, NP chart, P chart, FPY chart, Xbar-R chart and I-MR chart can send a MFG hold request to MDS. Users can view locks in different status as long as different values are selected in the lock status drop-down list. For example, if a user wants to find locked locks, select LOCKED from the lock status drop-down list, and click the icon in the toolbar.

 

Figure 121: Lock Search Drop-down

Users can search lock data by control chart type and lock status.
There are four statuses for locks: WAITING, LOCKED, UNLOCKED, and CANCELED. The CANCELED status was added in SPC 3.2.

• WAITING: the lock that is waiting to be sent to MDS. When an out-of-control case is detected, SPC will wait some minutes before sending the MFG hold to MDS until it reaches the number of minutes defined by Send MFG hold request after * minutes field in the Actions section. During this period, the lock is in WAITING status.
• LOCKED: MFG hold has been sent, associated location or process has been locked and OCAP has not been processed.
• UNLOCKED: User input OCAPs to unhold associated location or process, then the locked lock becomes UNLOCKED.
• CANCELED: This lock status is a new status as of SPC 3.2. For a better understanding of this status, consider the following scenario: A SPC monitor was created for Pareto Chart that 3 defect codes of the same type within 10 minutes will trigger the exception, and MFG hold will be sent to MDS 5 minutes later. A few minutes later, a first MFG hold will be triggered, if a second MFG hold is triggered during the first hold’s delay sending time in the new lock mechanism, the second hold will not be sent to MDS, and the status of the second MFG hold is CANCELED.

 

Unlock Lock

To unlock a lock:

1. Select the lock and click the icon in the toolbar.

 

Figure 122: Unlock Icon

 

2. In the pop-up window, input OCAP to unlock the associated location or process.

 

Figure 123: OCAP - Unlock

 

Export Lock List to Excel

User can export the lock list to Excel file:

1. On the Lock List page, click the icon at the bottom of the list.

 

Figure 124: Lock List -Export Icon

 

2. Select Yes in the pop-up window to confirm the action.

 

Figure 125: Export Confirmation Pop-up

 

 

 

 

View Monitor Details

To learn detailed information about a monitor:

1. Go to the Monitor List page, select a monitor, and click the text link at the right side of the line.

 

Figure 126: Function List - More

 

2. In the pop-up Monitor, the details window provides multiple items of information including monitor name, data collection strategy, interval, rules, selected charts, and actions.

 

Figure 127: Monitor Details Pop-up

 

 

 

View Monitor History

To view the modification history of a monitor:

1. Go to the Monitor List page, select a monitor, and click the icon.

 

Figure 128: Monitor List - Rev Icon

 

 

Email Maintenance

Brief Introduction

Email notification is an important way for SPC to monitor the manufacturing line in real-time. When exceptions are found, SPC will send an email alert to the associated employee or supervisor so that they can analyze the exception according to the alert email and other SPC tools, and take appropriate measures, such as checking the production line, writing OCAPs, and stopping the line.

To access the Email Maintenance Page:

1. Go to the Function List page and click the icon to enter the email maintenance module.

 

Figure 129: Function List - E-mail Maintenance Icon

 

The Email Maintenance page is displayed:

 

Figure 130: Email Maintenance

From the Email Maintenance page, the users are able to access the following functionalities:

• Email Group

• Add Monitor Receive Email Rules

• Edit Monitor Receive Email Rules

• Enable

• Disable

• Search

For further information, see the next topics.

 

Email History

Email History allows users to add, edit, delete, and search for alert emails.

 

Email History - New Alert Email

To create a new email alert, in the Monitor Maintenance Page, select the New button.

 

Figure 131: Email Maintenance - New Alert Email in the List

The Add Email page will display:

Fill the Add Email page fields;

 

Figure 132: Add Email in the list

 

Monitor Name: Select a monitor from the available monitor's drop-down list. All listed available monitors here are created in the current SPC server. The recipients will receive alert emails from the monitor defined here.

To: Input recipients of the alert email here. This field is mandatory.

Cc: Input additional recipients here. This field is optional.

Description: Write more information about the email if necessary. This field is optional.

Tip: Users can input more than one email address with a semi-colon(;) between two email addresses. Select Save to save the configuration to SPC.

 

Search Email

In SPC, users can search existing alert email by keyword:

1. Select the kind of keyword in the keyword category drop-down list.
2. Enter the keyword in the keyword textbox, and click the icon to search.

 

Figure 133: E-mail List - Search

 

Email Maintenance - Edit Email in the List

To edit an email:

1. Select the email record and click the icon in the toolbar to open the Edit E-mail page.

 

Figure 134: E-mail List - Edit

 

In the Update E-mail page, correct values in any of the four fields, and save the changes.

 

Figure 135: Update E-mail

 

Email Maintenance - Delete Email in the List

To delete an email from the email list:

1. Select the email record and click the icon in the toolbar.

 

Figure 136: E-mail List - Delete

 

2. Choose Yes to delete the email.

 

Figure 137: Delete E-mail Confirmation Window

 

 

 

 

Example of an Alert Email

Alert emails from SPC will contain titles like “Alert message from SPC application’. Here is an example of an SPC alert email, which contains seven information fields (the red background area): Line, Monitor, Part Number, Location, Chart, Date, and Description.

 

Figure 138: Alert E-mail Example

When the users click the link in the mail, the system will access the charts which were generated by the alert email.

Figure 138a:View the Chart from the Email Link

 

 

Email Group Maintenance

The Email Group Maintenance submodule allows users to add, edit, delete, and search email groups and also,  associate emails to groups.
See the next topics for further information.

Figure 139: Email Group Maintenance

 

 

Add Email Group

The first thing that the user needs to do is create a User Group with a name and description to create the Receive Emails Rules.

1. Click on the New button to create an email group.

 

Figure 140: Email Group Maintenance - New

 

The Add Email Group page will display;

 

Figure 141: Add Email Group

Enter the Name and Description (mandatory fields) for the new email group; Select the to save the configuration to SPC. 

 

Edit Email Group

To update the email group information:

1. Click the Edit button to update the email group information;

 

Figure 142: Email Group Maintenance - Edit

 

Update Name or Description fields as needed.

 

Figure 143: Update Email Group

 

Select the save the updates.

 

Associate Email

After creating an email grouper, the user is able to associate as many as emails is needed.

1. To associate emails to the group, select a group in the list and click on Associate Email.

 

Figure 144: Email Group Maintenance - Associate Email

 

The email list page will display, and the user can add, edit, or delete emails.

 

Add Email to Group

To add an email to the group:

1. From the Email List page, click on the New button:

 

Figure 145: Add New Email to Group

 

The Add Email page will display:

 

Figure 146: Add Email to Group

Insert the email in the Email field (mandatory) and select the  to save the email to the group.

Edit Email 

To edit an email:

1. From the Email List page, select the email and click the Edit button:

 

Figure 147: Edit Email

 

The Update Email page will display;

 

Figure 148: Update Email Page

 

Update de email as needed and select and select the to save the updated information.
 

Delete Email

To delete an email from the email list:

1. Select the email record and click the in the toolbar. 

 

Figure 149:Delete Email

 

Select Yes in the pop-up window to confirm the action. 

 

Figure 150:Delete Email Message

 

Search Email Group

Users can search existing email groups by keyword: 

1. Select the kind of keyword in the keyword category drop-down list (Name or Description). 
2. Enter the keyword in the keyword textbox, and click the Search icon to search. 

 

Figure 151: Email Group Maintenance - Search Email

 

Delete Email Group

To delete an email group from the email group list:

1. Select the email group record and click the in the toolbar. 

 

Figure 152: Email Group Maintenance - Delete Email

 

2. Choose Yes to delete the email. 

 

Figure 153: Delete Email Group Message

 

Figure 154: Email Group Maintenance - Tip

 

Figure 155: Tip Message

 

New Email Rule

 

This functionality allows users to create email rules as needed.

To create a new email Rule, in the Email Maintenance Page, select the New button.

 

Figure 156: Email Maintenance - New Email Rule

 

The Add Monitor Receive Email Rule page will display:

 

Figure 157: Email Maintenance - Add Monitor Receive Email Rule

 

From this page, the user needs to enter the Name, Description, and associate an Email Group (mandatory fields), created in the Email Group functionality.

After this, the rules can be created as needed by: Shop Floor ID, Part Number, Family ID, Process, Location, Family ID, and Monitor Group. 

Click on the Submit button to save the information.

 

Edit Email Rule

 

This functionality allows users to edit email rules as needed.

To edit a new email Rule, in the Email Maintenance Page, select the Edit button.

 

Figure 158: Email Maintenance - Edit Email Rule

 

The Edit Monitor Receive Email Rule page will display:

 

Figure 159: Email Maintenance - Edit Monitor Receive Email Rule

Edit the fields as needed and click on Submit to save the information.

 

Delete Email Rule

To delete an email Rule from the list:

1. Select the email rule record and click the in the toolbar. 

 

Figure 160: Email Maintenance - Delete Email Rule

 

Select Yes in the pop-up window to confirm the action. 

 

Figure 161: Email Maintenance - Delete Email Rule Message

 

 

Enable Email Rule

Enabling Email Rule restores an email rule record from disabled status. To do this:

1. Select the email rule record from the disabled data list, then click the in the toolbar. 

 

Figure 162: Enable Email Rule

 

 

Disable Email Rule

 

To disable an email rule:

Select an email rule and click the in the toolbar. 

 

Figure 163: Disable Email Rule

 

Choose Yes in the pop-up confirm window. 

 

Figure 164: Disable Confirmation Message

 

Location Family Maintenance

Brief Introduction

The location family is a collection of locations. One location family consists of one or more locations, which can be derived from different processes and departments. The authorized user can create, search, edit, disable, delete, and enable location family.

 

Create Location Family

To create a new location family:

1. Click the icon on the Function List page.

 

Figure 165: Function List - Location Family Maintenance

 

2.  On-Location Family List page, click button in the toolbar.

 

Figure 166: Location Family List Page - New Icon

 

3. Select Process, or Department.

 

Figure 167: Location Family

 

4. Enter values in the Location textbox to filter locations. If a user changes values of the Location textbox, its instant search function activates, and the SPC system automatically searches matching locations from the locations that belong to the selected department, displaying matching locations in the Location selection box.

 

Figure 168: Location Textbox

 

5. Select a location and click the button to add locations from the left panel to the right panel. More than one location can be selected at a time.

 

Figure 169: Add Location

 

6. Lastly, click the Save button to save your data to SPC.

 

 

Search Location Family

SPC enables users to search for location family by keyword and status. To search for a location family:

1. Go to the Location Family List page, select a keyword category (the green frame area in Figure 111), and input a keyword in the text input box (the red frame area in Figure 111).
2. Select a location family status (the blue frame area in Figure 111) and click the icon.

 

Figure 170: Search Location Family

 

 

Edit Location Family

To edit a location family:

1. Select a location family from the list, then click the icon in the toolbar. The Edit Location Family page will display.

 

Figure 171: Location Family List - Edit

 

2. On the Edit Location Family page, edit any field you want, and save the changes.

 

Figure 172: Edit Location Family Page

 

 

Disable Location Family

To disable a location family:

Select a location family and click the icon in the toolbar.

 

Figure 173: Location Family List - Delete

 

Choose Yes in the pop-up confirm window.

 

Figure 174: Disable Confirmation Window

 

 

Delete Location Family

To delete a location family:

1. Select the location family and click Disable.
2.  Search the disabled location family list for the disabled location family, select the location family, and click Delete.

 

Figure 175: Location Family List - Delete

 

3. Click Yes to confirm the action.

 

Figure 176: Delete Confirmation Message

 

 

Enable Location Family

To enable a location family:

1. Select a location family and click the icon in the toolbar.

 

Figure 177: Location Family List - Enable

2. Choose Yes in the pop-up window.

 

Figure 178: Enable Confirmation Message

 

 

System Log Maintenance

Brief Introduction

Some important system events, such as data modification and stopping a monitor, will be automatically added to SPC system log. System log plays an important role in system security. Users can analyze the system log and decide to take appropriate measures, like data recovery and file backup, to defend the system. In the SPC system, authorized users can search, view, and delete system logs.

 

 

Search and View System Log

On the Function List page, users can click the icon to navigate to the System Log page.

 

Figure 179: Function List - System Log Maintenance

In the System Log page, users can search the system log by time frame or by event owner:

 

Figure 180: System Log Page

 

1. Input event owner in the Performed by textbox or choose a time frame and click the icon in the toolbar.

 

Figure 181: System Log - Search

 

2. System log list table structure contains three columns - Date, Performed By and Operation:

• Date: when did the operation take place.
• Performed By: who did the operation, user or system.

• Operation: what is the operation.

 

Figure 182: System Log Search Results

 

Delete System Log

Every 24 hours, SPC automatically deletes system logs created 3 months before. Authorized users can delete logs manually via SPC UI. Users can delete logs individually or in batches.

 

Figure 183: System Log - Delete

 

Figure 184: Delete Confirmation Message

 

SPC System Parameter Maintenance

Brief Introduction

Authorized users are allowed to set general system parameters according to their local plants, manufacturing lines, or other special needs. This part of system parameters configuration affects the performance of the current SPC server, caution is necessary when defining the parameter values.

 

 

 

Maintain SPC System Parameters

Users may access SPC System Parameters Maintenance by selecting the  icon on the Function List page.

 

Figure 185: Function List - SPC System Parameter Maintenance

On SPC System Parameter page, eleven fields are displayed and the user can move their mouse over the icon to learn more information about the labels. See below the fields description:

 

Figure 186: SPC System Parameter Page

An explanation of the fields from the above screenshot follows: 

Interval of collecting data (second): During real-time monitoring, each monitor will periodically collect data from SFDC archive database or other data source, the setting determines how often each monitor collects data.

Interval of deleting log (hour): There is one background job (thread) responsible to periodically delete the system log, this setting determines how often the background job deletes some system logs.

Time of log saved (month): System log will not be saved forever, a too old log will be deleted by background job, this setting determines how long the system log is saved in the database.

Interval between lock reviews (second): How often the background job review lock (or called MFG hold request to determine if one waiting lock should be sent to the MES.

Display family ID in chart: By selecting this checkbox, the Family ID will display on the SPC chart.

Start time of data collection (month): After one monitor is created, this monitor related data can be retrieved from a past time, this setting determines how old data can be when retrieved by monitor. The default value is 3 months. 

Hide monitors with no data in chart in the past (hours): It allows users to filter out those monitors that have no new data coming in during the past settable hours. Users can input a positive number between 1 to 168 in the textbox. The default value for this textbox is 24. To view the effect, you can check the Hide Inactive Monitors feature on the Monitor List page. 

Hide on TV and dashboard if monitors with no data in chart in the past (hours): The SPC will automatically disable those monitors that have no new data during the past settable hours. The hours quantity textbox next to it, has a default value of 8 (hours). This textbox allows positive integers from 1 to 24. 

 Note: All the newly created monitors are enabled by default. Users can define this value, then the system will hide the monitors with no data to avoid there are too many monitors in the list. 

 

Enable Previous SPC Hold function: Previous Hold function will be invoked in the following scenario: after a part number was put on SPC Hold by SPC for the settable number of consecutive defect codes within a set time limit, will display ‘PREVIOUS SPC HOLD’ in NetDC rather than issuing an immediate SPC holds. 

Note:

• If a monitor is stopped, disabled, or deleted, the Previous Hold function of this monitor will be automatically turned off as well. 
• Users must enable the Send MFG hold to  MDS checkbox in Add Server Information page first, before enabling the Enable Previous SPC Hold function checkbox.

Enable PCB function:  Enable PCB function as global parameters affect one site. Its default value is unselected. PCB plants need to click the checkbox to make PCB function take effect. PCB checkbox affects monitor creation and their data collection.

Enabling PCB function will enable the  following requests from PCB plants, when creating SPC monitor: the ability to see the PN without a route assigned, the ability to display attributes with not defined PN as well as count defect code B.

 

Email Title: To set the title of the alarm email.

MESR URL Template: This field is to set a URL link to the MES Web. The URL template is plantcode-mesweb-med.42-q.com or plantcode-mesweb-med-uat.42-q.com. Hence, the original HTTP URL template is not suitable as a fixed URL link.

 

After all configurations are done, remember to click the   icon. If the save was successful, the user will see the message 'Configurations are successfully saved and will be immediately effective'. If there is a malfunction, users will see the error message 'Configurations are not saved, please try again or contact administrator.' 

 

Lock Maintenance 

 

Brief Introduction 

This functionality allows the user to unlock hold, search lock record by time range, and export hold records on one page.

 

Maintain SPC Lock Maintenance 

Users may access SPC Lock Maintenance by selecting the  icon on the Function List page. 

 

Figure 188: Function List - SPC Lock Maintenance

Users may view lock records and unlock existing locks as well. 

 

 

 

 

View Lock 

1. To view lock, from the Monitor List, select a monitor and click the in the toolbar. The Lock List page will display.

 

Figure 189: Lock Maintenance - Lock List

 

Beginning with SPC 3.2, the lock mechanism has been modified so that only the Pareto chart can send an MFG hold request to SFDC / MDS. Users can view locks in different status as long as different values are selected in the lock status drop-down list. For example, if a user wants to find locked locks, select LOCKED from the lock status drop-down list, and click the Search icon in the toolbar. 

Figure 190: Lock Search Drop-down

There are four statuses for locks: WAITING, LOCKED, UNLOCKED, and CANCELED. The CANCELED status was added to SPC 3.2. 

• WAITING: the lock that is waiting to be sent to MDS / SFDC. When the out-of-control case is detected, SPC will wait some minutes before sending the MFG hold to MDS until it reaches the number of minutes defined by Send MFG to hold requests after * minutes field in the Actions section. During this period, the lock is in WAITING status. 
• LOCKED: MFG hold has been sent, the associated location or process has been locked and OCAP has not been processed. 
• UNLOCKED: User input OCAPs to on-hold associated location or process, then the locked lock becomes UNLOCKED. 
• CANCELED: This lock status is a new status as of SPC 3.2. For a better understanding of this status, consider the following scenario: A SPC monitor was created for Pareto Chart that 3 defect codes of the same type within 10 minutes will trigger the exception, and MFG hold will be sent to MDS 5 minutes later. A few minutes later, a first MFG hold will be triggered, if a second MFG hold is triggered during the first hold’s delay sending time in the new lock mechanism, the second hold will not be sent to MDS, and the status of the second MFG hold is CANCELED.

 

 

SPC TV Portlet

Like the SPC portlet, SPC TV portlet is another component of the SPC system. SPC TV enables users to view SPC control charts in any combination in one page through some simple configuration so that users can learn the latest status of any line or location in real-time.

Add SPC TV Portlet

After the SPC portlet is installed, click the SPC TV sub-menu on the left side, move the cursor over the Add selection menu on the top left corner, and choose More from the drop-down menu.

 

Figure 191: SPC TV Add

 

From the MES menu tree, select SPC, then select TV from the SPC menu tree. Select Add. An SPC TV portlet will be added to the page.

 

Figure 192: SPC Menu Tree

 

Note: By default, there is only one SPC TV page on the left navigation menu, and only one SPC TV portlet added to the page. Users do not have the permissions to add an SPC TV page or SPC TV portlet. If a user wants to make such an addition they must submit a Work Request and have the MES Support team make the addition.

 

Set Page Layout

Move the cursor over the Manage selection menu and select the Page Layout sub-menu from the drop-down list.

 

Figure 193: Manage Menu

 

In the floating panel, 11 layout templates are available, users can select one, and click the Save button to apply the layout to the users' page. By default, the 2 Columns (30/70) layout template is selected.

 

Figure 194: Page Layout Menu

 

 

 

 

Configure Preferences

Users must perform some simple configuration before SPC TV portlet shows SPC control charts properly. Click the icon from the SPC TV portlet controls bar, and select Preferences from the drop-down menu.

 

Figure 195: SPC TV - Preferences

 

Select an available server, monitor, and chart from each drop-down selection box. Complete the remaining parameters and click Save.

 

Figure 196: Preferences Page

Some of the fields are explained as follows:

Monitor Group: Currently SPC monitors are grouped into two categories according to the data source: MDS and SPI. Users can select a monitor group name here.

Monitor: The monitor that users have created under the selected monitor group in the SPC portlet

Note: By default, users can only select the monitors that have data in the past few hours. The monitors that had no data in the past several hours will be hidden. Users can define the hours at the SPC System Paramper page Hide on TV and dashboard if monitor with no data since (hours) option.

       Users can also input the hidden monitors manually, that support fuzzy search, when users input the first 3 letters, the monitor will list out automatically.

Chart: the control charts that users have configured in the selected monitor. Please note that the Pareto chart and Yield chart will not be displayed in this field even if users have configured them in SPC monitor.

Number of point: The maximum points that will show on the selected chart.

Refresh(min): Every xx minutes, SPC TV will refresh for new data.

Display counter: Whether or not shows the countdown timer on SPC TV portlet (on top right corner).

Size: The size of SPC TV portlet, users can either select a fixed size or define their own size.

Tip: For details about how to get the best display effect under different screen resolutions, users can refer to SPC TV Configuration Guide.

 

 

 

Exceptional Icons

• If there is no setting for the SPC TV portlet, it will display a gear icon.

 

• If there is no data, SPC TV portlet will display  an exclamation mark icon.

 

 

• If the monitor is disabled, SPC TV portlet will display a minus icon.

• If the monitor is deleted, SPC TV portlet will display a cross delete icon.

• If there is an exception error, SPC TV portlet will display a question mark icon.

 

Roles ＆ Permissions

Roles→ Permissions↓	SPC_Corp_Support	SPC_Plant_Admin	SPC_Plant_Manager	SPC_Plant_User	*SPC_Plant_Operator
SPC
Add/Edit/Delete Monitor
Start/Stop Monitor
Disable/Enable Monitor
Add/Edit/Delete Monitor Group
Input/Edit Data
Add/Edit/Delete Email
Delete Log
Edit OCAP
Disable/Enable Data
Add/Edit/Delete Location Family
Disable/Enable Location Family
Edit System Configuration/Global System Configuration
Unlock
View
Add to Page
Configuration
SPC Server Information
Add/Edit/Delete Server
View
Add to Page
Configuration

 

Notification:

• ‘SPC_Plant_Operator’ is for plant E68 only.

 

For further information, please go to: How to create CPK/PPK charts.

 

Glossary

1. MFG hold: MFG hold is short for manufacturing hold. SPC sends MFG hold to MDS or SFDC to stop the manufacturing line. It is another action SPC can take when a point is out of control limit.

2. MDS: Short for Manufacturing Data System.

3. SFDC: The SFDC (Shop Floor Data Collection) System is the main software/hardware system used by 42Q for production control and the collection of manufacturing data.

4. Exception: SPC considers some out-of-control a valid group, meaning that the group is based on the rules that users selected when configuring monitor parameters.

5. Valid group: It means the data that is in the normal scope. On SPC control charts, a valid group of data points is plotted between the UCL and LCL.

6. DPMO: Short for Defects Per Million of Opportunities.

7. OCAP: Short for Out of Control Action Plan.

8. Ext JS: Ext JS JavaScript Framework. Ext JS is a pure JavaScript application framework for building interactive web applications using techniques such as Ajax, DHTML, and DOM scripting.