Both techniques are often complementary, but there are various tradeoffs. In packaging, optical and X-ray inspection techniques are non-destructive, meaning they can inspect packages without damaging them. That’s different than metrology tools, which characterize structures. Inspection systems are used to find defects in products. The new inspection systems involve different techniques, such as optical, X-ray and others, to find defects and other problems in both legacy and advanced packages. This has prompted the development of a new set of tools, but those tools are more expensive and there may still be some gaps. But as packaging becomes more complex, and as it is used in markets where reliability is critical, finding defects is both more difficult and more important. So even if you’re arguing that the scrap or the material is not that much there’s other things you need to think about, and one of the most important ones is what happens if that defective part gets out to the market.Several equipment makers are ramping up new inspection equipment to address the growing defect challenges in IC packaging.Īt one time, finding defects in packaging was relatively straightforward. And these external failure costs are often underestimated. The demand will drop, and these are name as then the external failure costs. We’re force to sell our products at a lower price or even loss of market. We could have even worse, recall cost, we could even badly have the loss of reputation and loss of reputation leads to things like lower prices That defective product gets out to the customer, we have for example, warranty cost, liability cost. Now, the case of crayons maybe is not that critical depends if there’s something toxic in it or something then it would be critical but you can think of this applied to something like to another product like our car or like some kind of medicine. Now the other problem is that, we have this defective crayon, and this defective crayon might end up getting out to the customer. Which although they may be small, they’re very real. So these though, in this part of the factory, the main impact of defect we’ve got internal failure costs. So the capacity is being used up and this can be critical when we have a capacity constrained process, which means we need every single part of our capacity every minute of our capacity, we need to make good parts to meet the demand. Now, the other interesting thing is, if we have a process where we have a high demand and we have a capacity constrained process, then we’re using on both cases even if it’s not capacity straight, we’re using up capacity on machines, we’re using up the energy costs for example, for heating up the mixture, the molding machine, we’re molding products that could potentially not sell. So the people that we’ve hired for our process, they’re there to make the products and we’re paying them for making parts that we cannot sell. Well we have also the labor, that went into making that crayon. Now, before the defect occurs, you have costs due to the materials.Įven though, we scrap the batches we know that it’s a small amount of money.īut, where else do we have costs? Internal Failure cost Let’s just arbitrarily draw defect occurs and this leads to in my example, to a defective crayon, defective crayon, defective product or if we were service process, would be defective service. So here, we see our crayon flow again, now, a defect is produced somewhere in our process. Now, as a quality engineer and from a quality perspective, are there any flaws in your thinking? So you say, the problem is under control. In fact, the scrap costs for this 40 batches is less than 0.05% of the cost of goods sold, extremely small. When you find out about a bad batch, you need to scrap around 40 batches but you estimate that the scrap costs are very low.
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