LED异常分析8D报告

CorrectiveActionRequest:8D8DReportFA13P042Buckingham8DREPORTFA13P042BuckinghamPage1Section1:CorrectiveActionRequestCustomerNameBuckinghamAnalysisStatusFinalCustomerAddressNo89FengShouEastRoad,QianDengTown,KunShanCity,JiangsuChinaCustomerContactName-CustomerContactPhone#-BridgeluxPartNumberBXRA-30E0740-A-03=4BXRA-30E1200-B-03=2BXRA-30E2000-B-03=2BXRA-30E4000-H-03=1BXRA-27E0540-A-03=1BXRA-27E2000-A-03=1BXRA-27E0740-A-03=4CustomerContactEmailAddress-DistributorNameRichpowerElectronicDevicesCo.,LtdBridgeluxSalesContactDiggerWangLot#/DateCode2jH023-19122gH187-19122qH583-25122qH322-25122sH342-26122sH341-26122sK0N1-501237K0E2-08132TK0G3-511238H142-0313FailureModeArrayunitnotlit,rowsordiesnotlitorflickerDateSamplesReceivedMay13,2013Quantity15LEDArraysDateFAInitiatedMay02,2013Section2:BridgeluxResponseD1:ESTABLISHTEAMSChampionKPLim–[e-mail][e-mail][phone]ContactNumber+1-925-583-8796TeamMembersPhilElizondo–DirectorofReliabilityMartinParry–ProductMarketingManagerQualityAssuranceD2:PROBLEMDESCRIPTIONLocationofFailureIQCProcessTestEndUserBridgeluxcustomerBuckinghamreturnedtotal15LEDarraysofdifferentpartnumberswiththefollowingissues¢7BuckinghamÄÞ15*™÷„7Áo‚-Arrayunitnotlit®-Rowsofdiesnotlitorflicker’à’¯G®¯GêÁAllfailuresweredetectedaftertheassemblytest.@ oý/(ÅMKÕÑ°„CorrectiveActionRequest:8D8DReportFA13P042Buckingham8DREPORTFA13P042BuckinghamPage2PackageasreceivedfromcustomercontainingtheLEDarraysgroupedbyproductnumber.60¢7Äބ„7Áł„‹÷§ÁÄ(™¡…‚þ1Figure1:CustomerReturnedLEDLightingArrays_________________________________________________________________________________D3:CONTAINMENTACTIONSNocontainmentactionneededforBridgeluxasfailurefoundtobeprobablyeithermishandlingormechanicalinduced.n^àÇÖô5ª½Ïn^Ñ°oïý1ŽSÍ\:°_O„__________________________________________________________________________________D4:FAILUREANALYSISD4-1:SummaryofAnalysisBridgeluxanalysishasconfirmed11outof15returnedLEDarrayswerepartiallylitandnon-functionalunits.Thex-rayanalysisrevealedthatabrokenbondwirewasacommondefectmode.Theelectricaldiscontinuitymadebythebrokenwiresinterruptedcurrentflowandcausedtheunittobenon-functionalorpartlyfunctional.n^n¤15*oÔÁ-„11*:讌àŸý„XIÑ°Ñ¿­Â/8Á„o!Ñ¿­Âüô5A„ÞíLED§ÁàŸý„ê èŸý„TheanalysisofthefailedLEDarraysindicatesthefailurewaseitherduetocontacttothelenssurfaceduringwiresolderprocessortheluminaireassemblyprocessoramechanicallyinduced.Thesolderingofwirestothearraypads,mountingthearrayontotheheatsinkandmountingthereflectors(luminaireassemblyprocess)arepossiblesourcesforthesetypesofdefects.HandsandtoolsmaybeclosetotheLEDlensduringtheassemblyprocessincreasingthepossibilityofunintentionalcontact.ùLEDÔÁ„Ñ°vo/1Ž(¿Ç-owvքÅMÇ-æ°ÑIb:°_$„¿
(cíG‰ÅLED§ÁåÊÍIo‰ÅÇowÅMÇ ïýüôåٛÍ{„oæ(ÅMÇ-`ÑÑIb„KŒåwàƄ¥æÑIb_üôå„oD4-2:FailureVerificationThereturnedLEDarraysweretestedtovalidatethecomplaintofnolight-up,partiallylitorflickering.TheLEDarraysweremanuallyDIMtested.Fourwereconfirmedfullyfunctional,fourbypartlyfunctional,andsevenwereconfirmednon-functional.ÔÁn¤ٛÔÁÏK¨KÕn¤v- 4*/Ÿýc8„4*ê èŸý„Œ7*àŸý„CorrectiveActionRequest:8D8DReportFA13P042Buckingham8DREPORTFA13P042BuckinghamPage3Figure2:ManualLight-UpTestIllustrationsoftheLEDDIMtestresultasshowninFigure-3below.LED§Á„¹®KՂþ3Figure3:DimTestLightOutputD4-3:RootCauseAnalysisandObservationsX-RayimagingperformedonthefailedLEDarrayisshowninthefollowing.ItisapartoftherootcauseanalysistodeterminethedefectmodeandbyunderstandingthevisualconditionoftheLEDchipsandthebondedwires.Thediscontinuityofthesebondwirescanbethecauseofnolightoutput.ResultsoftheanalysisareshowninFigure4below.o7Á„XIþ‚XIÀå/9,Ÿà„è忎n¤o!Œ†ãLED§Á„¯GåÊÑ¿„ŵÑ¿„Þí'üô¡ I“úÓœ‚þ4CorrectiveActionRequest:8D8DReportFA13P042Buckingham8DREPORTFA13P042BuckinghamPage4Figure4:AnalysisTableSummaryUnit-1BXRA-30E4000-H,DIMtestresultedrows2and3didnotlightup.1#7BXRA-30E4000-HKÕӜ,2
3L¯G®X-rayimaging(Figure5)revealedbrokenwiresatwirebondballneckandmid-spanonlocations2x4,3x4,and3x5.Furtheranalysisthroughahighpoweredmicroscopefounddamage/scratchonthelenssurfaceintheareawherebrokenwiresarelocated.Itisaclearevidenceofapossiblecontactwasaccidentallymadetothelenssurfaceduringtheassemblyprocess.XIþ5:(Mn2x4,3x4Œ3x5шèŒ-è¿ Ñ¿­Â(Ø®\ÛeÑ°(Ñ¿­ÂMn„ÑIb _$Œ$„Õùv:ïý(ÅMÇ-0æ°ÑIb„ÁnFigure5:X-rayImagesCorrectiveActionRequest:8D8DReportFA13P042Buckingham8DREPORTFA13P042BuckinghamPage5Unit-2BXRA-27E0540-A,DIMtestresultedtoArrayNoLit2#7BXRA-27E0540-AKÕӜ®.X-rayimaging(Figure6)revealedbrokenwiresatwirebondballneckonlocation2x1associatedwithwiredeformationspossibleinducedthroughmishandling.XIþ6:(2x1MnˆèÑ¿­Âv4 Ñ¿Øbïý/ùLED§ÁS„Í\„Figure6:X-rayImagesUnit-6BXRA-30E0740-A,DIMtestresultedtoArrayNoLit6#7BXRA-30E0740-A,KÕӜ®.X-rayimaging(Figure7)revealedbrokenwiresatwirebondballneckandmid-spanonlocations2x2,2x3,and3x3.Furtheranalysisthroughahighpoweredmicroscopefounddamageonthelenssurfaceint