In ST, we study every detail of the manufacturing and supply chain processes to bring our customers the highest levels of quality. We take a systematic, proactive approach to prevent and eradicate problems, cross-fertilize knowledge and continuously improve our performance.
Our objectives for manufacturing and supply chain quality are:
- Zero excursions for our customers
- Best-in-class DPPM for each industrial domain
- Best-in-class on-time delivery
- State-of-the-art supply chain processes and systems
Management commitment at all levels is critical to achieve these objectives. Manufacturing managers, from plant manager down to shift supervisors, are deeply and constantly engaged to operate in line with our approach to prevent and eradicate problems.
Our approach to quality is prevention driven. We use different tools and methodologies to prevent defects from occurring or reaching customers at every phase of production, focusing on three axes
- Prevention during product development using methodologies such as Failure Mode and Effects Anaysis (FMEA) and the Failure Mode Knowledge Matrix (FMKM)
- Tight process control through advanced SPC management for equipment, wafer and assembled parts. ST has its own proprietary method for outlier detection and control limit management, developed by a pool of statisticians
- Product screening using techniques for outlierdetection, such as Part Average Testing (PAT) and Statistical Bin Limits (SBL)
ZERO DEFECTS AND QUALITY IMPROVEMENT PLANS
Quality Improvement Plans (QIP’s) are an approach we have developed in ST to reach zero defects and continuously improve our baseline defectivity in manufacturing. QIP’s cover the vast majority of all failure modes encountered in customer premises and are used to identify, prioritize and implement opportunities for improvement, then monitor the selected improvement metrics versus the expected results. The application of this methodology across the board ensures a complete and consistent approach to problem solving, root cause analysis and implementation of corrective actions.
“Golden flow” specifications for manufacturing are also systematically updated with lessons learnt so that all factories use equivalent, formally validated specifications.
A team of senior quality and engineering experts is dispatched to work with each impacted manufacturing site to ensure we fully understand and eliminate the technical, system and escape root cause for any customer or internal excursion.
In the rare case when an excursion occurs, ST processes and IT tools allow us to quickly put into place containment and material segregation actions.
Lessons learnt are then cross-fertilized to all potentially impacted manufacturing sites, both front end and back end. Execution and completion of cross-fertilization actions are tracked to eliminate any risk of reoccurrence.
DATA ROBUSTNESS AND STATISTICS
Data robustness and availability is the foundation of all manufacturing and supply chain activities. In ST, we have a dedicated quality function fully focused on ensuring data reliability.Data robustness and availability is the foundation of all manufacturing and supply chain activities. In ST, we have a dedicated quality function fully focused on ensuring data reliability. Modern computing methods allow us to exploit huge quantities of data. By applying advanced statistical methods to this data, we will achieve a breakthrough in our quality levels.