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Defect Analysis Report (Tuner)

This document summarizes an investigation into issues with the left FM channel being dead on a tuner model. The root cause was determined to be short circuits occurring at contact points on the flexible printed circuit (FPC) used during function checking. This was due to wear and tear after 50 insertions and removals of the FPC. Temporary countermeasures included reducing the number of FPC insertions and adding resistance checks. A permanent solution of replacing the FPC with a pin jig for function checking was also proposed.

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Mohd Isa Harun
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© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
98 views

Defect Analysis Report (Tuner)

This document summarizes an investigation into issues with the left FM channel being dead on a tuner model. The root cause was determined to be short circuits occurring at contact points on the flexible printed circuit (FPC) used during function checking. This was due to wear and tear after 50 insertions and removals of the FPC. Temporary countermeasures included reducing the number of FPC insertions and adding resistance checks. A permanent solution of replacing the FPC with a pin jig for function checking was also proposed.

Uploaded by

Mohd Isa Harun
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Tettei Be thorough

BBGG Never give-up

TUNER 1 AMPR (A1846561Z)

FM Left Channel Dead

SOEM

Problem Detail
Tettei Be thorough

BBGG Never give-up

NG Photo

OK Photo
NG
FM Left channel Dead

OK

FM L and R channel

Comment: FM left channel dead is due to IC101 left channel become open

SOEM

Chronology
Tettei Be thorough
16th.Oct 17th.Oct 18th.Oct

BBGG Never give-up


19th.Oct
20th.Oct Sunday 21st.Oct

Kaga

Normal

Sorting using checker

to check IC 101 impedance

Sorting using meter

sorting HR=01
3/700 sets
FM Left Channel no output
FM Left Channel no output

sorting
FM Left Channel no output

3/700 sets

4/700 sets

Use by SONY Production

SOEM

Background
Tettei Be thorough

BBGG Never give-up

TUNER 1 AMPR (A1846561Z)

Process at Kaga
Auto mount
Dummy FPC

Checker
Checker to check radio function including FM left and right channel

Discharge circuit
Hand mount Dipping ICT

For inspection operator need to insert dummy FPC wire into Tuner1 connector

PWB breaking

Assembly Upper and Lower case

Checker Inspection

Transport

SONY detects L channel no output

SOEM

Defect Analysis
Tettei Be thorough

BBGG Never give-up

FM L channel dead is having open circuit between pin 2 (LCH) and Gnd at IC 101

IC 101 damage

OK pwb

Reject pwb

SOEM

Tettei Be thorough

BBGG Never give-up

Step Analysis
Static Discharge

Analysis flow
Hand Mount static Assembly station static Operator wrist strap

Status
Value less than 50V >OK Value less than 50 V> OK OK

Checker Voltage Discharge

Checker is equipped with discharge circuit where the voltage will discharge immediately after checking is completed and ready for next set to be inspected. > OK
FPC checking. Due to wear and tear issue, customer provide 1 FPC for every 100 sets.( As each bin contains 50 pcs.> operator will interchange end 1 and end 2.) >NG

Short circuit

2 1

SOEM

Tettei Be thorough
Study on FPC used on 18th.Oct
NG

BBGG Never give-up


FPC used Station 1

2 stations are running Tuner1 for 12 hours. Output 100 set/hour

NG

NG

3/12 FPC were found to be damaged/blister after 50 times insertion and pulling

Total 12 FPC for each station at end of working day


NG NG

2/12 FPC were found to be damaged/blister after end of 50 times insertion and pulling

FPC used by Station 2

SOEM

USED FPC

Tettei Be thorough

BBGG Never give-up

Terminal bend

Terminal short/almost short condition


Pin 2= L channel

Terminal short/almost short condition

Samples of OK FPC after 50 insertion and pull

NG FPC CONTACT POINT

Pin 1, 2, 3,4,5,6,7,8,9,10l

SOEM

Cause & Countermeasure


Tettei Be thorough

BBGG Never give-up

Root Cause (1):

Due to FPC used at Function checker having condition of short or almost short condition. This is due to FPC contact points having wear and tear condition after 50 times insert and pull

Countermeasure:

Temporary 1) Reduce FPC recycle from 50 times each to 25 times insert and pull for each end 2) Perform resistance for left and right channel after function test

Permanent 1) Redesign checker from using FPC to pin jig


SOEM

Why Leak Out?


Tettei Be thorough

BBGG Never give-up

Root Cause (1):

Due to damage is done by the inspection station

Countermeasure:
To perform resistance check after inspection station

SOEM

Stock Treatment
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BBGG Never give-up

Raw Part Sorting by Result Marking Date

(at Partner) 3/2313 NG R OK on Bin 20 th.OCT 2013

Sorting by (at SOEM) Result 10/1919 NG Marking R OK on Bin Date 19 th.OCT 2013 Completed sets Sorting by . Result Not applicable Date
SOEM

Preventive Action
Tettei Be thorough

BBGG Never give-up

Yokothenkai modification from using FPC to jig pin to other Sony models such as Tuner2 checkers.

SOEM

Tettei Be thorough

BBGG Never give-up

SOEM

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