Quality Assurance

General

The high demands the world market places on the quality of products and services to be supplied by us make a thorough, comprehensive and modern quality assurance and management system (QM) indispensable. The quality assurance system enforced in the Capacitors Division has been certified in accordance with EN ISO 9001 since June 1992. A large number of customer audits and awards bear witness to the effectiveness and good performance of this system. Our QM system is continuously being extended and enhanced, whereby the requirements of the relevant standards (EN ISO 9000 and related, CECC) and the EFQM criteria are always taken into consideration. We are now, in addition, certified in accordance with QS 9000 and VDA 6.1.

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1.1

Total Quality Management and Zero Defect Concept

The strategic aim of Total Quality Management (TQM) is to satisfy the demands which customers make on a product or on services in terms of function, quality, punctuality and price/performance ratio. All divisions, departments of our company, as well as our entire staff are involved in achieving this objective. Systematic planning, careful selection of suppliers and sure mastery of design and manufacturing processes are our means of ensuring a constant high quality standard. The quality consciousness of our staff is reinforced by continuous training and awareness measures. 38 04/00

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Modern quality tools such as FMEA, SPC and Zero-Defect Programs with CEDA1) diagrams supplement and support measures for quality assurance and enhancement. 1.2 Quality assurance system

Internal Quality Promotion Measures

Q promotion programs International and national standards and regulations pertaining to quality assurance and QA systems according to ISO IEC CECC DIN QS 9000 VDA 6.1 etc. Special quality demands made by customers Quality group activities Basic and further training Q lectures Q circles, experience interchange Q audits

Internal rules and guidelines on quality assurance

Quality Assurance System

Quality policy

Quality manuals

Procedural guidelines

Product planning

Acquisition

Development

Procurement

Production

Inspection Testing

Storage Despatch

Product applications

Quality assurance measures in the creation of the product Global tasks

Quality cost assessment Quality planning Documentation Quality reporting Quality promotion

1) FMEA SPC CEDAC

Failure Mode and Effects Analyses Statistical Process Control Cause and Effect Diagram with Addition of Cards

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Quality assurance procedure

The quality department examines chokes and inductors and approves them for production according to the following criteria: compliance with type specifications, process capability of available production equipment, test engineering. The entire production process from procurement of parts and materials, through the fabrication process to final inspection is accompanied by quality assurance measures. The flow chart (refer to section 2.5) shows the quality inspections stipulated for each individual step. 2.1 Material procurement

The high quality of parts and materials required for the manufacture of high-grade products is attained through close co-operation with suppliers. Focal aspects of these quality assurance measures are the choice and qualification of suppliers, harmonization of specifications, incoming-goods inspection, quality assessment and problem management. 2.2 Product quality assurance

All essential manufacturing processes are subjected to permanent monitoring. Critical parameters, in particular, are subjected to statistical process control (SPC). So-called QC gates are planned into the manufacturing process, i.e. there is an inspection for release at the end of the corresponding step. The permanent monitoring and evaluation of the test results are used to assess procedures and to determine how well the processes are mastered. 2.3 Final inspection

The chokes and inductors are subjected to a specification-based final inspection. The essential electrical and physical parameters, as well as the finish, are checked. 2.4 Product audit

Our quality assurance department periodically carries out tests on random samples taken from current production lots to check the ability to survive certain climatic conditions, operational reliability, solderability and resistance to soldering heat in accordance with DIN, CECC and IEC specifications.

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2.5

Manufacturing and quality assurance procedures for chokes and inductors

Example: SMT inductor SIMID 0603-C series

Production flow
Incoming goods QC gate Laser-cutting of windings QC gate Production Electro-polishing Electrical parameter value check Electrical parameters and winding quality check

Quality assurance
Raw materials and parts inspection

Coating

Physical quality and epoxy coat thickness check

Galvanic plating (100 % visual inspection)

Thickness and physical quality of Ni-Sn layer check

100 % routine test of electrical parameters and 100 % visual inspection, taping Testing and final inspection QC gate Packing

Automated testing and measuring equipment and settings check

Packing and date code check

Sampling for conformity tests QC gate Sales stocks

Random sampling for electrical and mechanical defects

Approval by quality control team

Despatch

Identity check

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Example: SMT inductors, SIMID 1210 and SIMID 1812 series

Production flow
Incoming goods QC gate Mounting of cores on carrier tape QC gate Winding Check of setting values and quality of windings Check of setting values, welding strength 100% test of resistance QC gate Injection molding Check of setting values, Visual inspection Check of strength and dimensions

Quality assurance
Inspection of raw material and parts

Production

Welding of wire to terminals

Marking

Visual inspection of marking

Separation, bending of terminal strips 100% inspection of electrical parameters Testing and final inspection QC gate Visual inspection, taping and packing Sampling for conformity tests QC gate Sales stocks

Visual inspection, random sampling of dimensions Check of automatic testers and settings

Check of packing (markings, contents, date code) Random sampling for electrical and mechanical defects

Approval by quality control team

Despatch

Identity check

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Example: RF chokes with axial/radial leads

Production flow
Incoming goods QC gate Wiring of cores QC gate Winding Production

Quality assurance
Inspection of raw material and parts

Check of tensile strength body dimensions

Check of setting values Continuous monitoring of wave solder bath

Soldering

Gluing, curing of adhesive

Test of

Base lacquer coating QC gate Top lacquer coating, color coding

lead tensile strength, soldering quality, solder wetting, body size, inductance

Check of setting values, coating quality and color coding Check of automatic testers and settings QC gate

Testing and final inspection

100% inspection of electrical parameters and visual inspection

Taping and packing

Check of packing (marking, content, date code) Random sampling for electrical and mechanical defects/packing QC gate

Sampling for conformity tests

Sales stocks

Approval by quality control team

Despatch

Identity check

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Example: SMT data line choke B 82 790

Production flow
Incoming goods QC gate Winding Check winding quality Check solder bath temperature and quality of tin layer

Quality assurance
Inspection of raw materials and parts

Tinning of wires

Assemble and wrap around pins Flux application, soldering and washing in ultrasonic bath Production 100 % test of voltage, inductance and symmetry

Check wiring quality Check soldering quality and cleanliness Check settings and accuracy of the measurements

100 % visual inspection

Check physical properties Check electrical and mech. parameters for compliance with specifications QC gate

Sampling for conformity tests

Despatch to EPCOS AG

Approval for despatch

Incoming goods inspection, EPCOS AG (semi-finished products) Bend "pin up", insert spacer, ultrasonic welding of cover Bend "pin down", 100 % electr. parameter test, mark, tape packaging Random sampling for conformity tests QC gate Sales stock

Identity, dimension and physical property check, approval for assembly

Dimensions, weld quality Adhesive offset distance, settings, dimensions, tape quality Random sample tests for electrical and mechanical compliance with specs.

Testing and final inspection

Approval by quality control team

Despatch

Identity check

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Example: Ring core chokes

Production flow
Incoming goods

Quality assurance
Inspection of raw material and parts

QC gate Check of setting values, winding and assembly quality

Winding of cores, assembly Production

Potting, resin curing

Check of potting quality and resin curing

Soldering, marking

Check of soldering quality and markings

100% inspection of electrical parameters

Check of automatic testers and settings

Testing and final inspection

QC gate Check of packing (markings, contents, date code)

Visual inspection and packing

Sampling for conformity tests

Random sampling for electrical and mechanical defects / packaging QC gate

Sales stocks

Approval by quality control team

Despatch

Identity check

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Delivery quality

The term delivery quality is used to indicate conformance with the mutually agreed specifications at the time of delivery. 3.1 Random sampling

The AQL (AQL = acceptable quality level) figures given in section 3.3 are based on random sample inspection specification ISO 2859 - 1, single sampling plan for normal inspection, inspection level II. The contents of this standard correspond to MIL STD105 D and IEC 410. The sampling instructions of this standard are such that a delivered lot will be accepted with a probability of 90 % if the percentage of defects does not exceed the stated AQL figure. As a rule, the percentage of defects in deliveries from EPCOS is significantly below the AQL figure. The acceptance figure we apply to inoperatives, i.e. unusable components is c = 0. 3.2 Classification of defects

A defect exists if a component characteristic fails to meet the data sheet specifications or an agreed delivery specification. A distinction is made between inoperatives (totally unusable components) and other defectives. Inoperatives: short circuit or open circuit breakage of case, terminals or coating wrong or missing identification of rated capacitance, rated voltage, rated inductance, rated current or part number mixing with other component types in one lot Other defectives: defects in electrical characteristics (electrical characteristics outside of specified limits) defects in mechanical properties, e.g. wrong dimensions, damaged case, illegible marking, bent terminals. 3.3 AQL figures

The following AQL figures apply to the defects listed above: inoperatives (electrical and mechanical) sum of electrical defectives sum of mechanical defectives 3.4 Incoming goods inspection 0,065 0,25 0,25

We recommend the use of a random sampling plan according to ISO 2859-1 (the contents correspond to MIL STD 105 D and IEC 410). The customer and the supplier should mutually agree upon the test engineering that is to be used.

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Single sampling plan for normal inspection inspection level II Excerpt from ISO 2859 -1: Sampling plan N = Lot size 2 51 91 151 281 50 90 150 280 500 N-0 N-0 N-0 N or 200-0 200-0 200-0 200-0 200-0 200-0 AQL 0,065 N-0 N-0 N or 125-0 125-0 125-0 125-0 125-0 125-0 500-1 AQL 0,10 N-0 N or 80-0 80-0 80-0 80-0 80-0 80-0 315-1 315-1 AQL 0,15 N-0 50-0 50-0 50-0 50-0 50-0 200-1 200-1 315-2 AQL 0,25

501 1 200 1 201 3 200 3 201 10 000 10 001 35 000 Columns 2 to 5:

Left-hand figure = sample size Right-hand figure = acceptable defects Defect classification: refer to section 3.2 4 Service life

This is defined as the time it takes until a given fraction failure is attained. The fraction failure is the the ratio of the number of failures to the total number of inspected components of the respective type. The service life depends on the operating conditions, i.e. on the electrical and thermal loads to which the component is subjected. The service life data are determined by carrying out endurance tests over extended periods and in some cases under more severe conditions (temperature, voltage, current) as well as from experience gathered in actual applications. The expected service life of SMT inductors is 175 000 h (confidence level = 60 %) at a component temperature of Top = 70 C. 4.1 Failure criteria

Generally, the limit values specified in the corresponding applicable standards will apply. 4.2 Operating conditions

The ambient temperature, direct current loads and the inherent heating caused by alternating current loads have a decisive effect on the service life and usability of chokes and inductors. 5 Reliability

Data on long-term reliability under severe or moderate operating conditions are gained from endurance tests which are carried out periodically. The data are based on the failures registered for

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components under a defined load, and long-term reliability of the individual types tested is based on a confidence level of 60 %. Our reliability data result from very large numbers of component testing hours. 5.1 Failure rate (long-term failure rate)

The failure rate is defined as the fraction failure divided by a specified operating period. The failure rate is expressed in fit (failures per 109 component test hours) or percentage failure in 1000 hours. 1 fit = 1 . 10-9 failures/h (fit = failure in time) Example of a failure rate test determined by a service life test: 1) 2) 3) Number of components tested Operating hours (duration of test) Number of failures N tb n = 8 000 = 25 000 h =2

2 1 n 1 test = --- --- = ------------ --------------- = 10 fit = 0, 001 %/1000h. - 8000 25000 N tb When failure rate values are stated, the corresponding failure criteria and the operating and ambient conditions must also be given. The failure rate of components, when plotted against time, shows the following characteristic curve with the three periods I: early failure period, II: service period, III: wear-out failure period
Period in which early failures occur Period in which failures due to wear increase

Period in which failure rate is constant

Unless otherwise specified, the given failure rate refers to the service period (phase II). During phase II, an approximately constant failure rate 0 can be assumed.

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5.2 Product

Failure rate values Failure rate 2,0 fit 2,5 fit 3,0 fit 6,0 fit 50 % rated current, ambient temperatures 40 C (IEC 1709) Reference conditions

SMT inductors RF chokes with wire leads Ring core chokes SMT data line choke 6 Supplementary information

The specification of quality data which refers to a fairly large number of components does not constitute a guarantee of characteristics or properties in the legal sense. However, agreement on these specifications does not mean that the customer may not claim for replacement of individual defective components within the terms of delivery. EPCOS AG cannot, however, assume any further liability beyond the replacement of defective components. This applies in particular to any further consequences of component failure. Furthermore, it must be taken into consideration that the figures stated for service life and failure rate refer to the average production status and are therefore to be understood as mean values (statistical expectations) for a large number of delivery lots of identical components. These figures are based on application experience and on data obtained from preceding tests under normal conditions or, for purposes of accelerated aging, more severe conditions. 7 Handling of claims and complaints

A main aim of our quality assurance system is to prevent any defects occurring. The following details will help us to respond quickly to any complaints which you may need to make: description of fault when and how the fault was detected logistic data (date code, delivery bill) operating conditions length of operation before the fault occurred

Usually an 8-D report is delivered in case of technical complaints. If transport damage has occurred, please describe it in detail and, if possible, mark it so that it can be distinguished from any other damage that may occur when the articles are returned. The original packing should also be examined and damage discovered should be described. To avoid further damage, wherever possible, use the original packing to return the articles being claimed for.

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