Fairchild Semiconductor

Quality Manual

Quality Manual (rev. 7/03)

Revision History
Issue Date 10/02/98 01/11/99 04/09/03 07/29/03 Revision Description Initial Fairchild Semiconductor Corporation Quality Manual draft. Includes QS9000 Quality System requirements and clarification of document language and style. Second edition of Fairchild Semiconductor Corporations Quality Manual. Format and contents were changed in order to align with and include QS9000 third edition requirements. Modified sections 6.1 and 6.2.3. Added sections 13.1.1 and 13.2.6. All changes to comply with customer environmental requirements. Modified Spec to comply and align with TS16949 requirements

Approvals: Fairchild Semiconductor Executive Vice President of Global Operations

___________________________ Laurenz Schmidt Fairchild Semiconductor Executive Director of Quality and Reliability

Quality Mission of Fairchild Semiconductor Corporation Deliver superior multi-market semiconductor products and
customer value through: r r r Innovation Service Manufacturing Excellence

Message from the President

The Mission of Fairchild Semiconductor is to be the premier multi-market supplier of high-performance semiconductors to the world. In support of our mission, Fairchild will continuously focus on three major strategic imperatives: r r r Product Innovation Cost-Effective Manufacturing, and Superior Customer Service

The implementation of these strategic imperatives is dependent on the development, execution, and continuous improvement of our systems, processes, and controls. These systems are designed to ensure our customers satisfaction by providing quality multi-market products that meet current and evolving needs for the innovative and cost-effective semiconductors. This Quality Manual has been developed to support Fairchilds mission, strategic imperatives, and quality goals. This manual contains an outline of our Quality System tools that are designed to ensure the quality and reliability of our products and services.

Kirk Pond President, CEO & Chairman

Table of Contents
Page Document History and Approvals Quality Mission Message from the President Section 1. Introduction and Scope Section 2. Quality Policy & Objectives Section 3. System Description Section 4. Quality Management System Section 5. Management Responsibility Section 6. Resource Management Section 7. Product Realization Section 8. Measurement, Analysis and Improvement Table 1 - Quality Management System Specifications Corporate Glossary 2 3 4 6 6 6 7 9 13 15 30 37 38

1. Introduction and Scope

This Quality Management Manual defines the policies and procedures used by Fairchild Semiconductor to ensure that our products and services meet both the specified requirements of our customers and our business objectives in a consistent, economical and reliable manner. The policies and procedures contained in this manual are intended to establish and communicate the minimum requirements that all groups at Fairchild Semiconductor must meet. These requirements are based on the requirements of our customers as well as applicable international and national standards. These requirements will be updated as the needs of our customers and the respective standards are changed and for continuous improvement of the quality system. This specification defines corporate policies and references corporate level specifications. Each site has an associated addendum to this specification that references site level specifications, exceptions, additions, or clarifications applicable to their own site.

2. Quality Policy & Objectives

2.1.Quality Policy:
Our quality mission is to deliver superior multi-market semiconductor products and customer value through innovation, service and manufacturing excellence.

2.2. Quality Objectives:

Fairchilds quality objectives are derived from the AOP process and are aligned with the Built In Quality (BIQ) initiative. Key objectives of BIQ are: 1. Aligning all Fairchild employees with a common quality system 2. Driving improvement in quality; and 3. Ensuring that Fairchilds products and services meet or exceed our customers quality and reliability expectations Specific corporate goals and metrics associated with these BIQ objectives are listed on the corporate BIQ web site.

3. System Description
Fairchilds Quality Management System is defined in the following sections (4-8). It is based on the requirements of TS-16949:2002, Customer Requirements, and BIQ (Built in Quality) minimum requirements.

4 Quality Management S ystem

4.1 General
Quality systems are established at Fairchild Semiconductor to ensure that its products conform to specified requirements. These systems are documented in this corporate Quality Management Manual and in such other business group and site quality manual addenda as appropriate. The defined quality systems are intended to be ISO 9000:2000 compliant (ANSI/ASQC-Q 9001-2000) or meet ISO/TS 16949 (Second Edition) requirements for those Fairchild groups and sites that are certified to the TS standard. Fairchild Semiconductor Internationals CEO, executive staff, and site management (hereafter known as top management), and the entire Fairchild organizations are committed to developing and implementing a quality management system that ensures customer satisfaction. Top management: a) Identifies processes needed for the quality management system, b) Determines the sequence and interaction of these processes, c) Determines criteria and methods to ensure that both the operation and control of these processes are effective, d) Ensures the availability of resources and information to support the operation and monitoring of these processes, e) Monitors, measures and analyzes these processes, and Implements actions necessary to achieve planned results and continual improvement of these processes. Fairchild ensures control over all processes that are outsourced. (see FSC-QAR-0009: Wafer Subcontractor Qualification and Quality Monitor and FSC-QAR-0010: Subcontractor Quality Management Policy)

4.2

Documentation Requirements
4.2.1 General

The Fairchild quality management system is documented by: a) The quality policy and quality objectives, b) This quality management manual and site addendums, c) Other site and product line documented procedures needed to ensure the effective planning, operation and control of processes, and d) Records required to ensure the effective planning, operation and control of processes. 4.2.2 Quality Management Manual

The Fairchild Quality Management Manual and the site Quality Management Addendums: a) define the scope of the quality management system, 7

b) define specific procedures relevant to the quality management system, and c) define the interactions between the processes of the quality management system (Appendix A). 4.2.3 Control of documents

Document and data control procedures (FSC-DOC-0001: Corporate Document Control Procedure) are implemented at Fairchild Semiconductor to ensure that processes and procedures are performed with current instructions and data.
These documented procedures define the methods used to: a) Review and approve documents for adequacy by authorized personnel. Changes are reviewed and approved by the same functions and organizations that performed the original review and approval.

b) Review and update documents on a regular basis. c) Generate, approve, change, obsolete, and distribute documents. Where practical, the nature of the change is identified in the documents or in the appropriate attachments. d) Operating and work instructions are available at or near the pertinent workstation location. e) Ensure that documents remain legible and readily identifiable. f) Control the use and amendment of External documents, such as standards and customer drawings. g) Identify the current revision status of documents to preclude the use of invalid and/or obsolete documents. Obsolete documents that are retained for legal and/or knowledge preservation purposes are all identified. 4.2.3.1 Engineering specifications

Customer engineering standards are reviewed using the corporate drawing review process (see FSC-QAR-0003: Customer Drawing Review Process). This process ensures that alignment exists between customer expectations and Fairchilds overall capability to meet the customer requirements. Timely review, distribution, and implementation of all customer engineering standards, specifications, and changes are implemented based, as closely as possible, on customer schedules. 4.2.3.2 Records and customer notification of changes to specifications

Records of the dates on which changes to customer engineering standards and instructions are implemented in production are maintained. 4.2.4 Control of records

Records are maintained that provide evidence of conformity to requirements and the effective operation of the quality management system. Procedures are defined at each site to ensure records are legible, identifiable, retrievable, stored appropriately, retained for appropriate time and disposed of when appropriate.

5 Management Responsibility
5.1 Management commitment
Management clearly defines and communicates the quality objectives of Fairchild Semiconductor, provides the resources and dedicated infrastructure necessary to accomplish those objectives, and monitors the performance of the organizations effectiveness and efficiency in meeting these objectives. This is done to ensure consistency in product and process quality and enable it to meet current and evolving customer requirements. 5.1.1 Process efficiency Management reviews the processes in the quality management system to assure they are effective and efficient.

5.2

Customer focus
Management ensures that customer requirements are understood and are met.

5.3

Quality policy
The quality policy as stated in section II of this manual and the associated quality objects were defined by top management, are communicated throughout the organization and reviewed to ensure continuing suitability.

5.4

Planning
5.4.1 Quality objectives Management defines the quality objectives for Fairchild. All of the quality objectives are measurable and achievable within a defined time period. Top level objectives are defined in the AOP (Annual Operating Plan) or Business Plan.
The groups within Fairchilds that use formal business planning processes ensure that these Guidelines are met: a) Business goals and plans are developed through analysis of competitive products and benchmarking studies from within and outside of the industry. The short- and longterm goals and plans of the organization take into consideration customers current and future expectations; quality and performance requirements; and projected technology, quality, and product development roadmaps. b) Definitive schedules and prescribed data gathering formats are used as an integral part of information collection processes to ensure consistent results. c) Comprehensive business plans are formally documented and tracked as controlled documents.

5.4.2

Quality management system planning Documented methods are implemented that control how business plans are reviewed, revised, updated, and communicated throughout the organization.

5.5

Responsibility, authority and communication

5.5.1 Responsibility and authority Management ensures that employees understand their responsibility and authority. 5.5.1.1 Responsibility for quality
The responsibility for defining and implementing the quality policy, goals, and objectives of the organization is defined as follows: 1) Fairchilds senior executive personnel responsible for Quality will define: a. The Quality and Reliability Program Management Systems used by Fairchild to comply with external quality standards. b. The policies, goals, and requirements that ensure acceptable levels of product quality, reliability, and customer service. c. The policies for interfacing with Fairchilds customers and suppliers on quality, reliability, and customer service issues. d. The programmed management overview and reporting processes that ensure the communication of the results of Quality Metrics Performance and Quality System Reviews to Fairchilds senior management. 2) Business group personnel who are responsible for Quality ensure that: a. Fairchilds quality, reliability, and customer service goals are integrated within the business plans of the business group. b. Necessary procedures are defined and communicated to support quality, reliability, and program management systems. c. Procedures are defined and communicated for interfacing with Fairchilds customers and suppliers on quality, reliability, and customer service issues. d. Procedures are defined and communicated for reporting and reviewing quality performance metrics and quality system performance. 3) Site personnel who are responsible for Quality ensure that: a. The site implements and complies with the requirements of the Fairchilds Quality Manual and other appropriate standards. b. The overall performance of the site quality system is reported to management on a predetermined periodic basis for managements review and action. c. Procedures are implemented to ensure liaison with Fairchilds customers or other external parties on matters that relate to Fa irchilds quality system from a site perspective. d. Internal and external assessment procedures are implemented to ensure compliance with Fairchilds policies, procedures, and specifications. e. Preventive and corrective action procedures are implemented to ensure the effective closure of quality problems and that management reviews these activities on a programmed basis.

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4) Each of Fairchilds business groups and sites is responsible for the implementation and maintenance of the policies and pertinent quality system requirements as contained in Fairchilds Quality Management Manual. 5) All personnel (regardless of position or shift) understand they are

responsible for product quality and have the authority to stop production to correct quality problems. Managers and supervisors are promptly informed of products or processes which do not conform to requirements. 5.5.2 Management representative A management executive is identified who has the responsibility for ensuring compliance to the requirements of the Fairchilds Quality Manual as well as to other applicable standards. This executive is to ensure that results of quality system performance are reported to Fairchilds management and to promote awareness of customer requirements throughout Fairchild. 5.5.2.1 Customer representative Management has designated personnel with responsibility and authority to ensure that customer requirements are addressed through the use of the business planning process and the APQP process. The business planning process includes setting quality objectives and related training, corrective and preventive actions, and product design and development project direction and objectives. The APQP process addresses specific product design and development customer requirements, special characteristics, and quality objectives. 5.5.3 Internal communication Management ensures that communication takes place regarding the effectiveness of the quality management system.

5.6

Management review
5.6.1 General Management reviews the quality management system, at planned intervals, to ensure its continuing suitability, adequacy and effectiveness. 5.6.1.1 Quality management system performance

Cross-functional review of overall Quality System performance for a business group or site is done by the senior executive level of the business group or site at predetermined intervals. Records of these reviews are maintained as evidence: a) The quality system is effectively deployed and meets the requirements of Fairchilds Quality Management Manual as well as other appropriate standards. 11

b) Quality policies and quality objective goals, are being met. c) All elements of the quality system are reviewed as part of the management review process as required by the organizations pertinent quality standard. 5.6.2 Review input Input to management review includes information on a) results of audits, b) customer feedback, c) process performance and product conformity, d) status of preventive and corrective actions, e) follow-up actions from previous management reviews, f) changes that could affect the quality management system, g) recommendations for improvement, h) analysis of actual and potential critical PQAs (Product Quality Alerts) and their impact on quality, safety and the environment. 5.6.3 Review output Outputs from the management review include any decisions and actions related to a) improvement of the effectiveness of the quality management system and its processes, b) improvement of product related to customer requirements, and c) needed resources d) changes needed to the quality policy and objectives.

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6 Resource Management
6.1 Provision of resources
Fairchilds business planning process identifies adequate resources and trained personnel to support: a) the management, performance, verification, and assessment of the quality management system, processes, materials, products, and services of the organization, b) customer satisfaction by meeting customer requirements consistent with company policies and practices.

6.2

Human resources
6.2.1 General Fairchild Semiconductor establishes job skill requirements and provides training to employees to ensure that the quality of products, processes, and services is reinforced at all leve ls of the organization; to minimize errors, drive continuous improvement to optimize customer and employee satisfaction, and to maintain a safe working environment. 6.2.2 Competence, awareness and training Fairchild: a. determines the necessary competence for personnel, b. provides training or takes other actions to satisfy these needs, c. evaluates the effectiveness of the actions taken, d. ensures that personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives, and e. maintains appropriate records of education, training, skills and experience. 6.2.2.1 Product design skills Personnel with product design responsibility are competent to achieve design requirements and are skilled in applicable tools and techniques. Determination of skill sets are established by the appropriate organization to assure alignment with objectives. 6.2.2.2 Training Fairchild establishes and maintains documented procedures for identifying training needs and achieving competence of all personnel performing activities affecting product quality. Personnel performing specific assigned

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tasks are qualified, as required, with particular attention to the satisfaction of customer requirements. 6.2.2.3 Training on the job On-the-job training is provided for personnel in any new or modified job, including contract or agency personnel. Personnel where work can affect quality are informed about the consequences to the customer of nonconformity to quality requirements. 6.2.2.4 Employee motivation and empowerment Fairchild has an annual performance review process to motivate employees to achieve quality objectives, to make continual improvements, and to create an environment to promote innovation. Fairchild has a process to measure the extent to which its personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives. These processes include but are not limited to performance reviews, individual and group goal score cards, and organizational metrics.

6.3

Infrastructure
Fairchilds business planning process determines, provides and maintains the infrastructure needed to achieve conformity to product requirements. Infrastructure includes: a. buildings, workspace and associated utilities, b. process equipment (both hardware and software), and c. supporting services (such as transport or communication). 6.3.1 Plant, facility and equipment planning A multidisciplinary approach is used for developing plant, facility and equipment plans. Where possible, plant layouts optimize material travel, handling and valueadded use of floor space, and facilitate synchronous material flow. Methods linked to lean manufacturing principles are used to evaluate and monitor the effectiveness of existing operations. 6.3.2 Contingency plans Contingency plans are prepared to satisfy customer requirements in the event of a significant emergency such as utility interruptions, labor shortages, and key equipment failure.

6.4
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Work environment

The work environment is managed as needed to achieve conformity to product requirements. Working environments are suitable for all employees and are kept in states of order, cleanliness, and repair with the following key process control features being controlled: a) ESD (electrostatic discharge) controls and discipline, where required b) Environmental control of work environment c) Environmental control of ancillary materials and process equipment d) Cleanroom discipline 6.4.1 Personnel safety to achieve product quality Product safety and means to minimize potent ial risks to employees are addressed especially in the design and development process and in manufacturing process activities. 6.4.2 Cleanliness of premises Premises are maintained in a state of order, cleanliness and repair consistent with clean room and efficient office protocol.

7 Product Realization
7.1 Planning of product realization
Quality planning procedures are documented, including those that pertain to new product and process development, change, and transfers. These procedures define how the requirements for quality are met. As required, the Advanced Product Quality Planning and Control Plan reference manual is used in the quality planning process. Quality planning processes are determined by cross- functional teams that consider and ensure action as required on the following: a) Determine quality objectives and requirements for the product, b) FMEAs are developed for major processes. They are focused on defect prevention rather than defect detection. Process control features are implemented for potential failure modes that have high risk priority numbers. c) Control Plans (quality plans) with established process controls for special characteristics are developed at the system, subsystem, process, or material level as appropriate. These plans are developed during the development phase of a process and continue throughout its evolution to production and beyond. Control plans are reviewed and updated as changes are made to the product, process, the process inspection methods, frequency, etc.; and as processes become non-capable. d) Special customer and Fairchild characteristics are defined in Control Plans, FMEAs, and other documentation. These are identified with customer-specific and Fairchildspecific symbols.

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e) Additional resources (including equipment, controls, processes, etc.) are identified and acquired as needed. f) The compatibility of the design, manufacturing processes, testing methods, and documentation are ensured. g) Quality controls as well as inspection and testing controls are updated along with the acquisition of new test and/or measuring equipment as needed. h) Measurement requirements are identified and reviewed as required. i) Appropriate verification and feasibility steps as well as standards of acceptability for all features and requirements are reviewed and/or developed. j) The acceptability of quality records is reviewed and updated as needed. 7.1.1 Planning of product realization Customer Requirements Customer requirements and references to its technical specifications are included in the planning of product realization as a component of the quality plan. 7.1.2 Acceptance criteria Acceptance criteria is defined and, where required, approved by the customer. For attribute data sampling, the acceptance level is zero defects. 7.1.3 Confidentiality Customer-contracted products, projects under development, and related product information are kept confidential. 7.1.4 Change control Process and product changes are identified, documented, reviewed, and approved prior to implementation. Consideration is given to the impact of a design change on the system in which the product is used before the change is made. When required by the Production Part Approval Process (PPAP), customer approval is obtained prior to any design change. Design rules are modified when the design is no longer robust under current processing conditions.

7.2

Customer-related processes
7.2.1 Determination of requirements related to the product Fairchild determines: a) requirements specified by the customer, including the requirements for delivery and post-delivery activities, b) requirements not stated by the customer but necessary for specified or intended use, c) statutory and regulatory requirements related to the product, and

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d) requirements for any recycling or environmental impact concerns of the product or manufacturing process. 7.2.1.1 Customer-designated special characteristics If customers designate any special characteristics, FSC follows our customers requirements for designation, documentation, and control on our processes and product. 7.2.2 Review of requirements related to the product Product requirements are reviewed prior to Fairchilds commitment to supply a product to the customer (e.g. submission of tenders, acceptance of contracts or orders, acceptance of changes to contracts or orders) and we ensure that: a) product requirements are defined, b) contract or order requirements differing from those previously expressed are resolved, and c) we have the ability to meet the defined requirements. Records of the results of the review and actions arising from the review are maintained. Where the customer provides no documented statement of requirement, the customer requirements are confirmed before acceptance. Customer acceptance is assumed if the customer orders and specifies a standard FSC part number. Where product requirements are changed, we ensure that relevant documents are amended and that relevant personnel are made aware of the changed requirements. 7.2.2.1 Manufacturing feasibility Manufacturing feasibility of the proposed products is investigated, confirmed and documented in the APQP process, including risk analysis. 7.2.3 Customer communication Arrangements have been determined and implemented for communicating with customers in relation to a) product information, b) enquiries, contracts or order handling, including amendments, and c) customer feedback, including customer complaints.

7.3

Product and process design and development

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The APQP process is used to ensure that product design and development activities are structured and organized to ensure that internal and external customer requirements are clearly defined, agreed upon, documented, and implemented in designed products. This conceptual alignment occurs before design begins. Subsequent implementation of ongoing design development and programmed reviews by design personnel occurs throughout the design process and are key to ensuring that designed products meet customer expectations. Product and manufacturing process design and development methods focus on error prevention rather than detection. 7.3.1 Design and development planning During design and development planning, the following are determined: a) the design and development stages, b) the review, verification and validation that are appropriate to each design and development stage, and c) the responsibilities and authorities for design and development. Interfaces between different groups involved in design and development are managed to ensure effective communication and clear assignment of responsibility. Planning output is updated, as appropriate, as the design and development progresses. 7.3.1.1 Multidisciplinary approach A multidisciplinary approach (including design, manufacturing, engineering, quality, production, and other appropriate personnel) to prepare for product realization is used, including - development/finalization and monitoring of special characteristics, - development and review of FMEAs, including actions to reduce potential risks, and - development and review of control plans. 7.3.2 Design and development inputs Inputs relating to product and process requirements are defined and recorded. These inputs include a) functional and performance requirements, b) applicable statutory and regulatory requirements, c) information derived from previous similar designs, and d) Special characteristics 7.3.2.1 Product design input Product design input requirements are identified, documented and reviewed including the following: a) customer requirements such as special characteristics identification, traceability and packaging; 18

b) information gained from previous design projects, competitor analysis, supplier feedback, interna l input, field data, and other relevant sources, for current and future projects of a similar nature; c) targets for product quality, life, reliability, durability, maintainability, timing and cost. 7.3.2.2 Manufacturing process design input The manufacturing process design input requirements are identified, documented and reviewed, including a) product design output data, b) targets for productivity, process capability and cost, c) customers requirements, and d) experience from previous developments. e) Error-proofing 7.3.2.3 Special characteristics Special characteristics (either product characteristics or process parameters) are identified and a) included in the control plan, b) comply with customer-specified definitions and symbols, and c) marked on process control documents including drawings, FMEAs, control plans, and operator instructions with the customer's special characteristic symbol or Fairchilds equivalent symbol. 7.3.3 Design and development outputs The outputs of design and development are provided in a form that enables verification against the design and development input. The results of this verification are approved prior to release. Design and development outputs: a) meet the input requirements for design and development, b) provide information for purchasing, production and for service provision, c) contain or reference product acceptance criteria, and d) specify the characteristics of the product that are essential for its safe and proper use. 7.3.3.1 Product design outputs Product design output also includes: a) design FMEA, reliability results, b) product special characteristics and specifications, c) product error-proofing, d) product definition including drawings or mathematically based data, e) product design reviews results, and f) diagnostic guidelines where applicable. 19

7.3.3.2

Manufacturing process design output Manufacturing process design output also includes: a) specifications and drawings, b) manufacturing process flow chart/layout, c) manufacturing process FMEAs, d) control plans e) work instructions, f) process approval acceptance criteria, g) data for quality, reliability, maint ainability and measurability, h) results of error-proofing activities, and i) methods of rapid detection and feedback of product/manufacturing process nonconformities.

7.3.4

Design and development review Throughout the design and development stages, systematic revie ws are performed: a) to evaluate the ability of the results of design and development to meet requirements, and b) to identify any problems and propose necessary actions. Participants in these reviews include representatives from manufacturing, process, design and development, as per APQP phase requirements. Records are kept of the results of the reviews and any necessary actions. 7.3.4.1 Monitoring Measurements (including quality risks, costs, lead-times, critical paths, etc.) at specified stages of design and development are defined, analyzed and reported with summary results as an input to management review.

7.3.5

Design and development verification Design verification is performed to ensure that design-stage outputs meet design inputs. The verification activity is documented and maintained as quality records.

7.3.6

Design and development validation Design validation (characterization and qualification) is performed to ensure that the product conforms to defined customer needs, including customer program timing requirements and is capable of meeting the requirements for the specified application or intended use, where known. Validation is completed prior to the delivery or implementation of the product. Validation results including design failures are recorded. Corrective and preventive action procedures are followed to address these design failures.

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7.3.6.1

Design and development validation Customer Requirements Design and development validation is performed in accordance with customer requirements (as required) including program timing.

7.3.6.2

Prototype program Customer prototype programs are in place for customers that require this service. Prototypes are provided in accordance with FSC policies. When possible, the same subcontractors, tooling, and processes that are used in production will be used for prototypes. All subcontracted services receive technical leadership from Fairchild Semiconductor.

7.3.6.3

Product approval process The Production Part Approval Process (PPAP) is adhered to for those customers that require it. Suppliers are qualified using some of the requirements of the PPAP process as well as some determined by the individual sites. Changes to processes and products are validated through appropriate testing.

7.3.7

Control of design and development changes Design and development changes are identified and records maintained. The changes are reviewed, verified and validated, and approved before implementation. The review of design and development changes includes evaluation of the effect of the changes on constituent parts and product already delivered. Records of the results of the review of changes and any necessary actions are maintained.

7.4 Purchasing
7.4.1 Purchasing process Fairchilds purchasing control systems are used to ensure that the materials and services purchased by Fairchild meet the requirements necessary to support customers quality and environmental expectations. This system relies on the controlled selection and periodic evaluation of suppliers or subcontractors and the clear communication of material quality and service requirements to these suppliers or subcontractors. When there are mergers, acquisitions or affiliations associated with suppliers, Fairchild verifies the continuity of the supplier's quality management system and its effectiveness. 7.4.1.1 Regulatory conformity

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Governmental and safety requirements are always met for purchased materials. As appropriate, this includes all environmental, electrical, and electromagnetic considerations applicable to the country of manufacture and sale. 7.4.1.2 Supplier quality management system development Supplier quality management system development is performed with the goal of supplier conformity with Fairchilds supplier quality system requirements and TS-16949:2002. Conformity with ISO 9001:2000 is the first step in achieving this goal. Unless otherwise specified by our customers, critical direct and indirect raw material suppliers are third party registered to ISO 9001:2000 by an accredited third-party certification body. 7.4.1.3 Customer-approved sources Where specified by the contract (e.g. customer engineering drawing, specification), purchase products, materials or services are purchased from approved sources. 7.4.2 Purchasing information Purchasing documents clearly define requirements for purchased products. Where applicable, this includes: a) The type, class, grade, or other precise identification b) The applicable issues of specifications, drawings, process requirements, inspection instructions, and other relevant technical data, including requirements for approval or qua lification of product, procedures, process equipment, and personnel c) The title, number, and issue of the quality system standard to be applied. 7.4.3 Verification of purchased product Activities necessary for ensuring that purchased product meets specified purchase requirements are established and implemented. If we or our customers intend to perform verification at the supplier's premises, the intended verification arrangements and method of product release are stated in the purchase order. 7.4.3.1 Incoming product quality Fairchild Semiconductor implements processes that ensure the inspection and testing of procured materials and products during manufacture and at final acceptance operations. This results in the use of process-compliant materials

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and on-going verification that manufactured products meet Fairchilds defined internal and external customers expectations. Document procedures with controlled inspection instructions are used to ensure that received materials are not used without being inspected and accepted at incoming inspection to the Quality Plan or documented procedures. Inspection levels are determined based on the presence of applicable supplier process controls as well as the proven ability to comply with specified requirements. Acceptable incoming inspection techniques consist of: a) Receipt and evaluation of statistical data or Statistical Process Control data which conforms to QS Statistical Process Control & Measurement System Analysis methods, b) IQA inspection with sampling based on historical performance. As required, inspection acceptance criteria for attribute data sampling plans is zero defects, c) Independent assessments of suppliers locations, d) Acceptance based on suppliers certification. Certification acceptance is based on the suppliers test results to Fairchild-approved acceptance plans or one of the other methods noted above. Supplier test results as provided by accredited laboratory facilities must be able to provide traceability to NIST or other national standards, e) Part evaluation by a designated laboratory, f) Other method specified and agreed to with our customers 7.4.3.2 Supplier monitoring Supplier performance is monitored through the following: a) delivered product quality; b) customer disruptions including field returns; c) delivery schedule performance (including incidents of premium freight); d) special status customer notifications related to quality or delivery issues.

7.5 Production and service provision

Manufacturing and its support operations define and implement qualification, control, and monitoring systems. This is to ensure that processes are controlled according to clearly documented internal and external guidelines, and results in the manufacture of products that consistently meet the quality and reliability requirements of Fairchild and its customer. Compliance of customers configuration control requirements are also assured. 7.5.1 Control of production and service provision The production operations are designed to ensure that:

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a) information that describes the characteristics of the product or process is defined, b) work instructions are created and available at or near the point of use (electronic or hard copy), c) capable equipment is available for use, d) monitoring and measuring devices are calibrated and used, e) delivery, implementation and post-delivery activities are defined. 7.5.1.1 Control plan Control plans take into account the design FMEA and manufacturing process FMEA outputs and are developed: a) at the process and raw material level, and b) for pre- launch and production. The control plan: a) lists the controls used for manufacturing process control, b) includes methods for monitoring special characteristics defined by both the customer and by Fairchild, c) includes the customer-required information, and d) initiate the specified reaction plan when the process becomes unstable or not statistically capable. Control plans are reviewed and updated when significant change s affecting product, manufacturing process, measurement, logistics, supply sources or FMEA occur. 7.5.1.2 Work instructions Process monitoring and operator instructions are defined. These instructions are accessible at or near the workstations and are created using sources listed in Fairchilds Quality Plans or the Advanced Product Quality Planning and Control Plan reference manual. 7.5.1.3 Verification of job set-ups Job set-ups are verified whenever performed, such as an initial run of a job, material changeover or job change. Work instructions are available for set-up personnel. Statistical methods of verification are used where applicable. 7.5.1.4 Preventive and predictive maintenance Equipment is maintained through a total preventive maintenance system that includes scheduled maintenance activities, packaging and preservation of equipment, use of predictive maintenance methods, availability of replacement parts, and optimization of uptime. 24

Predictive maintenance methods are used to continually improve the effectiveness and the efficiency of production equipment. 7.5.1.5 Management of production tooling

Resources are provided for tool and gauge design, fabrication and verification activities. A system is implemented for production tooling management including: a) maintenance and repair facilities and personnel; b) storage and recovery; c) set-up; d) tool-change programs for perishable tools; e) tool design modification documentation, including engineering change level; f) tool modification and revision to documentation; g) tool identification, defining the status, such as production, repair or disposal. If any work is outsourced, a system to monitor these activities is implemented. 7.5.1.6 Production scheduling Production schedules are designed to meet customer requirements. When just- in-time requirements are required, information systems are implemented that permits access to production information at key stages of the process and is order driven. 7.5.1.7 Feedback of information from service A process for communication of information on service concerns to manufacturing, engineering and design is established. 7.5.1.8 Service agreement with customer Not Applicable

7.5.2

Validation of processes for production and service provision Process parameters and product characteristics are defined, monitored, and controlled. Where results of processes cannot be fully verified by subsequent testing or inspections, continuous process monitoring techniques are used. Actions generated from process control activities are incorporated into FMEAs. Customer requirements regarding documentation and control of special characteristics and access to control plans or corrective actions are implemented.

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Validation is used to demonstrate the ability of these processes to achieve planned results. Arrangements for these processes include, as applicable: a) defined criteria for review and approval of the processes, b) approval of equipment and qualification of personnel, c) use of specific methods and procedures, d) requirements for records, and e) revalidation. 7.5.3 Identification and traceability

Fairchild Semiconductors product is identified throughout the manufacturing, testing, and delivery processes via supporting documentation and via electronic systems. This ensures proper product processing, assurance that customers receive their complete orders, and product traceability to common processes or raw material sources. Documented procedure ensure that products are uniquely identified by product type or batch identifier from the raw silicon wafer state throughout the manufacturing process until delivery of packaged circuits or devices to the customer. Records of the identifier are maintained. Records are available which document the history and traceability of product during all steps of manufacturing, test, and shipment. Products are traceable backward and forward through the process within a timely manner so as to meet customer requirements for traceability data. Identified suspect or non-conforming products are prevented from shipping to customers within the containment timeframe required by the customer. 7.5.4 Customer property Customer owned property is identified, verified, protected and safeguarded when it is provided for or being incorporated into Fairchilds product. If any customer property is lost, damaged or otherwise found to be unsuitable for use, this is reported to the customer and records are maintained. This includes intellectual property and customer-owned returnable packaging. . 7.5.4.1 Customer-owned production tooling Systems to inspect and protect customer supplied materials, tools ,or equipment are implemented. These systems are used when customer-supplied items are included in, or used to, support the manufacture of Fairchilds products for that customer. These systems are to also ensure that the customer is kept informed of the status of these items while they are under Fairchilds control. 7.5.5 26 Preservation of product

Fairchild Semiconductor has processes to protect products during all phases of development, manufacturing, storage, and delivery. These processes ensure that products are readily identifiable, flow in an orderly and controlled manner, are protected from damage or deterioration, and are periodically assessed to ensure their continued viability. 7.5.5.1 Storage and inventory Techniques used to plan and manage inventory so as to optimize inventory turns, assure stock rotation, and minimize inventory levels. These include: a) Assessment of product inventory to prevent deterioration, b) Order-driven, first- in- first-out (FIFO) production scheduling, Obsolete product is controlled in a similar manner to nonconforming product.

7.6 Control of monitoring and measuring devices

Inspection, measuring, and test equipment controls are implemented at Fairchild Semiconductor to ensure that critical metrology equipment and software are compatible to the process control needs of its processes, that they are maintained at the necessary accuracy levels, that they correlate with internal and external measurement standards, and that they are identified as to their performance status at all times. These procedures ensure that process and test results are properly quantified, enabling process controls to be optimized and variations in results to be minimized. These control features also provide a method whereby Fairchild and customers can correlate test and measurement results against common reference standards. Control of Inspection, Test and Measurement Equipment (Calibration) is performed by qualified Fairchild facilities or subcontracted facilities that meet recognized accreditation requirements. Documented procedures outline the methods used to: a) Evaluate test, inspection, and measurement (metrology) tool capability against the accuracy needed to effectively support the process being measured b) Calibrate the metrology equipment against certified standards. Calibration process details include: a. Equipment type, unique identification, and location, b. Frequency of checks, check method, and acceptance criteria, c. The documented basis used for calibration when national or industry standards are not available, d. Maintenance of calibration records. These are to include as received gauge conditions or readings, affirmation of post calibration conformance to required standards, and evidence of customer notification when suspect material may have been shipped, e. The indicator used to identify the metrology equipment status, f. Action to be taken when results are unsatisfactory.

27

c) Assess and document the validity of previous inspection and test results when metrology equipment is found to be out of calibration. As required, customers are notified whenever suspect material has been shipped. d) Maintain specified environmental conditions for any metrology equipment that is undergoing calibration e) Handle, preserve, and store metrology equipment so that the accuracy and fitness for use is maintained f) Verify test software, test hardware, and testing reference devices for acceptability prior to release and again at programmed intervals. g) Safeguard metrology equipment, test hardware, and test software from adjustment which would invalidate the calibration setting .The monitoring and measurement undertaken and the monitoring and measuring devices needed to assure conformity of product to defined requirements are determined. 7.6.1 Measurement system analysis Statistical studies are conducted to analyze the variation present in the results of each type of measuring and test equipment system. This applies to measurement systems referenced in the control plan. The analytical methods and acceptance criteria used conform to the MSA manual produced by AIAG. 7.6.2 Calibration/verification records Records of calibration/verification activity for all gauges, measuring and test equipment, including employee and customer owned equipment include: a) equipment identification, including the measurement standard against which the equipment is calibrated, b) revisions following engineering changes, c) any out-of-specification readings as received for calibration/verification, d) an assessment of the impact of out-of-specification condition, e) statements of conformity to specification after calibration/verification, and f) notification to the customer if suspect product or material has been shipped. 7.6.3 Laboratory requirements 7.6.3.1 Internal laboratory Internal laboratory facilities that perform reliability, qualification or durability testing have a defined scope that includes the capability to perform required inspection, test or calibration services. This laboratory scope is included in the quality management system documentation. The laboratory shall specify and implement technical requirements for: a) adequacy of the laboratory procedures, b) competency of the laboratory personnel, c) testing of the product, d) capability to perform these services correctly, traceable to the relevant process standard (such as ASTM, EN, etc.), and 28

e) review of the related records. 7.6.3.2 External laboratory External / commercial / independent laboratory facilities used for inspection, test or calibration services have a defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and either: a) the laboratory is accredited to ISO/IEC 17025 or national equivalent, or b) evidence is obtained that the external laboratory is acceptable to Fairchild and if required our customer.

29

Measurement, analysis and improvement

8.1 General
Monitoring, measurement, analysis and improvement processes are implemented: a) to demonstrate conformity of the product, b) to ensure conformity of the quality manage ment system, and c) to continually improve the effectiveness of the quality management system. 8.1.1 Identification of statistical tools Fairchild Semiconductor utilizes statistical techniques that are based on valid and generally accepted statistical tools and standards. These techniques ensure that process capability, product performance, and service- level variations are minimized, that the defined characteristics of the products and services of the organization are maintained at required levels, and that products and services meet customers expectations. Documented procedures include: a) Quality planning establishes and documents the statistical process control systems needed to control process capability. As required, APQP methods are used to identify statistical tools and to document them in the applicable processes of the control plans for the product or service. b) Controls to deploy statistical sampling methods and statistical process control systems so that they are used properly and are effectively implemented 8.1.2 Knowledge of basic statistical concepts Site personnel understand the concepts of process capability, control, variation, and over-adjustment.

8.2 Monitoring and measurement

8.2.1 Customer satisfaction Information relating to customer perception as to whether we have met customer requirements is monitored. Each site or business unit determines the methods for obtaining and using this information with consideration given to both internal and external customers. 8.2.1.1 Customer satisfaction Performance Indicators Performance indicators are based on objective data and include: a) delivered part quality performance, b) customer disruptions including field returns, c) delivery schedule performance (including incidents of premium freight),

30

d) customer notifications related to quality or delivery issues, e) related manufacturing performance

8.2.2

Internal audit Internal audits are conducted at planned intervals to determine whether the quality management system a) conforms to the planned arrangements, to the requirements of TS-16949 and to the quality management system requirements, and b) is effectively implemented and maintained. Audit programs are planned, taking into consideration the status and importance of the processes and areas to be audited, as well as the results of previo us audits. The audit criteria, scope, frequency and methods are defined. Selection of auditors and conduct of audits ensures objectivity and impartiality of the audit process. The responsibilities and requirements for planning and conducting audits, and for reporting results and maintaining records are defined in a documented procedure for each site. The management responsible for the area being audited ensures that actions are taken promptly to eliminate detected no nconformities and their causes. Follow-up activities include the verification of the actions taken and the reporting of verification results. 8.2.2.1 Quality management system audit The quality management system is audited to verify compliance with TS16949 and Fairchild Semiconductors quality management system requirements. 8.2.2.2 Manufacturing process audit Manufacturing processes are audited for effectiveness. 8.2.2.3 Product audit Products are audited at appropriate stages of production and delivery to verify conformity to specified requirements. 8.2.2.4 Internal audit plans Internal audits cover quality management related processes, activities and shifts, and are scheduled according to an annual plan. Audit frequency is appropriately adjusted based upon internal/external nonconformities or customer complaints.

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8.2.2.5

Internal auditor qualification Internal auditors are qualified to audit the Fairchild Quality Management System.

8.2.3

Monitoring and measurement of processes Methods for monitoring and measurement to demonstrate the ability of the processes to achieve planned results are defined. When planned results are not achieved, corrective actions are taken to ensure conformity of the product. 8.2.3.1 Monitoring and measurement of manufacturing processes Process studies are performed on all new manufacturing (including assembly or sequencing) processes to verify process capability and to provide input for process control. The results of process studies are documented with specifications as applicable. Manufacturing process capability or performance is maintained as specified by the customer part approval process requirements. Control plans are implemented, including adherence to the specified: a) measurement techniques, b) sampling plans, c) acceptance criteria, and d) reaction plans when acceptance criteria are not met. Significant process events, such as tool change or machine repair, are recorded. A reaction plan is initiated from the control plan for characteristics that are either not statistically capable or are unstable. These reaction plans include containment of product. A corrective action plan is completed indicating specific timing and assigned responsibilities to assure that the process becomes stable and capable. Effective dates of process changes are maintained.

8.2.4

Monitoring and measurement of product Characteristics of the product are monitored and measured in the manufacturing process to verify that product requirements have been met. Evidence of conformity with the acceptance criteria is maintained and, if appropriate, indicating the person(s) authorizing release of product.

32

Product release and service delivery does not proceed until all the planned arrangements have been satisfactorily completed, unless otherwise approved by the customer. When selecting product parameters to monitor, the following are determined: a) the types of measurement, b) suitable measurement means, and c) the capability and skills required. 8.2.4.1 Layout inspection and functional testing A layout inspection and a functional verification to customer engineering material and performance standards is performed for each product as specified in the control plans. Results are available for customer review. 8.2.4.2 Appearance items a) Not applicable for Fairchild Products.

8.3 Control of nonconforming product

Fairchild Semiconductors procedures are used to identify, segregate, evaluate, and dispose of non-conforming and suspect materials or products. These control techniques ensure that problem products are properly evaluated and dispositioned, and that appropriate corrective measures are taken to resolve the product discrepancy. These activities are undertaken to ensure that only compliant products are shipped to customers. Nonconforming product is handled in one or more of the following ways: a) Actions are taken to eliminate the detected nonconformity; b) Use, release or acceptance is authorized under concession by the customer; c) Actions are taken to preclude its original intended use or application. All materials, direct or in-direct, used during the manufacture of Fairchild products must conform to the requir ements of FSC-EHS-0001, Environmental Health and Safety Requirements for Suppliers of Equipment, Materials and Services to Fairchild Semiconductor. Records of nonconformities and any subsequent actions taken, including concessions obtained, are maintained. When nonconforming product is corrected, it is subjected to re-verification to demonstrate conformity to the requirements. When nonconforming product is detected after delivery or use has started, actions are taken to assess and remove the effects of the nonconformity. 8.3.1 Control of nonconforming product Suspect Products

33

Products with unidentified or suspect status are classified as nonconforming product. 8.3.2 Control of reworked product Instructions for rework are defined and accessible to the users. 8.3.3 Customer information Customers are promptly informed in the event that nonconforming product has been shipped. 8.3.4 Customer waiver Customer waivers are obtained prior to further processing whenever product or manufacturing process is different from that whic h is currently approved. Records of waiver expiration dates or quantity authorized are maintained. Materials shipped on an authorization are properly identified on each shipping container. This applies equally to purchased product. Any requests for waivers from suppliers are agreed upon by Fairchild before incorporation into the product.

8.4 Analysis of data

Fairchild determines, collects and analyzes data to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement can be made. The analysis of data provides information relating to: a) Customer satisfaction, b) Conformity to product requirements, c) Characteristics and trends of processes and products including opportunities for preventive action, d) Suppliers. 8.4.1 Analysis and use of data Trends in quality and operational performance are compared with progress toward objectives. This leads to actions to support the following: a) development of priorities for prompt solutions to customer-related problems; b) determination of key customer-related trends ; c) the timely reporting of product information arising from usage. NOTE: As available, data should be compared with those of competitors and/or appropriate benchmarks.

8.5 Improvement
34

8.5.1

Continual improvement Fairchild continually improves the effectiveness of the quality management system through the use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive actions and management review. 8.5.1.1 Manufacturing process improvement Manufacturing process improvement focuses upon control and reduction of variation in product characteristics and manufacturing process parameters. NOTES: 1. Controlled characteristics are documented in the control plan. 2. Continual improvement is implemented once manufacturing processes are capable and stable, or product characteristics are predictable and meet customer requirements.

8.5.2

Corrective action Fairchild takes actions to eliminate the cause of nonconformities in order to prevent recurrence. Documented procedures are established to define requirements for a) reviewing nonconformities (including customer complaints), b) determining the causes of nonconformities, c) evaluating the need for action to ensure that nonconformities do no t recur, d) determining and implementing action needed, e) records of the results of action taken and f) reviewing corrective action taken. 8.5.2.1 Problem solving A process for problem solving leading to root cause identification and elimination is designed. 8.5.2.2 Error-proofing Error-proofing methods are considered and used in the corrective action process. 8.5.2.3 Corrective action impact Corrective actions are applied to other similar processes and products to eliminate the cause of nonconformity. 8.5.2.4 Rejected product test/analysis

35

Fairchild analyzes parts rejected by the customers using our PQA and Failure Analysis systems. Records of these analyzes are kept and made available upon request. Analysis is performed and corrective actions are initiated to prevent recurrenc e. Cycle time related to rejected product analysis is consistent with the determination of root cause, corrective action and monitoring the effectiveness of implementation. 8.5.3 Preventive action Actions are determined to eliminate the causes of potential no nconformities in order to prevent their occurrence. Documented procedures are established to define requirements for a) determining potential nonconformities and their causes, b) evaluating the need for action to prevent occurrence of nonconformities, c) determining and implementing action needed, d) records of results of action taken, and e) reviewing preventive action taken.

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Table 1

Important Quality Management System Specifications - Corporate

System Change Notification Quality Goals & Objectives Document Control Supplier Assessment Customer Returns Drawing Review Prod Id Reliability Reliability Monitor Traceability Foundry

Spec. No. FSC-ADM-0005

Spec. Title Fairchild Semiconductor Product/Process Change Notification (PCN) Fairchild Semiconductor Forecast Procedure Corporate Document Control Procedure Supplier Assessment and Policy Procedure Process Requirements for Customer Returns Customer Drawing Review Process Special Product Identification General Reliability Requirements Reliability Monitor Program Lot Traceability Wafer Subcontractor Qualification and Quality Monitor Subcontractor Quality Management Policy Customer Feedback Process APQP for PKG Engineering Subcontractor Assessment Policy and Procedure Planning, developing, qualifying new silicon process

FSC-ADM-0014

FSC-DOC-0001 FSC-QAR-0001 FSC-QAR-0002 FSC-QAR-0003 FSC-QAR-0004 FSC-QAR-0006 FSC-QAR-0007 FSC-QAR-0008 FSC-QAR-0009 FSC-QAR-0010

Customer Feedback APQP-PKG Subcon New Process Technology Phase Review System

FSC-QAR-0011 FSC-QAR-0013 FSC-QAR-0014 FSC-TECH-0001

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Glossary
Accreditation Body An organization with authority, typically from the national government, to accredit bodies (such as certification bodies/registrars for quality system certification, test laboratories, etc.) Accredited Laboratory A laboratory that has been reviewed and approved by a nationally recognized accreditation body. ANSI American National Standards Institute APQP, a.k.a., Advanced Product Quality Planning and Control Plan (Ref: Advanced Product Quality Planning and Control Plan Reference Manual) A structured method of defining and establishing the steps that are necessary to assure that a product satisfies the customer. ASN Advance shipment notific ation ASQC American Society for Quality Control Assessment An evaluation process that includes a review of documents, an on-site audit, an analysis of the process or product, and a report. Benchmarking A technique used to determine best practices for a particular system, process, or product. Calibration An operation which compares values taken from inspection, measuring, and test equipment with a known standard under specified conditions. Capability Capability is the total range of inherent variation in a stable process. Control document A document that is generated, approved, distributed, and obsoleted to prescribed controlling guidelines. Control plans Written descriptions of the systems for controlling parts and processes that address the important characteristics and engineering requirements of the product. Control systems The organized operational techniques and activities implemented by an organization in order to fulfill requirements for quality. Cost of quality The costs associated with the production of non-conforming material. Includes the sum of the cost of prevention, inspection, and failure. CP The capability index for a stable process, typically defined as: [the upper engineering specification limit minus (-) the lower engineering specification limit] divided by (/) [six times (x) the estimate of the standard deviation of a stable process using the average range of subgrouped samples taken fro the process]

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CPK The capability index for a stable process, typically defined as the minimum of CPU (upper capability index) or CPL (lower capability index). CPL The lower capability index, typically defined as: [the average of subgroup averages minus (-) the lower engineering specification limit] divided by (/) [three times (x) the estimate of the standard deviation of a stable process using the average range of subgrouped samples taken from the process]

CPU The upper capability index, typically defined as: [the upper engineering specific ation limit minus (-) the average of subgroup averages] divided by (/) [three times (x) the estimate of the standard deviation of a stable process using the average range of subgrouped samples taken from the process]

Customer satisfaction Occurs when the products that are received meet the customers expectation. Design for Manufacturing A simultaneous engineering process designed to optimize the relationship between design function, manufacturability, and ease of assembly. Design of Experime nt A formal programmed experimental technique used to manipulate process inputs in order to better understand their effects on process output. DFMEA, a.k.a, Design Failure Mode & Effects Analysis (Ref: Advanced Product Quality Planning and Control Plan Reference Manual) An analytical technique used by a design responsible engineer/team as a means to assure that potential failure modes and their associated causes/mechanisms have been considered and addressed. Engineering Approved Product Authorization Written customer authorization required whenever the product or process varies from those currently approved by the customer. External audits An on-site verification activity based upon a sample used to determine the effective implementation of a suppliers documented quality system as performed by an independent organization, either a customer or a quality systems certification body/registrar. FMEA, a.k.a, Failure Mode & Effects Analysis A systematized group of activities intended to: 1. Recognize and evaluate the potential failure of a product/process and its effects

39

2.

Identify actions which could eliminate or reduce the chance of the potential failure occurring 3. Document the process

Functional Verification Testing to ensure the product conforms to all customer and supplier engineering performance and material requirements. Instructions (Job) Formal written procedures that describe the methods that must be followed by one specific function of an organization. Internal audits An on-site verification activity based upon a sample used to determine the effective implementation of a suppliers documented quality system as performed by the supplier on itself. IQA Incoming Quality Assurance ISO-9000 Quality Management and Quality Assurance Standards/Guidelines for Selection and Use The international standard which provides guidance for the selection and use of the ISO 9000 family of International Standards for quality management and quality assurance. Laboratory A test facility that validates chemical, metallurgical, dimensional, physical, electrical, or reliability properties. Laboratory Scope A quality record that contains the following for any laboratory: 1. The specific tests, evaluations, and calibrations performed by a laboratory 2. A listing of the equipment used by a laboratory to perform validation testing 3. A list of the test methods and standards used to perform validation testing Layout Inspection The complete measurement of all part dimensions shown on the design record for a product. Maverick lot A lot whose parameters fall outside of the normal distribution, but remain within the specification limits. MIL-STD-883 Military Standard/Test Methods and Procedures for Microelectronics The military standard that establishes uniform methods, controls, and procedures for designing, testing, identifying, and certifying microelectronic devices for use within Military and Aerospace electronic systems. Mistake Proofing Use of design or process features to prevent the manufacture of non-conforming product. Multi-Disciplinary Approach A formal process that involves all of the various knowledgeable functions in the decision making necessary to complete an activity. NIST National Institute of Standards Technology OEE, a.k.a., Overall Equipment Effectiveness A measurement of equipment utilization effectiveness based on the product of three measurements: Availability x Performance Efficiency x Yield

40

Where availability is the percentage of time the machinery is available, Performance Efficiency is how fast the machinery or equipment is running relative to its design cycle, and Yield is the percentage of the resulting product within quality specifications. Organizational interfaces The inter-relationships and communication processes that exist between the various functions of an organization as a result of performing business activities associated with the design, manufacture, test, and delivery of products and services. PPAP, a.k.a, Production Part Approval Process The process used to: 1. Justify that customer engineering design records and specification requirements are properly understood by the supplier 2. To ensure that the process has the potential to produce products meeting these requirements during an actual production run at the quoted production rate. PPK, a.k.a., Preliminary Process Capability The performance index, typically defined as the minimum of: [the upper engineering specification limit minus (-) the average of subgroup averages] divided by (/) [three times (x) the estimate of the standard deviation of a process using the sample standard deviation of a set of individuals about the average of the set]

or [the average of subgroup averages minus (-) the lower engineering specification limit] divided by (/) [three times (x) the estimate of the standard deviation of a process using the sample standard deviation of a set of individuals about the average of the set]

PPM, a.k.a., Parts per million Numerical method used to state the performance of a process in terms of actual non-conforming material. Preliminary Process Capability Studies Short-term studies conducted to obtain early information on the performance of new or revised processes relative to internal or customer requirements. Preventive Action Action that is taken based on analysis of on-going performance to eliminate the cause of potential non-conformity or undesirable situations. Problem Solving A formal disciplined process to analyze problems so as to determine and eliminate root causes. Procedures Formal written procedures that describe the methods that must be followed by more than one specific function of an organization.

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Process capability The total range of inherent variation in a stable process. QS-9000 The fundamental quality system expectations of Chrysler, Ford, General Motors, Truck Manufacturers, and other subscribing companies for internal and external suppliers of production and service parts and materials. Quality Function Deployment (QFD) Structured method by which customer requirements are translated into technical and procedural requirements for each stage of product development and production. Quality Manual A supplier document that describes the elements of the quality system that is used to assure customer requirements, needs, and expectations. Quality metrics The indicators that are used to measure the product and service performance of an organization. Quality plan A document that sets out the specific quality practices, resources, and sequence of activities that are relevant to a particular process or product. Quality planning A formal structured process for defining the methods (i.e., measurements, tests, etc.) that will be used in the production of a product or family of products. Quality records The documented evidence that the supplier's processes were executed according to the prescribed quality system procedures and instructions. Quality systems The organizational structures, resources, processes, and procedures needed to design, manufacture, and deliver products and services that meet stated or implied customer requirements. Reaction plan The action specified by a control plan or other quality system documentation when a nonconformity or process instability is identified. Registered supplier or subcontractor A supplier or subcontractor which has received third (3rd) party registration or certification to a specific quality system standard. Repair Remedial action taken on non-conforming product so that the product fulfills intended usage but may not conform to the original requirements. Rework Remedial action taken on non-conforming product so that it meet the specified requirements. Set-up verification A method for gauging production run capability as measured by SPC performance using the following guidelines: Production runs are initiated only when the results fall within the central third of the control limit zone Simulation Techniques A practice of mimicking the behavior of one system with a different, dissimilar system. SPC, a.k.a., Statistical Process Control The use of statistical techniques (such as control charts) to analyze a process or its outputs so as to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capability. Theory of Constraints A manufacturing analysis process that focuses on continuous improvement by identifying and addressing anything that limits performance to a stated goal or objective.

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Validation Confirmation by examination and objective evidence that the requirement for a specific intended use has been fulfilled. Value analysis The method used for analyzing a product or process in order to eliminate non-essential functions and thereby reduce overall cost. Verification Confirmation by examination and objective evidence that the specified requirement has been fulfilled. WIP, a.k.a., Work in Process Product which is in the process of being manufactured and/or tested.

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Appendix A

Markets

Customer

Forums: Technology, Quality, HR / Mgmt, Finance

FAIRCHILD QUALITY SYSTEM

Manufacturing Development

Management Responsibility

Demand Creation/ Business Process

Resource Management

Measurement, Analysis, and Improvement

Sales Support

Product Realization

Competitors
HR Management Purchasing

Suppliers, Subcons, Foundries 1

Demand Creation/ Business Process

MISSION
Market Needs

STRATEGIC IMPERATIVES

STRATEGIC BUSINESS PLAN

ANNUAL OPERATING PLAN

QBR / IBR REVIEW

Quarterly Strategy Review

QUARTERLY FINANCIAL FORECAST

Business Unit Operations Review

Plans and Goals

Development
SBP Plan Tech Exists? No Tech Dev (Process / Package) Yes Release to Mfg

Products Product Dev Release to Mfg

Manufacturing
Orders Availability Mfg Plan

Raw Materials Purchase Order

Suppliers

Fab

Assembly

Warehouse

Deliveries

Sales Support
Customer Complaint Root Cause Analysis Define Corrective Action Implement Actions

Customer Customer Survey

Analyze Results

Define Action

Implement Actions

Human Resource Mgmt

AOP Hire Train Competency and Empowerment

Performance Review Motivated Employees

Compensation & Awards

Purchasing
Need Identified Approved Vendor Required? Purchase Order

No

Purchase

Yes

Approved Vendor Available? No

Yes

Qualify Vendor

NOTES