3d plus quality handbook3dpq-0340-2 3d plus quality hanbook - 2016 page 5/26 for the improvement of...

3DPQ-0340-1 3D PLUS Quality Hanbook - 2016 /26

3D PLUS QUALITY

HANDBOOK


TABLE OF CONTENT 1. QUALITY POLICY AND GENERAL INFORMATION .................................................................................................... 4

1.1. 3D PLUS Quality Policy ........................................................................................................................ 4 1.2. Core Business ....................................................................................................................................... 5 1.3. Creation of products of very high reliability ...................................................................................... 5 1.4. Corporate Strategy ................................................................................................................................ 5 1.5. Space Flight Heritage............................................................................................................................ 5

2. CONTINUOUS QUALITY IMPROVEMENT OVERVIEW ............................................................................................... 6 2.1. 3D PLUS’s Quest for Continuous Improvement ................................................................................ 6 2.2. Continuous Improvement ..................................................................................................................... 8 2.3. Quality organization .............................................................................................................................. 8 2.4. External Certifications .......................................................................................................................... 8 2.5. Employee Training and Skill Development ........................................................................................ 8 2.6. Quality Improvement Plan .................................................................................................................... 9

3. CUSTOMER SATISFACTION PLAN ...................................................................................................................... 10 3.1. 3D PLUS Strategy to achieve Customer Satisfaction ...................................................................... 10 3.2. Customer Feedback ............................................................................................................................ 10 3.3. Survey .................................................................................................................................................. 10 3.4. Buisiness Review ................................................................................................................................ 10 3.5. Field Quality Organization .................................................................................................................. 10 3.6. Customer Specification Review Process ......................................................................................... 10 3.7. Customer Order acknowledgment .................................................................................................... 10 3.8. Returned MAterial Acceptance (RMA) .............................................................................................. 11 3.9. Failure Analysis Process .................................................................................................................... 11 3.10. Product Change Notice (PCN) ........................................................................................................... 11 3.11. 3D PLUS Quality and Reliability Web Site ........................................................................................ 12

4. QUALITY BUSINESS SYSTEM ............................................................................................................................ 13 4.1. Quality Business System Model ........................................................................................................ 13 4.2. Quality System basic Flow Chart for SiP .......................................................................................... 13

4.2.1. Product definition ........................................................................................................................... 13 4.2.2. Design and Development .............................................................................................................. 13 4.2.3. Assembly ....................................................................................................................................... 13 4.2.4. Electrical Test ................................................................................................................................ 13 4.2.5. QA Control ..................................................................................................................................... 13 4.2.6. Pack and Ship ............................................................................................................................... 13 4.2.7. Customer ....................................................................................................................................... 13

4.3. Quality Control & Statiscal Process Control (SPC) ......................................................................... 14 4.4. Product Traceability System .............................................................................................................. 14 4.5. Supplier Selection, Monitoring and Control ..................................................................................... 14 4.6. Document Control System ................................................................................................................. 15 4.7. Audit and Review System .................................................................................................................. 15

5. NEW PRODUCT DEVELOPMENT AND INTRODUCTION .......................................................................................... 16 5.1. Overview .............................................................................................................................................. 16 5.2. Major Milestones and Criteria ............................................................................................................ 16

6. RELIABILITY QUALIFICATION AND MONITORING .................................................................................................. 16 6.1. Overview and Philosophy .................................................................................................................. 16 6.2. Highly Accelerated Stress Test (HAST) ............................................................................................ 17 6.3. 3D PLUS Products Reliability ............................................................................................................ 17 6.4. Reliability Qualification Methodology ............................................................................................... 17 6.5. Data Retention Bake (DRB) ................................................................................................................ 20 6.6. Electrostatic Discharge (ESD) ........................................................................................................... 20 6.7. Life Test ................................................................................................................................................ 20 6.8. Temperature Cycle (TC) ...................................................................................................................... 20 6.9. Reliability Modeling............................................................................................................................. 20 6.10. Failure Rate .......................................................................................................................................... 20 6.11. Reliability Monitoring .......................................................................................................................... 20 6.12. Radiation .............................................................................................................................................. 21 6.13. Failure Analysis and Corrective Actions .......................................................................................... 21 6.14. Reliability targets ................................................................................................................................ 21

7. SUBCONTRACTOR MONITORING AND CONTROL ................................................................................................. 22 7.1. Overview .............................................................................................................................................. 22 7.2. Subcontractor Control ........................................................................................................................ 22


7.3. Subcontractor Performance tracking................................................................................................ 22 7.4. Rating ................................................................................................................................................... 23 7.5. Rating formula ..................................................................................................................................... 23

8. QUALITY ASSURANCE MONITORING .................................................................................................................. 24 8.1. In Line Quality Assurance .................................................................................................................. 24 8.2. Quality Assurance Inspection ............................................................................................................ 24 8.3. Shipping Quality Inspection ............................................................................................................... 24

9. GLOBAL QUALITY POLICIES .............................................................................................................................. 25 9.1. Quality Manual ..................................................................................................................................... 25 9.2. Reliability Qualification Methodology ............................................................................................... 25 9.3. Reliability Monitoring .......................................................................................................................... 25 9.4. Radiation .............................................................................................................................................. 25 9.5. Return Material Acceptance (RMA) ................................................................................................... 25 9.6. Failure Analysis, Non Conformance Report (8D) ............................................................................. 25 9.7. Product Change Notice and End of Life Policy ............................................................................... 26 9.8. Date Code ............................................................................................................................................. 26 9.9. Part Number Decoder ......................................................................................................................... 26 9.10. Customer Documentation Review ..................................................................................................... 26

TABLES AND FIGURES

Figure 1: 3D PLUS 2016 Quality Organization ........................................................................................ 8 Figure 2: System Quality Control ........................................................................................................... 15 Figure 3: bathtub curve .......................................................................................................................... 16


1. QUALITY POLICY AND GENERAL

INFORMATION

1.1. 3D PLUS QUALITY POLICY

3D PLUS is a company, specialized in micro-electronics, using an innovative technology for the implementation of miniaturized products with components designed, manufactured and marketed by it. Its specificity is based on the interconnection of electronic components in three dimensions.

3D PLUS is providing a competitive advantage to its customers through timely, innovative, and defect-free products with outstanding service and specific customer support organization with systematic continuous improvement.

The strong involvement of the personnel working in the Aerospace field since the creation of the company has leaded to achieve such a high level of quality that our technology was qualified in 2004 by both French and European Space agencies. This is why, in relying on our history, our dual objective is, on one hand, to have a very strong growth leading to positive results and, on the other hand, to conduct and improve Quality procedures according to our essential values:

THE DEVELOPMENT OF INNOVATIVE PRODUCTS 3D PLUS has to develop its catalog of high-technology and high value-added products to insure its growth. To do it, 3D PLUS wishes to preserve its leadership and still be a main actor in the field of interconnection and packaging of components. That is why, the Direction incites the entire staff to get involved in the innovation to position better with regard to the competition. Our objective is to place on the market a new product a month.

LISTENS ACTIVELY TO CLIENTS Every 3D PLUS employee in direct relationship with customers should focus on the following:

Knowledge of customer expectations and needs,

Customer satisfaction in terms of follow-up, services and relationships,

Penetration of new fields, different from our existing space markets. This focus will provide values created for new activities to be added on those of our present markets. Attentive communication with our customers, linked to substantial efforts of industrialization, should allow us to increase our order entry by 15% each year.

THE REALIZATION OF PRODUCTS OF VERY HIGH RELIABILITY The Quality Product approach implemented since the founding of 3D PLUS in October 1995 has given the company a very high reliability reputation, which has to be maintained and further developed. The whole manufacturing process of products, since the design until the tests, must therefore meet the following objectives:

Compliance to PID "Process Identification Document" for space business,

Conformity of the products to customer demands,

Commitment for announced deadlines,

Optimization of purchase order process,

Total control of Design and Manufacturing processes,

Control of the selected suppliers. The company wishes that the Management System of the Quality based on the standard ISO 9001 stays a real corporate development plan. It makes a commitment to supply the resources necessary


for the improvement of the Management System of the Quality and asks to the entire staff to participate in its evolution towards the version 2015.

1.2. CORE BUSINESS Developer of advanced high density 3D package and die stacking technology Designer of Analog and Digital Space Radiation Hardened electronics Manufacturer of 3D standard products and System in Package for high reliability and high performance product applications

1.3. CREATION OF PRODUCTS OF VERY HIGH RELIABILITY The Quality Product approach implemented since the founding of 3D PLUS in October 1995 has given the company a very high reliability reputation, which has to be maintained and furthermore developed. The whole process and product manufacturing, from design to testing, must therefore meet the following objectives:

Compliance to ESA approved PID "Process Identification Document" for space business,

Conformity of products to customer request,

Commitment to lead time

Optimization of purchase order process

Total control of Design and Manufacturing processes

Master selected suppliers The company wishes that the Quality Management System based on the ISO 9001: 2008 requirements to remain a true company project and commits itself to supply the necessary resources to improve the Quality System, meaning all employees must be involved in this approach.

1.4. CORPORATE STRATEGY A key element of our business strategy includes innovation for our customers, introducing added value components to our portfolio, in order help Space and Industrial community to reach ambitious targets such as increase performances, Zero Defects, Cost improvement and lead time cut. The future is definitely going to a world that changes very fast, with optimized solution.

1.5. SPACE FLIGHT HERITAGE 3D PLUS has a very large Proven Track Record of supplying Space Qualified and Radiation Tolerant modules:

More than 20 years of involvement in Space projects,

More than 12 years, ESA approved manufacturing line for 3D PLUS Hi Rel products,

More than 100.000 products in orbit beginning of 2016,

Products launched in Space every month worldwide,

Flight proven with no failure for more than 18 years. 3D PLUS Flight Heritage on all the Space Market segments and for all types of equipment is very well established and recognized worldwide by our customers.


2. CONTINUOUS QUALITY IMPROVEMENT

OVERVIEW From the early stages in 1995, 3D PLUS’s philosophy of continuous improvement has ensured that our customers receive products with not only the highest levels of quality and reliability, but that every group within the company operates with the same customer expectations in mind. 3D PLUS’s improvement process consists of mid-term programs that require employee involvement at all levels and strong knowledge in testing activity.

2.1. 3D PLUS’S QUEST FOR CONTINUOUS IMPROVEMENT 2016

More than 100.000 modules in Space with no failure

New certication targeted

JPL award for best customer support

Automatic bonding capability

Employees: 170

2015

ESA approved PID rev10 achieved

ISO: 9001 renewal

New building laying of the first stone ceremony,

Mc Kinney, Texas office moved to Fremont, California.

Employees: 150 2013 - 2014

New Horizons & Rosetta success after a 10 years flight in deep space demonstrates 3D PLUS products and technology reliability.

ESA approved PID rev9 achieved

Interface and Peripherals activity boosted

Digital development capability introduced (first 3D PLUS ASIC)

Introduction of new tray designed by 3D PLUS for small quantity needs

Develop and promote Customer trainings

Employees: 130 2012

Curiosity with on board 3D PLUS memory modules, computers and micro cameras lands on Mars

ISO: 9001 renewal

With more than 55 000 modules in Space, and with more than 13 years of Flight Heritage with no Failure, 3D Plus is recognized as the largest Space qualified catalog products and custom System-In-Packages (SiPs) manufacturer in Europe.

8D problem solving methodology deploiement

Reinforce Customer QA support

Employees: 115 2011

ESA approved PID rev8 including building change achieved

New Building (Headquarter & Factory) opening

3D PLUS USA Fremont, CA Technical center and Headquarter creation

3D PLUS joined the Electronic Technology Group of the HEICO Corporation (NYSE:HEI.A and HEI).

2010

Production Management change

3D PLUS launched its LVDS interfaces product line for Space applications.

Employees: 83


2009

3D PLUS released the first Rad Hard, SEL/SET Immune POL Converter for Space Applications.

2008

3D PLUS set up an adaptable and cost-optimized supply chain in Asia for industrial product line.

2005

3D PLUS received in January 2005 ESA certification for its manufacturing line at Buc. With first release of the 3D PLUS Process Identification Document PID 3300-0549-4.

2004

3D PLUS launched the Radiation Tolerant and Intelligent Memory Stack “RTIMS” product line for Space applications with NASA

2003

ISO9001 certification for 3D PLUS and 3D PLUS USA 2002

3D PLUS created the Wafer level stacking technology with the development of its WDoD™ process

2001

3D PLUS set up a Marketing and Sales Office for North America in Mc Kinney, Texas, USA. 2000

First space qualified products from 3D PLUS launched with European Space Agency missions.

1998

First Reliability databook

1997

3D PLUS set up its High Rel. manufacturing line


2.2. CONTINUOUS IMPROVEMENT 3D PLUS Continuous Improvement program are driven by following major areas:

Speed up the New Products Development & their Market Introduction.

Improve Anticipation / Planification of the activities to identify in advance bottlenecks and to propose accurate action plans.

And of course – It is the basis of 3D PLUS growth:

Focus on Individual values & Communication.

Improve Products Reliability & Robustness Throughout this handbook, each of these four major areas will be covered in more detail.

2.3. QUALITY ORGANIZATION 3D PLUS’s Quality and Reliability Organization is the executive arm of the quality for the entire compagny. It is responsible for ensuring that 3D PLUS has the most competitive systems, processes, and programs in place to drive the strategic quality improvement goals. It maintains, analyzes, and reports all internal and external quality and reliability data. As the customer advocate, it also has the overall responsibility for 3D PLUS’s Customer Satisfaction Plan, which includes scorecard and customer survey management. 3D PLUS’s Global Quality and Reliability structure is outlined in Figure 1. The Global Quality and Reliability Team are all together in the same room to exchange on daily basis to develop major goals, initiatives, and programs based on internal and external data. Quality metric goals have owners that are responsible for measuring, analyzing and driving improvements toward defined targets. These goals and initiatives are closely monitored and shared with all levels of the organization.

Figure 1: 3D PLUS 2016 Quality Organization

2.4. EXTERNAL CERTIFICATIONS Certification to external standards is one example of how 3D PLUS strives to meet the needs of its worldwide customers. 3D PLUS Heaquarter factory, Technical Center and Sales sites, as well as our major subcontractors, are certified to prestigious internationally recognized quality standards. 3D PLUS has continued its Quality excellence path by successful periodic renewal audits performed by third-party LRQA. On site twice a year LRQA monitor the 3D PLUS growth and ensure strong application of ISO9001 standard. All of 3D PLUS’s current registration certificates can be downloaded from our web site (http://www.3d-plus.com/certificates.php,).

2.5. EMPLOYEE TRAINING AND SKILL DEVELOPMENT Achieving our strategic objectives, 3D PLUS requires that we not only focus on continuous improvement of systems, equipment, and processes, but most importantly on continuously improving the knowledge base and degree level of our employees. 3D PLUS emphasizes the importance of the training and re-training of our personnel at all levels of the organization to maintain a total quality culture and ensure that we stay competitive in our marketplace. 3D PLUS have its own master trainer for manufacturing area. His role is to maintain employees to right level of performance and quality. 3D PLUS implemented years ago a control of acknowledgement for

Quality Director

Products Quality Assurance

Supplier Quality System Quality Customer Quality Final Control

http://www.3d-plus.com/certificates.php


training right after the training, followed by a control of acknowledgement 6 month after, still in the aim to maintain people confident on what they are doing on daily basis. All groups have their competence matrix defining for each task whom is qualified for what. The matrix is also usefull to manage internal back up, in case of someone is away for a while. In a yearly basis Human Ressources is editing a training plan for trainings that needs to be founded by 3D PLUS, according to the individual annual interview and budget defined by the President.

2.6. QUALITY IMPROVEMENT PLAN

Identification of Key Improvement Programs 3D PLUS has developed a systematic quest through ADELES program for improvement opportunities. These are derived from various inputs including:

Yearly Customer Satisfaction Surveys

Routine Customer Feedback

Customer visits and audits

Community need

Key Initiatives From all derived actions, the following initiatives are of the highest priority and are sponsored by 3D PLUS’s committee management. Progress is reviewed on a periodic basis. Listed are some of the initiatives that have been implemented since 2011.

Manufacturing Initiative: In Source plating activity to secure a key process in 3D PLUS technology

Manufacturing Initiative: Implement 5S best practices across all 3D PLUS groups,

Manufacturing Initiative: Double Curing capacity in clean room ISO7,

New projects Initiative: Implement Clean room ISO5,

Management initiative: Implement automatic wire bonding activity,

Testing initiative: Implement Hoshin best practices within the group,

Design Center: In Source testing activity, to get better knowledge of our screenings and to achieve better testing coverage with regards to components capacity,

Sales initiative: Hire digital designers, and create added value 3D PLUS products such as peripherals, interfaces and System in Packages,

Management initiative: Launch a building extension, to support 3D PLUS growth

Management initiative: Develop build in ERP database, with dedicated resources,

IT initiative: Secure data, backup plan, and limit access to right furniture and people,

Conterfeit program.

Quality Monitoring The efficiency of the overall system is continuously monitored by a set of quality controls. Each controls are deployed within the organization and mastered by Quality. 3D PLUS is going to launch a remote Statistical Process Control (SPC) projects.


3. CUSTOMER SATISFACTION PLAN

3.1. 3D PLUS STRATEGY TO ACHIEVE CUSTOMER SATISFACTION Since the creation in 1995, 3D PLUS has prided itself on providing outstanding service to its customers. All teams in direct connections with customers have always been listening customers and supporting them from the design to the after market sales. 3D PLUS is worldwide recognized for its outstanding customer service and has historically been many times congratulated from its major customers, through customer survey or meetings, for its excellence in customer support.

3.2. CUSTOMER FEEDBACK 3D PLUS relies heavily on formal feedback from its customers to identify opportunities for continuous improvement. This feedback is usually received through periodic scorecards from key customers who provide useful information about our performance in areas most important to them. Typically, this criteria includes Logistics, Commercial, Technical, Customer Support, and Quality performance. This process has resulted in several continuous improvement initiatives at 3D PLUS.

3.3. SURVEY 3D PLUS has complemented the results obtained via scorecards with 1 annual customer satisfaction survey process with our Sales Representatives during our yearly Sales Meeting. 3D PLUS is going to conduct same type of survey with direct customer contact from its web site.

3.4. BUISINESS REVIEW 3D PLUS promotes regular business reviews leaded by its Sales Manager Area with its major accounts, as a formal forum for feedback in various business aspects including product and technology strategy, logistics, systems, and quality.

3.5. FIELD QUALITY ORGANIZATION 3D PLUS has appointed field quality support personnel in North America based in Fremont California, in China, Russia and Japan with our Sales representatives organization, field application support is in place , elsewhere and as backup of Sales representatives. Product Managers are in charge of technical customer support in addition to project managers and Quality when necessary.

3.6. CUSTOMER SPECIFICATION REVIEW PROCESS 3D PLUS has a system for the formal review of all customer documents specifications and information requests. These requests are generally submitted through your 3D PLUS Sales Representatives or 3D PLUS Sales Managers. The response will be prepared by Sales Managers linked with product managers and project managers. All in coordination with experts like process engineering, design center, business planning, manufacturing and quality. Any exceptions to customer requirements are negotiated with and approved by the customer before an order can be placed.

3.7. CUSTOMER ORDER ACKNOWLEDGMENT 3D PLUS has a project management system established. A formal review for every purchase order is taking place prior any activity can be launched. This formal meeting called “contract review” is leaded by Sales representatives, with project managers, quality, test representatives, manufacturing and procurement. They all verify compliance of customer purchase order with 3D PLUS feasibility in terms of quantity, quality and delivery date.


In all cases Sales representatives gives feedback to customer by the return of Acknowledgement form, confirming prices and delivery time.

3.8. RETURNED MATERIAL ACCEPTANCE (RMA) 3D PLUS strives to supply defect-free products with the highest levels of quality and reliability. Should a product not operate according to the customer expectations in their systems, investigation and analysis is handled by our Failure Analysis (3.9) and Returned Material Acceptance (RMA) system. 3D PLUS field sales and applications groups work closely with the customer to determine the root cause of failures. However, if further analysis is required, the 3D PLUS Quality group procedure should be used and the suspect parts to be analyzed are returned to 3D PLUS factory. We ask our customers to provide detailed information on any product returned for analysis in order to ease the fastest response and closure. 3D PLUS places top priority on providing quick containment and quick initial feedback (24hours) to our customers. A specific process to return materials already delivered to customers is in place at 3D PLUS. Return Material Acceptance can be authorized in different cases:

Need options to finish products like tinning, varnish, …

Need 3D PLUS support for on going customer activities,

Need 3D PLUS investigate conformity of products (Failure analysis). Depending the case, 3D PLUS will issue a RMA, to authorized customer return to 3D PLUS and ensure good traceability of customer product property. For some countries with the military grade -55°C or +125°C products will have to go through customs with a specific procedure. In this case directions will be transmitted by 3D PLUS to customer prior return.

3.9. FAILURE ANALYSIS PROCESS When customer ship us back products with authorized RMA for Failure analysis purpose, 3D PLUS will open a Non Conformance Report with a chronologic number. 3D PLUS will conduct the necessary actions to complete properly the failure analysis with the 8D problem solving methodology, and issue a failure analysis report with a statement of either customer responsibility or 3D PLUS responsibility. 3D PLUS will ask customer agreement prior any destructive analysis activity. In all cases 3D PLUS responsibility will conduct to internal corrective actions to eradicate the concern. In some cases 3D PLUS may alert other customers about the concern.

3.10. PRODUCT CHANGE NOTICE (PCN) 3D PLUS relies heavily on continuous improvements to enhance our products. In our fast moving technology, 3D PLUS must also stay competitive. These factors result in changes to our products after they are released for mass production. 3D PLUS has a comprehensive system to manage such changes including inventory management and customer notification when required. Customers are notified through a change notice prior to the implementation of a major change available in our web site. In some cases, change notices will result in product obsolescence. In these instances, specific details on the last time buy (LTB) date, last time ship (LTS), and replacement part information will be widely distributed through our Sales and Marketing group including worldwide Sales representatives. The 3D PLUS Web Site includes a PCN query screen that allows customers to easily search our database: 3D-plus.com/Support/Technical Support Center/Documentation/PCN.


3.11. 3D PLUS QUALITY AND RELIABILITY WEB SITE 3D PLUS has made a strong effort to utilize our web site as the primary vehicle for quality and reliability data dissemination. It is our intent to continuously improve and enhance the site so that customers can have immediate access to all relevant quality and reliability information. Items that are available at: 3D-plus.com/Support/… And it is including information such as:

Quality Handbook

Environmental Information

Certificates

Assembly recommendations

Traceability informations

Quality inquiry

RMA request form

FA request Information

FAQ Response Summary


4. QUALITY BUSINESS SYSTEM

4.1. QUALITY BUSINESS SYSTEM MODEL 3D PLUS core business is to develop advanced high density 3D package and die stacking technology, design Analog and Digital Space Radiation Hardened electronics and manufacture 3D standard products and System in Package for high reliability and high performance product applications. For the last System in Package, customer interaction is required from the product definition stage to the time the product goes into production and obsolescence. The entire process to define, develop, manufacture, and deliver products starts and ends with the customer. At each of these steps, 3D PLUS has clearly defined procedures to guarantee that our products meet or exceed customer requirements. All design and manufacturing groups must comply with the procedures and requirements to ensure product consistency regardless of the customer original design.

4.2. QUALITY SYSTEM BASIC FLOW CHART FOR SIP

4.2.1. PRODUCT DEFINITION

Customer SoW

Customer specification

Business cases

Data sheets

Detail Specification

Worldwide Standard

4.2.2. DESIGN AND DEVELOPMENT

Product Management

Design reviews

Design to test

Traceability

Product Evaluation

4.2.3. ASSEMBLY

Control Plan

Incoming material control

Data Analysis

Equipment control and maintenance

Separate non conforming material control

4.2.4. ELECTRICAL TEST

Test program control

Separate non conforming material control

4.2.5. QA CONTROL

Documentation review and edition

Visual inspection

Primary Packing

4.2.6. PACK AND SHIP

Final Packing

Delivery sheet edition

4.2.7. CUSTOMER

Quality reviews

Score cards

Annual survey

Issue Analysis and corrective actions


4.3. QUALITY CONTROL & STATISCAL PROCESS CONTROL (SPC) 3D PLUS manufacturing is mainly manual activities.Its quality control is based on several checkpoints along the manufacturing process. All operations are 100% controlled, no sampling. Many formal controls have been set up with dedicated and approved controlers. Every steps need to be recorded in a traveler sheet that follows the parts from the start to the end. All operators register their responsible step and place comments when needed. 3D PLUS is going to implement a Statistical Process Control (SPC) system in 2016 starting with the in house plating activity and continuing with testing activity and finally all equipements getting data. Each manufacturing area will then monitor the performance of each critical process parameter. Corrective actions will be taken in a real time with appropriate data for decision.

4.4. PRODUCT TRACEABILITY SYSTEM All 3D PLUS products are traceable to lot trace code number. In addition, date code traceability allows quick identification of the test/assembly and fab time periods with the part number, date code, and single serial number. Product traceability information is also provided on the inner and outer package boxes in addition to the data package and certificate of conformances.

4.5. SUPPLIER SELECTION, MONITORING AND CONTROL All direct material used in 3D PLUS products manufacturing must be procured from approved and certified suppliers. For memory products 3D PLUS care about the history of components, and accept incoming only from memory manufacturer or approved distributors by memory manufacturer.

Conterfeit program It the case of obsolete memory and after the last time buy, a specific quality policy is in place to protect customers from counterfeited parts introduced in 3D PLUS modules. If 3D PLUS cannot locate material from the Original Component Manufacturer (OCM) or Authorized Distribution Chain (ADC), then the writen approval from 3D PLUS senior management is required to procure parts from an Independent Distributor. In this case any customer placing order using these batches will be warned through the acknowledgement of order communication . In any case, EEE components that are not procured from OCM or ADC may not be used for Flight Models in Space applications unless 3D PLUS can commit on full qualification by batch.

Supplier evaluation Suppliers are evaluated by Purchasing and Quality. Decisions to approve or certify a supplier are based on the team’s evaluation and its ability to meet all 3D PLUS requirements in key areas of the supply chain processes.

Control Verification of the procured material may occur in the form of acceptance inspection by 3D PLUS. Periodic supplier audits are performed to ensure continued conformance to 3D PLUS requirements. In addition, formal business reviews are held with key suppliers when needed. Key performance indicators could be discussed for the identification of improvements needed and business allocation.


4.6. DOCUMENT CONTROL SYSTEM

Figure 2: System Quality Control

The 3D PLUS Quality Assurance System is based on the same Quality system than for ESA qualified hybrid manufacturer and it is organized around 3 Major Topics:

The 3D PLUS Quality Manual 3DPQ-0080 that is ISO9001:2008 certified by LRQA: it defines the Generic Quality Process at 3D PLUS. The Quality Manual is available for a check in site in French and English version. 3D PLUS system quality is controlled twice a year by LRQA by process in rolling for 3 years period. A complete audit according to ISO9001 is then performed by LRQA for ISO renewal every 3 years.

The Process Identification Document (PID) ESA/CNES approved, reference 3300-0546. This document is freezing the ESA/CNES qualified technological capability domain of 3D PLUS products (i.e Process list, inspection criteria, material list, parts procurement rules, screening test, acceptance criteria, …). The Process Identifcation Document is delivered by ESA since 2005 and renewed every 2 years, with manufacturing deep inspection and documentation review.

The Product Configuration Management, with the products detailed specification, Compliance Matrix to ESA/CNES qualified PID, Product definition data base, Manufacturing travelers, Test specification and test programs.

All documents managed within the Document Control System are under formal revision control. Changes to the documents can be initiated by anybody in the company. However, all changes must be evaluated and approved by all functions affected at the appropriate level. All documents listed in the apporoved PID with major impact should be delivered to ESA and CNES for review prior revision change.

4.7. AUDIT AND REVIEW SYSTEM 3D PLUS maintains a system of internal and external audits to ensure compliance with our procedures. The main purpose of these audits is to ensure that 3D PLUS’s System Quality is effective, adequate, and suitable to the requirements of Quality Management System standards, 3D PLUS’s Quality Policy, and objectives. These audits are in addition to the bi-annual ISO 9001 quality system audits which are conducted by certified third-party auditors. All issues and improvement opportunities are reviewed and followed up with appropriate corrective actions. 3D PLUS cutomers are also involved in the opportunities of improvement, during their formal or informal audits, where action items have to be completed with a reasonable time period.


5. NEW PRODUCT DEVELOPMENT AND

INTRODUCTION

5.1. OVERVIEW In order to meet our customer and market needs, it is mandatory that 3D PLUS develop and introduce new products in a timely manner. To achieve this goal, 3D PLUS uses a comprehensive product development plan. This plan defines development stages, milestones, and deliverables in the development process. This ensures consistency across the design, development,qualification product introduction in the market. The new product introduction flow is introduced in order to improve engineering project execution, improve effectiveness of product launches and to increase customer satisfaction.

5.2. MAJOR MILESTONES AND CRITERIA

Phase Gated Approach: Checks and balances at each phase of development,

Risk Management Applied Throughout: Focus on ‘right first time’,

Management Oversight: Regular process reviews,

Continuous improvement Methods Used to Drive new products development achievment.

6. RELIABILITY QUALIFICATION AND

MONITORING

6.1. OVERVIEW AND PHILOSOPHY Reliability is the ability of a product to perform under stated conditions for a specified period of time. Generally, reliability levels are expressed as the probability that a part will fail to function after a specified time interval. The same part will have different probabilities of failure under different use conditions. In the electronics industry, this failure rate over time exhibits characteristics that, when summed, are commonly referred to as the “Bathtub Curve”. This curve is typically divided into the three regions depicted below (Early Failure Rate, Intrinsic Failure Rate, Wear Out Failure Rate).

Figure 3: bathtub curve


The specific shape and position of the bathtub curve is dependent on the product design, material, processing and defect density for both die and package. When considering the overall reliability of the product, the intended application(s) and the board/system level manufacturing processes will contribute to the observed reliability. As the knowledge and understanding of all these factors grows, designs and processes can be implemented and improved to ensure a robust and reliable product. 3D PLUS screening module performed on 100% of our Engineering and Space products ought to eliminate early failures, when the Lot Acceptance Test performed on a sampling given by standard is in place to ensure reliable products after time without achieving the wear out zone. As products can operate in a system for more than twenty years without failing, any test designed to accurately evaluate reliability must utilize accelerated use conditions. This acceleration is achieved through the use of extreme environmental (temperature, humidity, pressure) and operating (voltages, currents) conditions that serve to shorten the overall test times to more manageable levels. Even under accelerated conditions, these tests may take several months to complete. 3D PLUS supplies high reliable products to its customers using its high reliable stacking technology proven since 1995 and with more than 100 000 products in Space.

6.2. HIGHLY ACCELERATED STRESS TEST (HAST) The purpose of this test is to evaluate a plastic packaged component’s ability to withstand harsh environmental conditions with extreme temperature and humidity levels. The parts are stressed to high temperature (110°C) and relative humidity (85%RH) conditions for a define period (264hours) in a biased state to achieve maximum acceleration (JESD22-A110).

6.3. 3D PLUS PRODUCTS RELIABILITY *June 07th ,2016 update. 3D PLUS products Period

LAT Samples

LAT results

DPA Samples

DPA results

Quantity of products Delivered

2012 919 919/919 266 266/266 10768

2013 719 718/719 258 258/258 9273

2014 1032 1031/1032 385 385/385 13471

2015 755 755/755 268 268/268 11183

2016* 479 478/479 157 157/157 6704 Total 3904 3901/3904 1334 1334/1334 51399

LAT = Lot Acceptance Test 1000hrs@125°C. DPA = Destructive Physical Analysis More Reliability Data on request, please complete contact form.

6.4. RELIABILITY QUALIFICATION METHODOLOGY Methodology to ensure that the requirements for Product Assurance aspects comply with the contractual requirements specified in agreement with the client.

The main objectives are:

Ensuring that the products supplied by 3D PLUS in the contractual framework of a project achieves the objective defined mission and that these products are safe, available and reliable,

Participate in the project that offers the best cost effectiveness by implementing appropriate product assurance methods,

Contribute to project risk management by ensuring, as appropriate, identification, evaluation, prevention and control of risks in accordance with the technical constraints of the project including the following two points to take into account very early:


o Electrical, electronic, electromechanical (EEE) components The objective associated with EEE components is to ensure that the components meet the requirements of mission accomplishment during the entire life cycle of 3D PLUS product.

o Materials and Processes Mechanical Components

The objective associated with materials, Mechanical Components and Process is to ensure that the use of these satisfy the realization of the mission requirements. The 3D PLUS Product Assurance Manager make sure all the selection, evaluation / qualification has followed ESA ECSS-Q-ST-60-05C and add on in detail specification. The Product Assurance Manager is in charge to prepare and coordinate customer source inspection (precap, CSI, Buy Off) and gather all necessary traceability for the key elements such as:

EEE components Materials Mechanical componentsProduct Assurance Manager must ensure that potential

suppliers proceed well and collect all necessary information.


Design and Manufacturing Flow Chart (custom products)

PDR

Preliminary detail specifcation

Design file

Customer agreement

Is the module design covered

by PID

Module Prototyping Qty=5+customer samples

Test vehicles manufacturing Evaluation of test vehicles

Module prototyping 5+customer samples

Product Qualification (if necessary)

Schematic diagram, part list and design recommendations

Preliminary study (module dimensions, number of layers, connectic, etc...

Flex Design

CTA (x4 protos)

Electrical tests (Tmin, Tamb, Tmax)

Burn-in 240hrs

Electrical tests ( Tamb)

Life Tests 1000hrs

Electrical tests (Tmin, Tamb, Tmax)

DPA (1pc)

Module Design

CDR

Evaluation of Test Vehicles / CTA / Product Qualification Report

Final detail specification

Customer samples delivery

Customer agreement

Electrical Test patterns

Module Manufacturing

Yes No

Customer input

3D PLUS input

Design & Manufacturing

steps

Electrical Test tools and methods


6.5. DATA RETENTION BAKE (DRB) This test is used to measure a device’s ability to retain a charge for extended periods of time without applying voltage bias. Stressing at high temperatures (125°C) accelerates any discharge causing the memory state to change.

6.6. ELECTROSTATIC DISCHARGE (ESD) Device’s sensitivity is mainly driven by components sensitivity. 3D PLUS package does not impact ESD Device sensitivity. Human Body Model (HBM) min. value for 3D PLUS catalog products is 2KV (STM 5.1-1998).

6.7. LIFE TEST This test is performed in order to evaluate a device’s ability to be still functional, programmable, erased, and verified after a long time period, which represents end of product life in the “Bathtub Curve” or about more than 12 years for 1000hours.

6.8. TEMPERATURE CYCLE (TC) This test is used to measure a product’s sensitivity to thermal stresses due to differences in expansion and contraction characteristics of the die and package materials by repeated alternating temperature dwells between high (+125°C) and low (–55°C) temperature extremes.

6.9. RELIABILITY MODELING Failure rates for 3D PLUS products are typically calculated based on test data with acceleration factors based on the Arrhenius Model for thermal acceleration. The other model, Coffin-Manson (temperature cycling) may be used for specific applications or customer concerns.

6.10. FAILURE RATE Failure rate is the frequency with which an engineered system or component fails, expressed in failures per unit of time. In practice, the Mean Time Between Failures (MTBF= 1/λ) is often reported instead of the failure rate. The Failures In Time (FIT) rate of a device is the number of failures that can be expected in one billion (109) device-hours of operation This is valid and useful if the failure rate may be assumed constant – often used for complex units / systems, electronics – and is a general agreement in some reliability standards (Military and Aerospace). It does in this case only relate to the flat region of the bathtub curve, also called the "useful life period".

6.11. RELIABILITY MONITORING Once a year, 3D PLUS’s Quality release representatives quality data of products subjected previously to the stress tests for reliability qualification. These data are gathered from one year manufacturing testing. This release is completed to ensure that the reliability of 3D PLUS stacking technology continues to meet the assigned goals since its initial qualification in 1995. These data are accumulated over several years to determine reliability trends in manufacturing, design rules, and assembly processes. Additionally, this data allows customers to predict the expected reliability performance of their overall system (3300-5709: Qualification results for 3D PLUS products).


6.12. RADIATION With more than 100 000 modules in Space in 2016, and with more than 16 years of Flight Heritage with no Failure, 3D PLUS is the largest Hybrid Space Qualified catalog products and custom System-In-Packages (SiPs) manufacturer in Europe. 3D PLUS Radiation Assurance Policy has been initially set-up for its Radiation Tolerant Memory Products, and it covers all the effects induced on the semiconductor devices by the Space radiation environment. In Space, electronic devices are subject to radiations (electrons, heavy ions, high energy protons,…). Interactions between these particles and the silicon structure of the 3D PLUS stacks induce two types of effects:

Total Ionizing Dose effect (TID) This is a cumulative, long term destructive effect. The device tolerance is dependant on die design (die mask revision) and on manufacturing process (Wafer diffusion lot - Batch Code). The device tolerance is expressed in kRad(Si) and can be improved with additional shielding (depending on mission’s radiation profile).

Single Event Effects (SEE) This is a single event effect that can happen at any time of the mission. The device tolerance is dependant on die design (die mask revision). The Single Event Effects can be distinguished in three main categories:

Single Event Latchup (SEL) This is a destructive effect. The device tolerance expressed in MeV/mg.cm².

Single Event Upset (SEU) This is a Non destructive effect. The device tolerance is expressed in LET threshold (MeV/mg.cm²) and saturated cross section (cm2/bit). These parameters allow calculating the bit error rate for a given mission profile. SEU effects can be mitigated by appropriate correction algorithm (TMR, EDAC, …)

Single Event Functional Interrupt (SEFI) This is a Non destructive effect. The device tolerance is expressed in LET threshold (MeV/mg.cm²) and saturated cross section (cm2/device). These parameters allow calculating the Sefi error rate for a given mission profile. SEFI effects can be mitigated by appropriate correction algorithm (TMR, Power cycles,…). 3D PLUS Radiation Tolerant Products follow the guidelines of our Radiation Assurance Policy: Radiation Verification Tests are performed for the space qualification of every new semiconductor device:

SEU/SEL is die revision dependant, and the verification tests are performed for each die revision used in the modules during the die qualification flow (then, for every batch, the die revision – die mask is controlled to be sure that the qualification data are applicable to the batch),

TID is batch dependant, and the verification test is performed for every batch. The Radiation Tolerance of the modles derivates from these radiation verification tests results with the following rules :

SEL and TID : the stacks behave the same than the basic semiconductor devices,

SEU and SEFI: taking into account the basic devices’ characteristics, the error rate of the module can be calculated for a given mission profile (the curve cross section vs LET threshold are provided to our customers for making their simulations).

6.13. FAILURE ANALYSIS AND CORRECTIVE ACTIONS In order to continuously improve reliability, it is mandatory to understand the root cause of failures and prevent their recurrence. A systematic approach is necessary to ensure that the more prevalent failures are eliminated first. 3D PLUS has a policy to analyze every reliability failure for root cause identification using 8D problem solving methodology. Sources of failures include customer returns (RMA) and internal reliability evaluations. Supported by an outsanding discipline and expertise, 3D PLUS succeeds on eliminating or reducing several failure mechanisms in recent years.

6.14. RELIABILITY TARGETS

Results of the reliability monitoring and qualification programs help 3D PLUS trend to zero defects.


7. SUBCONTRACTOR MONITORING AND

CONTROL

7.1. OVERVIEW 3D PLUS made a strategic decision in 2012 to invest in double sourcing all of its key technologies leaded by subcontrators. 3D PLUS choose either to in source activities such as plating and testing or qualified new suppliers to share the activities and to be less supplier dependent. This reduces drastically exposure to the changes in the business climate, eliminates the dependance to suppliers and improved our responsiveness to customers with better capacity.

7.2. SUBCONTRACTOR CONTROL We must ensure that services provided by our subcontractors meet both internal and external requirements. Consequently, we have implemented a comprehensive system to select, assess, and control our subcontractors. 3D PLUS has a just-in-time production, suppliers are challenged on delivery lead time in 2 ways :

Contracts / Long Term Agreements or Orders : o Key suppliers have contracts o Long lead time product or managed by stepped orders / yearly orders o Partnership agreements to keep a good reactivity

Supplier and sub-contractor continuous follow up : o Visits and audits of suppliers o Weekly follow up is performed with key sub-contractors o Buyers send warning notification to suppliers to secure lead time acknowledgement.

The Space Industry requires complete traceability of 3D PLUS products and it is declined to sub-products as well. Traceability is secured by :

o Lot sorting o Ordering supplier certificates

Lot Sorting : Goods are managed by lot number in the stock and ERP. For strategic products, single lot is expected from the supplier. Certificates : CoC, test report, security datasheet, micro section report, material characterization report… depending on the products. All supplier certificates are scanned and recorded in 3D PLUS database.

7.3. SUBCONTRACTOR PERFORMANCE TRACKING 3D PLUS is performing a continuous supplier assessment based on 2 key indicators :

Delivery performance: Number of items delayed / Number of items delivered Delay Tolerance : 0

Quality performance: Number of Non Conformance Report / Number of items delivered No distinction between Major or Minor NCR 3D PLUS makes differences between manufacturing suppliers, subcontractors and non production suppliers.


7.4. RATING A first sorting select suppliers that are being over 5k€ for more than one purchase order. One time delivery in the year is not counted. The elements that are being rated in the Supplier database are:

Delivery (30%)

Quality (50%)

Business (20%)

7.5. RATING FORMULA

Rating = Delivery x Non Conformance x Turnover

Delivery (30%)

Non Conformance (50%)

Turnover (20%)

>= 95% 10/10 = 0 10/10 < 5k€ 10/10 >= 90% 7/10 <= 0,05 7/10 >= 5k€ 7/10 >= 80% 5/10 <= 0,1 5/10 >= 7,5 k€ 5/10 >= 60% 3/10 <= 1 3/10 >= 17,5k€ 3/10 < 60% 1/10 > 1 1/10 >= 50k€ 1/10

Top 5 manufacturing suppliers are considered for specific action plan as well as, Top 5 sub contractors suppliers will be followed with priority 1. Non production suppliers will be rated priority 2.


8. QUALITY ASSURANCE MONITORING

8.1. IN LINE QUALITY ASSURANCE Through in Line Quality Control, and soon with Statistical Process Control, 3D PLUS is able to achieve a high level of control over product quality in our manufacturing processes. 3D PLUS’s outgoing Quality Assurance monitoring is ensuring that the product being shipped is of the highest quality. This results in a continuous improvement plan of product quality levels to achieve the goal to provide our customers products that are free of not acceptable defects.

8.2. QUALITY ASSURANCE INSPECTION Final Quality Assurance Inspection is being conducted at the end of the process to ensure product Quality. The verification is done with the documents filled during manufacturing (travelers) to ensure that the lot or product passed the required processes. All products are also going through visual inspection to verify the compliance to accurate requirements. Quality Inspector verifies that the parts marking, quantity and shipping labels correspond with the information given by the manufacturing documents. For Space products datapackage are initiated by Documentation group and controlled by Quality. A Key Performance Indicator (KPI) is in place to identify loss of performances and to implement corrective actions.

8.3. SHIPPING QUALITY INSPECTION Shipping Quality Inspection by logistics, is performed for every customer order to compare:

Documentation delivered by Quality Final Control,

Product package that includes parts in vacuum sealed bag with description sticker by Quality,

Certificate of Conformance by Quality,

Delivery note prepared by Sales Administration.


9. GLOBAL QUALITY POLICIES To ensure that stringent product quality and reliability expectations are integrated throughout the company, 3D PLUS has established a global quality policy. The policy is spread within several key management control system documents. The following policies are currently in effect:

9.1. QUALITY MANUAL This document 3DPQ-0080 can be controlled by customers at 3D PLUS. Only partial information can be shared under NDA. The main ISO 9001 document provides detailed information and references about 3D PLUS.

9.2. RELIABILITY QUALIFICATION METHODOLOGY The selection of new memory products is a full evaluation and qualification reported in an executive summary report made by 3D PLUS. 3D PLUS catalog products are qualified through our ESA approved Process Identification Document 3300-0546, with the application of ECSS-Q-ST-60-05C and ECSS-Q-ST-60-13C (added mid 2016). Specific Space products like SiPs, since not fully compliant to our approved PID are qualified with supplementary Product Qualification.

9.3. RELIABILITY MONITORING Yearly release (3300-5709: Qualification results for 3D PLUS products) of main tests that 3D PLUS standard products should whistand. On specific demands customer is free to ask for some of them, if required for its project.

9.4. RADIATION 3D PLUS Radiation Assurance Policy has been set-up for the Radiation Tolerant Stack Products, and it covers all the effects induced on the semiconductor devices by the Space radiation environment. In Space, electronic devices are subjected to radiations and 3D PLUS monitor Total Ionizing Dose effect (TID) and Single Event Effects (SEE). 3D PLUS Radiation Tolerant Products follow the guidelines of our 3D PLUS Radiation Assurance Policy.

3D PLUS products Period

TID LOT

TID FAIL

2012 49 30 2013 33 8 2014 20 5 2015 55 13 2016* 23 9

Total 180 65

9.5. RETURN MATERIAL ACCEPTANCE (RMA) This policy applies to all return material authorization request from the field, to get 3D PLUS support, initiate complaint and failure analysis process, to exchange parts if error in the order or to add options like varnish and tinning.

9.6. FAILURE ANALYSIS, NON CONFORMANCE REPORT (8D) 3D PLUS has a policy to analyze every reliability failure for root cause identification using 8D problem solving methodology. This policy applies to all return of materials authorization that needs strict investigation and root cause analysis.


9.7. PRODUCT CHANGE NOTICE AND END OF LIFE POLICY This policy outlines the 3D PLUS Customer Notification Policy for Product/Process Change Notification (PCN) and Product End-of-life.

9.8. DATE CODE

This policy outlines the minimum acceptable topside date code requirements for shipping product to customers (see PCN_001).

9.9. PART NUMBER DECODER A part number decoder table is defined to ease customer purchase order edition, in order to have same language in front of a need. Part number decoder, specification and options table are defined by:

3DPI-0030 - Part Number Decoder - Memory products

3DPI-0130 - Part Number Decoder - Sensor modules

3DPI-0940 - Part Number Decoder - Power - Computer - SIP

3DPI-1010 - Part Number Decoder - Interface modules http://3d-plus.com/how-to-buy.php.

9.10. CUSTOMER DOCUMENTATION REVIEW This document specifies the global policy and procedure for customer document review assessed by 3D PLUS during contract review with the acknowledgment of order.

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