Copy Exact Training For SMC Suppliers

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Copy Exact Training For SMC Suppliers
Created by SMC Corporation of America
Noblesville 10100 SMC Blvd Noblesville, IN
46060 Marc Godwin
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QAD 7.4.1B Rev.A 8/09/2013
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To SMC Suppliers

• The following information is presented to provide
  suppliers the understanding and the need for a
  strict process and design control for products
  purchased by SMC under Copy Exact requirements.
• The Copy Exact requirement has been driven by
  SMCs customers and the flow down of this
  requirement to sub-tier supplier is mandatory for
  eliminating quality excursions.
• SMCs Copy Exact Requirements are defined in the
  SMC Quality Assurance Supplier Manual.

QAD 7.4.1B Rev.A 8/09/2013
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What Is Copy Exact?

• It ensures that identical tools perform
  identically upon installation for our customers
  without the need for any additional adjustment or
  tuning.
• Parts are Build to Print - any deviations from
  the drawing or process changes must be approved
  in advance.

QAD 7.4.1B Rev.A 8/09/2013
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Supplier Compliance

• Approach
• Design Control and Change Management focus
• Reiterate existing Supply Agreement expectations
  as defined in SMCs Quality Assurance Supplier
  Manual
• Establish communication for all Copy Exact issues
  
• Emphasize accountability
• Training

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How do I know if the products I supply to SMC
require Copy Exact compliance?

• If your company have been sent this training
  material, your company has been confirmed as
  supplying product to SMC that falls under the
  Copy Exact requirements.

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When does Copy Exact Take Effect?

• When SMC receives and accepts your first article
  report with your accompanying certification of
  compliance or first shipment where applicable.

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Why is Copy Exact Critical?

• Many of SMCs customers are in the medical
  equipment and microelectronic wafer processing
  industries.
• Defective components can cost our customers
  losses in the millions of dollars with effect of
  the potential of loss of business to SMC.
• Our customers demand this.

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What is a Copy Exact Violation?
When a supplier makes an uncontrolled and/or
undocumented change from the drawing or to the
manufacturing process of a part without prior
SMC/Customer approval, a Copy Exact VIOLATION is
deemed to occur.
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Copy Exact Violation (cont.)Suppliers
Subcontract Change

• A supplier shall not change the established
  subcontractor for components, processes or
  completed / substantially completed items
  supplied to SMC without prior notification and
  approval.

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Manufacturing Process Elements5Ms 1 E

• The 5 Ms.
• Methods.
• Machines.
• Material.
• Manpower (Untrained personnel).
• Measurement.
• 1 E
• Environment.
• No changes are to be made to these elements
  without prior approval.

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How to ensure products delivered are Copy Exact?

• Establish series of well defined steps that
  repeatedly produce a part within an agreed to
  specification
• Any uncontrolled process step is inadequate and
  will have impact on copy exact product.
• Copy exact in everything that is produced, do
  not change anything (5ME) without prior
  notification and approval.
• Key parameters (on the part, on the tool set,..)
  are routinely measured and SPC maintained (if
  required by SMC).
• The parts produced are within the UCL and LCL
  (upper lower control limits)
• There are well defined responses when there is
  any deviation in an SPC parameter
• Parameter impacts are understood for control
  parameter changes
• Measurement tools are calibrated according to set
  standards
• Adequate preventive maintenance is determined.
• Determine tool wear behavior and identify yield
  improvements.

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How does a supplier notify SMC of a proposed Copy
Exact change?

• The instructions and form are included in your
  SMC Quality Assurance Supplier Manual.

QAD 7.4.1B Rev.A 8/09/2013
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Copy Exact Non-compliance Examples

• Some Actual Case Examples

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Non-compliance Example

• Machine Change
• Supplier changed from milling machine A to
  another milling machine B in order to meet a
  production schedule.
• Resulting Impact
• The components which arrived had numerous
  leak/sealing issues on the manufacturing floor
  and upon closer inspection it was noted that
  machine B was a different make/model than machine
  A. Once the specs for the milling machines were
  compared, it was noted machine B could not
  produce to the same tolerances as A, resulting in
  the original leak/sealing issue.

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Non-compliance example Material Change

• Problem Statement
• Windows failed at several customers for high
  particles

• Root Cause
• Supplier used wrong material
• Material shortage of as specified material
  resulted in substitution of a different higher
  grade material. Not approved prior to
  implementation.

• Short-Term Containment
• All windows were screened for correct material.
• World wide purge/recall of all effected parts.
• Long-Term Containment
• Supplier improved their material tracking
  process. All parts are now traceable to boule
  number and original raw material supplier P.O.
• 100 secondary inspection performed at final
  clean prior to delivery.

• Liability Cost
• Supplier 100K
• Customer 1.3M

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Non-compliance example Design Change
Thermal Control plate, side A
Thermal Control plate, side B
Problem Statement High particle count in chamber

• Root Cause
• Supplier increase chamfer around Helicoil in
  improve manufacturing yield.
• Increased chamfer allows gasses to flow past
  fasteners transporting loose particles to the
  wafer.
• Notification submitted after implementation and
  rejected.

Large chamfer allows gas to flow between side A
and side B transporting trapped particles from
the helicoil
Add a picture

• Short-Term Containment
• Deviation OK to build as is until DOE is
  complete
• Long-Term Containment
• New part number created to evaluate tools
  requiring small chamfer.

• Liability Cost
• 140,000 investigation, including DOE 2 months
• Customer could have lost and chargeback to
  supplier.

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In summary, Copy Exact means

• No changes are to be made to the established
  process or subcontract supplier without SMC
  approval once the First Article or first shipment
  has been accepted by SMC.

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The Bottom Line...

• Copy Exact requires coherent change management.
• Copy Exact violations can cost any one of our
  customers millions of dollars .
• Conformance to Copy Exact standards enhances
  SMCs customers business results, productivity
  satisfaction, and therefore our FUTURE BUSINESS.

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Copy Exact In Review
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Thank-you for reviewing this training.

• Please document all personnel who have reviewed
  this training in your company and keep in your
  training records. SMC may periodically request
  documented evidence of the training completion as
  necessary.
• If you have any questions or concerns, please
  contact
• Craig Nagahori Purchasing Manager
• Noblesville - [phone]
• Terry Moody Quality Engineer
• Noblesville - [phone]
• Mark Miller Quality Manager
• Noblesville - [phone]

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