Flex Circuits – Not Always as Easy as They Seem
This little beauty has been a consistent runner for us. At first glance, this seems to be an easy looking flex but don’t let its looks fool you; it is a challenging part to produce correctly. In 2009 our customer came to us because of pricing and quality problems with another supplier. This is not uncommon in the flex world as about 70% of our customers come to us because of quality issues they need resolved – and surprisingly they usually get a cost savings on most of their FLEX part numbers.
This customer is no easy walk in the park when it came to getting qualified either. At the bottom of this post you will see a copy of their vendor survey required just to be considered. We passed the survey, of course, with ease.
Again, while this flex board seems easy, and without giving away the secret sauce on why it is difficult and how it was built…it just points out that again that if we can do it for this customer, we can most likely do it for…
This PN has the following specifications:
- 1 Layer flex board
- Polyimide (Taliflex)
- Adhesive
- Immersion Gold
- .13mm thick
- 63.4*53.8 mm
Call us at:
(866) 517-9792
email us:
quotes@pcb-solutions.com
Rest assured we can help you with your product if you are in the design phase or if you having a hard time with your current suppliers price or quality.
SUPPLIER EVALUATION QUESTIONNAIRE
Supplier Name: ____________________________________________ Vendor No. _____________
Address: ____________________________________________________________________________
City/State/Zip: _______________________________________________________________________
Phone: _______________________ Fax: ____________________ E-mail: ______________________
Contact Name &Title: _________________________________________________________________
BUSINESS INFORMATION
Business Type: Mfr._____ Distributor. ____ Service (Specify) ____________________________
Ownership: Sole_____ Partnership _____ Privately Held Corp. _____ Publicly Held Corp. ______
Number of Employees: Direct. _________ Indirect. ________
Sales Volume (Last 3 Yrs.): _____ $____________ _____ $____________ _____ $ ____________
(year) (year) (year)
Years in Business _______ Years at Location ______ Plant Area _____________ (Sq. Feet)
General Manager ________________________________ Years of Service ____________
BUSINESS REFERENCES
Principal Customers Percent(%) of Business
_______________________________________________ __________________________
_______________________________________________ __________________________
_______________________________________________ __________________________
If currently ISO registered, please send a copy of your certificate. Do not answer sections 1.0 – 10.0
1.0 QUALITY ASSURANCE ORGANIZATION
YES
PARTIAL
NO
100%
80%
60%
40%
20%
1.1 Do you have a Quality Assurance Manual?
If yes or partial please provide us with a copy.
1.2 Does the Quality Manual define responsibilities? 1.3 Are the procedures effectively implemented? 1.4 Are you ISO 9000 approved?
If yes please provide a copy of certificate.
1.5 Are quality capabilities of subcontractor reviewed prior to placement of an
order?
1.6 Is your calibration system in accordance with ANSY/NCSL Z540-1? 1.7 Are procedures provided for control and accuracy of test and measurement
equipment?
1.8 Is there a system to prevent the use of obsolete drawings and defective
parts?
1.9 Is there a system for continual maintenance and updating of a Quality
Manual and Quality Procedures?
1.10 Are procedures provided for control of nonconforming products? 1.11 Is the quality program implemented through written procedures? 1.12 Do you have a system to prevent the shipment of defective parts? Quality Assurance Organization Rating – Possible 300 points 25 20 15 10 5 0
TOTAL Add line 1.1 through 1.12 ________ /300 X 100 = ________%
2.0 DRAWINGS, DOCUMENTS AND CHANGES
2.1 Are drawings checked to assure adequacy and completeness?
2.2 Are drawings reviewed for compatibility with manufacturing processes?
2.3 Are superseded drawings removed from points of use?
2.4 Are drawings and changes reviewed for compatibility with acceptance
capabilities?
Drawings, Documents and Changes Rating – Possible 20 points
5 4 3 2 1 0
TOTAL Add line 2.1 through 2.4 ________ /20 X 100 = ________%
| 3.0 PURCHASING CONTROL |
YES |
PARTIAL | NO | |||
| 100% | 80% | 60% | 40% | 20% | ||
| 3.1 Does the quality assurance organization have a system for evaluation ofpotential suppliers? | ||||||
| 3.2 Is an Approved Vendor List available and maintained? | ||||||
| 3.3 Are suppliers quality history maintained? | ||||||
| 3.4 Does supplier uses a positive means of identification of all raw stock? | ||||||
| 3.5 Are quality capabilities of subcontractor reviewed prior to placement of anorder? | ||||||
| 3.6 Are purchase orders reviewed and (contractual) quality requirements areimposed? | ||||||
| 3.7 Does vendors selection includes quality control? | ||||||
| 3.8 Is there a procedure for the selection of a new supplier? | ||||||
| 3.9 Does supplier maintains a adequate control area for materials that havebeen furnished by customers? | ||||||
| Purchasing Rating – Possible 45 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 3.1 through 3.9 ________ /45 X 100 = ________% | ||||||
| 4.0 HANDLING, STORAGE AND DELIVERY | ||||||
| 4.1 Is there a program that provides adequate instructions for storing,preservation, packaging and shipping ? | ||||||
| 4.2 Are procedures established for controlling the storage and issuance of agesensitive materials? | ||||||
| 4.3 Are appropriate measures implemented to prevent damage and deteriorationto stored material? | ||||||
| 4.4 Are products subject to corrosion or oxidation during fabrication cleanedand preserved? | ||||||
Handling, Storage and Delivery Rating – Possible 20 points |
5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 4.1 through 44 ________ /20 X 100 = ________% | ||||||
| 5.0 RECEIVING INSPECTION |
YES |
PARTIAL | NO | |||
| 100% | 80% | 60% | 40% | 20% | ||
| 5.1 Are materials and products inspected to assure conformance torequirements? | ||||||
| 5.2 Are procedures established governing the Receiving Inspection activities? | ||||||
| 5.3 Are adequate inspection instructions made available to all in-processinspection personnel? | ||||||
| 5.4 Are raw materials identified and traceable to test or certification reports? | ||||||
| 5.5 Is all incoming material properly identified to prevent mixing and misuse ofdefective stock and maintain lot control where required? | ||||||
| 5.6 Are procedures established for identifying and controlling discrepantreceived goods? | ||||||
| 5.7 Are adequate receiving inspection records maintained? | ||||||
| 5.8 Are drawings used by inspection legible and reflect the latest changes? | ||||||
| 5.9 Are any statistically based acceptance sampling plans used? | ||||||
Receiving Inspection Rating – Possible 45 points |
5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 5.1 through 5.9 ________ /45 X 100 = ________% | ||||||
| 6.0 IN- PROCESS INSPECTION | ||||||
| 6.1 Are adequate written inspection instructions for each in-process operationperformed? | ||||||
| 6.2 Is there an effective traceability system for in-process materials? | ||||||
| 6.3 Is there an effective system for material identification, inspection status andhandling of in-process material including segregation of non-conformingmaterials? | ||||||
| 6.4 Are proper inspection instruments available? | ||||||
| 6.5 Is the inspection status of parts/material adequately identified in movingfrom one operation to another? | ||||||
| 6.6 Are in-process inspection records maintained? | ||||||
| In-Process inspection Rating – Possible 30 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 6.1 through 6.6 ________ /30 X 100 = ________% | ||||||
| 7.0 FINAL INSPECTION |
YES |
PARTIAL | NO | |||
| 100% | 80% | 60% | 40% | 20% | ||
| 7.1 Are all finished goods inspected by quality assurance to insure that contractrequirements have been met? | ||||||
| 7.2 Are procedures established for the final inspection activities? | ||||||
| 7.3 Are measuring devices, gages and test equipment required for finalinspection, available and adequate? | ||||||
| 7.4 Are adequate final inspection records being maintained? | ||||||
| 7.5 Are procedures established for identifying and controlling discrepantmaterial? | ||||||
| 7.6 Does supplier maintain a system to prevent an unauthorized use ofmaterials that have not yet been inspected? | ||||||
| 7.7 Are adequate inspection records maintained? | ||||||
| 7.8 Are drawings used by final inspection personnel legible and reflect thelatest revision? | ||||||
| 7.9 Are adequate inspection instructions available to final inspection personnel? | ||||||
| 7.10 Is acceptable product identified in some manner? | ||||||
| Final inspection Rating – Possible 50 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 7.1 through 7.10 ________ /50 X 100 = ________% | ||||||
| 8.0 TRAINING | ||||||
| 8.1 Are records of training available? | ||||||
| 8.2 Do the records show length of training class? | ||||||
| 8.3 Is periodic training provided for inspection personnel? | ||||||
| 8.4 Is periodic training provided to production personnel? | ||||||
| 8.5 Do the records indicate the retraining personnel? | ||||||
| 8.6 Do the records detail the subject matter reviewed? | ||||||
| Training Rating – Possible 30 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 8.1 through 8.6 ________ /30 X 100 = ________% | ||||||
| 9.0 NON-CONFORMANCE |
YES |
PARTIAL | NO | |||
| 100% | 80% | 60% | 40% | 20% | ||
| 9.1 Are nonconforming materials positively identified and immediatelysegregated? | ||||||
| 9.2 Are access to non-conforming material limited? | ||||||
| 9.3 Does quality assurance have the authority level for disposition of non-conforming material? | ||||||
| 9.4 Are rework/repair items inspected before release? | ||||||
| 9.5 Are procedures established for identifying and controlling discrepantmaterial? | ||||||
| 9.6 When non-conforming material is encountered, does the supplier documentcorrective action? | ||||||
| 9.7 Does supplier investigate the process and/or quality system to determineprobable causes of non-conforming material? | ||||||
| 9.8 Does supplier have a system to prevent recurrence for non-conformingmaterial? | ||||||
| 9.9 Are corrective actions taken immediately upon discovery of nonconformingmaterial? | ||||||
| 9.10 Does supplier maintain a system for following up on all corrective actions? | ||||||
| Non-Conformance Rating – Possible 50 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 9.1 through 9.10 ________ /50 X 100 = ________% | ||||||
| 10.0 CALIBRATION AND MAINTENANCE | ||||||
| 10.1 Are gages, test/test inspection equipment maintained and adequately stored? | ||||||
| 10.2 Is a documented calibration system available? | ||||||
| 10.3 Are all applicable instruments in calibration? | ||||||
| 10.4 Are calibration intervals consistent within type of equipment? | ||||||
| 10.5 Is a calibration recall system in place? | ||||||
| 10.6 Does the calibration schedule include personally owned measuring tools? | ||||||
| Calibration Rating – Possible 30 points | 5 | 4 | 3 | 2 | 1 | 0 |
| TOTAL Add line 10.1 through 10.6 ________ /30 X 100 = ________% | ||||||
The following section to be filled out by ……..Quality Department
SURVEY RESULTS SUMMARY
Subject to the recommendations and supplier commitments herein, the Quality System of
____________________________________________ Vendor No.__________________ Has been found to be:
ÿ _______________ PREFERRED (90 – 100)%
________________________________ ______________
ÿ _______________ APPROVED (75 – 89)% Q.A. Coordinator Date
ÿ _______________ RESTRICTED (< 75)%
________________________________ _____________
ÿ _____________ Others
Quality Manager Date
Scoring by section is as follows:
SECTION TOTAL ACTUAL PCT%
1. Quality Assurance Organization 300 Points _________ ________
2. Drawings Documents and Changes 20 _________ ________
3. Purchasing Control 45 _________ ________
4. Handling Storage and Delivery 20 _________ _______
5. Receiving Inspection 45 _________ ________
6. In-Process Inspection 30 _________ ________
7. Final Inspection 50 _________ ________
8. Training 30 _________ ________
9. Non-Conforming 50 _________ ________
10. Calibration 30 _________ ________
TOTAL = 620 Points _________ ________