Flex Circuits – Not Always as Easy as They Seem

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
Flex circuit

complex circle flex PCB

 

Call us at:

(866) 517-9792

email us:

[email protected]  

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                                      _________                              ________

 

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