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2021-01-26 18:43 developer |
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Hi Henry ALT don't have any materials for the giftbox, manual, HDMI, Ethernet cables. So, I think we have 3 option below 1. open the SET, Just send the PCBA to VN factroy. : With the last experience of SWAN Housing delivery to VN factory, sending only part was no problem. 2. ALT send to you (TW office) and TW office send to VN factory : need to find a way from the Taiwan office to the VN factory. 3. FXN VN factory send additional materials first. and I'll make it the way you said and send it Please let us know, what is the best way Thanks SON |
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Hi SH Thanks for your suggestions. In response to your solutions 1. Will be hard to define the root cause once there are other issues with PCBAs during transport. 2. We don't have accessories and giftboxes in RD office. 3. The factory will not agree to ship materials only... I'd like to propose another solution below: We will update the RMA specification with our comment by 2/2 then if no any other issues, let's proceed with the RMA process along with other filed RMA back to VN. Plz let me know your thoughts Thanks, Henry |
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Hi Henry Chiou, SKB asked us to provide Defect LED analysis report. I think it should review by yourself or your vendor directly. SKB now worried that their customer issued these kind issue recently. So they asked to review urgently. If your factory is checking all LED color during production, then it should be review by your vendor. So can we provide defected samples to your vendor directly ? I think it is the fastest way that we can choose. If you have any other idea, please let us know. Best regards, SuhYoung YOON |
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Hi Henry please update Failure analysis report. as you requested defective sample was delivered last month. Fedex 772934204609 772843791235 Thanks SON |
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Hi SH, I'd like to update the FA from the vendor in the file. However, as the analysis is till ongoing, the FA merely serves the purpose of updates on the progress and the status of the analysis so far. According to the vendor, the next analysis result will come out within the upcoming week. Will keep you posted. Thanks Henry |
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2021-03-06 18:52 developer |
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Hi Henry Thank you for update. and please note that, this LED issue is the top issue from field return units. - 37% - 1700 pcs total return units : 636 pcs LED defect (same as LED color change, like purple, yellow, red...) So, FXN with vender proceed to analyze the exact root cause and should be made preventive action. Thanks SON |
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Hi Sean Additional question for report to customer, please upload on mantis below items 1. The minimum LED operating current for each color (R/G/B) 2. LED block schematic Thanks SON |
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@Henry Please update this issue. this issue is defined "critical level" by customer. we have to update analysis status. Thanks SON |
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@SH Son 1. The minimum LED operating current for each color (R/G/B) =>R=7mA, G=7mA, B=5mA 2. LED block schematic =>as below Thanks Cooper led schematic.JPG (52,051 bytes) |
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@Cooper Could you provide LED's datasheet? Best regards Lonnie Kim |
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Hi SH Sorry to keep you waiting. I update the vendor FA on the last slide. Everlight did the analysis on another LED chip and still no abnormality found this week. They will proceed with SEM shooting next week. I will continue to push them to close this case and keep you posted. Thanks Henry |
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Hi Henry Thank you for update LED report, please check the LED spec : Absolute Maximum Ratings (Ta=25) of Forward Voltage (Vf) Also let us know LED vender report and 8D report due date. Thanks SON |
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Hi SH, Our RD will comment on the LED spec later. We will try to push the vendor to complete the analysis this week and update the 8D report by 3/22. (As you know the vendor did some analysis before and was unable to define the root cause yet and they are still trying other ways) Thanks, Henry |
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Hi Cooper, Please check this and reply to ALT. please check the LED spec : Absolute Maximum Ratings (Ta=25) of Forward Voltage (Vf) Regards, Sean |
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Hi SH, please check the LED spec : Absolute Maximum Ratings (Ta=25) of Forward Voltage (Vf) =>Max VF of R : 2.2V Max VF of G : 3.3V Max VF of B : 3.2V Thanks, Cooper |
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@Henry If you need more defect sample, we can send to you. we have lots of LED defect STB. : 636 pcs LED defect (same as LED color change, like purple, yellow, red...) @Cooper, Sean Thank you for update. Thanks SON |
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Hi Henry Please update LED analysis and 8D report customer still wait about this. Thanks SON |
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Hi SH, I'd like to update on the vendor FA analysis. As briefly explained the cause is from Ag migration and the vendor will replace the silver adhesive. I will work with factory to provide a formal 8D report based on the content within this week. Thank you so much for your patient waiting. Henry |
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Hi Henry Please update 8D report for Fii side - make sure that LED improvement sample (mounted Eagle) Verification plan and ECO plan - Plan for LED defective STB from end user (field) Thanks SON |
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Hi SH, I'd like to update the 8D report as attached. -The improvement schedule is in the report p.8 -Follow RMA process in Fii warranty coverage Need your help to provide some more data for us to dig into this issue further. 1. How many RMA of LED issue? What is the deployed qty so far? We need to check the defect rate. 2. Could you provide the SN of all defects with LED issue? Thanks Henry |
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Hi Henry Thank you for update 8D report. as your request : will update to you soon - defect Q'ty, depoly q'ty, and SN list question about -Follow RMA process in Fii warranty coverage [ALT] I think this is to be an LED design defect and progression defect. Please let us know about out-of-warranty LED defect STB? free or need to charge? request action item 1. Fii have to Verify root cause from LED Vender : make reappearance LED issue use a normal board 2. After received improvement LED sample : Check if the defect is reappearance Thanks SON |
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Hi Henry here is more question from SKB manager about root cause - Is there a possibility that all set-top boxes can happen? due to long time - Is there a possibility that only certain set-top boxes are defective? (Specific production lot) - Is there a possibility that only happening in a specific user environment? - Is there a possibility that EOS or ESD damage? for new improvement LED - moisture absorption , reverse voltage will be fixed new LED structure? Thanks SON |
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Hi Henry, About the 8D report, there mention that new part will be implemented on Aug. Therefore, the product that produces before Aug. what plan and action will be executed to prevent the not qualify LED get into the production line, please propose a solid plan in detail ( vendor side & VN factory side). Also from now on, all the production products need to be recorded P/N for tracking ( in case bad units pop out, P/N needs to clarify which production lot to corresponding compensation plan ). Please proposal LED bad units compensation plan in detail and what certain conditions can be verdict to LED bad units and can apply for the compensation plan. Any questions, please let us know. Thanks Sophie |
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Hi Henry, Here is LED defect (Color changed - Purple, yellow, red...) list field return unit q'ty : 2413 pcs [2020.02~2021.03] LED defect q'ty : 636 pcs Total deployed unit q'ty :830,000 -[2019.06~2021.03] Thanks SON |
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Hi SH, Sorry to keep you waiting. Our Q manager was reviewing the report from Everlight and there are some modifications to be made which are already requested to Everlight to update again on 4/9. Quickly summarize below 1. We analyzed the list and found out the distribution of defects lies mainly on several DC. D190730*181pcs takes the 1st place and the D190818*132pcs takes the 2nd. The others spread out evenly. Thus we suspected the defect comes from the manufacturing in Everlight and requested them to dig out the root cause. The updated content plz find attached p.15. 2. The long term solution will be removing the silver paste. We also pushed the vendor to give out the short term solution to mitigate the risk; however, they still need some time to discuss. We requested for reply by 4/9. I will update again on 4/9. Thanks, Henry |
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2021-04-08 19:15 developer |
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Hi Henry please including 8d report by Fii will updated by 4/9 The total number and serial range this lot was used for "D190730" / "D190818" lot LED Thanks SON |
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Hi SH, I'd like to update the 8D report and plz let me know if any questions. The report includes more analysis about the defect list FYI. Thanks Henry |
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Hi Henry the 8D report form Fii still not mentioned as I requested. 0001129:0006540 Please answer the below question. 1. Is there possible LED defects in so far deployed units? 1.1 if yes, what is Fii plan for defective LED units? 1.2 if No, let us know sppecific production lot 2. Fii should be make same LED issue reproduced according to the root cause currently Eagle unit. It only can verify the LED issue improved after using long term solution LED "removing the silver paste" I think the big problem is not being able to filter in the factory. Please make short term solution ASAP and update 8D report I also pushed every week from customer, this issue is getting bigger Thanks SON |
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Hi SH, The vendor defined the root cause and provided the short term and long term solution as updated in the 8D report. To answer your question: 1. If there are defect units, plz follow the RMA process to return to Fii. 2. The short term solution will be verified by 4/23 and I will follow up to have the vendor reproduce the issue at the same time. As to the long term solution...if the root cause is verified along with short term solution, then the long term solution will be effective for sure as the issue comes from the silver paste. Plz let me know if any questions Thanks Henry |
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Hi Henry, Please provide VN factory plan of this LED material screening process or another method can screen out the defect LED, we require this for preventing defect LED to go into the production line and make more defect Egale or SWAN, thanks. As I know you have 65K stock on hand in VN factory, please ask the vendor to help VN factory screening out defective LED, thanks. |
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Hi Henry Chiou 0001129:0006697 1. It means, Fii will responsible for all the RMA cost of LED defect? Regardless of the warranty period? 2. as Sophie mentioned, Factory should be make short term solution . We cannot approved the MP while aware of the LED defect. Apply short-term solution, the next MP should be no additional defects. Thanks SON |
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Hi SH, Sophie, For the stock in the factory, in fact there is a 35K MO in process for Eagle 35K shipment in April. After that we only have 30K on way which is estimated to arrive within this week. Our current solution is to send back these 30K back to Everlight for sorting and ship back. Considering the customs process to return the defective part(2WKs) and the logistics&sorting(2WKs), the fastest we can get the 30K back in WK5/24... I also check the next shipment which will have introduced the short term solution, the ETD TW 5/26...I'm still asking the vendor to pull in the schedule. I will push for the reply by 4/23. On that day we will have to decide if we should adopt this solution considering the impact of delivery. Thanks Henry |
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Hi SH, Sophie, The accelerated aging starts from today in vendor's. It will last for 168hr. and the we will monitor the status every day. Meanwhile, could you send another 15pcs defects with LED issue for the vendor to verify the solution again? Thanks Henry |
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Hi Henry, Please update the latest status of the LED short-term solution as yesterday we talked on the phone. I will check with SH if can send another 15pcs to TW ASAP. Thanks Sophie |
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Hi Henry The LED defect unit will send within today. Fedex : 773594910626 Please remind that, these STB including the last one sent should be return to SKB – Total 23pcs So after RD review, send the VN factory, will pack with other RMA. Or repair in Taiwan and send it to Korea 1 2149688001201908010076 2021-04-29 LED불량 2 2149688001201908020100 2021-04-29 LED불량 3 2149688001201904046357 2021-04-29 LED불량 reddish 4 2149688001201904017642 2021-04-29 LED불량 5 2149688001201908016895 2021-04-29 LED불량 6 2149688001201909004950 2021-04-29 LED불량 7 2149688001201904048988 2021-04-29 LED불량 8 2149688001201904013337 2021-04-29 LED불량 9 2149688001202001085953 2021-04-29 LED불량 bluedish 10 2149688001201909013118 2021-04-29 LED불량 11 2149688001201904015299 2021-04-29 LED불량 12 2149688001201904000058 2021-04-29 LED불량 13 2149688001201904014644 2021-04-29 LED불량 white color 14 2149688001201904010316 2021-04-29 LED불량 reddish 15 2149688001201908001795 2021-04-29 LED불량 Purple 2149688001201909023362 2149688001201908031823 2149688001201904035168 2149688001201904041675 Yellow 2149688001201904040599 2149688001201904024318 2149688001201904032610 2149688001201904017454 Thanks SON |
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Well noted with thanks. We will ship back to ALT once the analysis is done. |
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Hi Mr. Sean Chiang, Could you update status of LED short term solution and Long term solution ? I know you are checking other vendor's LED now. And there is no update from the end of last month. Could you check the status of each solution ? |
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I'd like to update the 8D report and plz let me know if any questions. The report includes more analysis about the defect list FYI. Thanks Dennis |
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I'd like to update the 8D report and plz let me know if any questions. The report includes more analysis about the defect list FYI. |
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Hi Dennis I have question below as your updated 8D report. 1. Page 5. Result : LED fail with DC190730 ( 30%) & DC190818 (21% ), and LC LY190818S1001DDFWX35 ( 20%) & Y190730S1002DF (30%). LED fail issue concentrate DC& LC 2019-July & 2019-Aug. ALT: update the total STB S/N range used below lot. DC190730, DC190818, LC LY190818S1001DDFWX35, Y190730S1002DF 2. Page 14. please let us know, when FII new LED (Long term solution) apply to MP? Thanks SON |
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I'd like to update the Long term solution schedule and update the total STB S/N. plz let me know if any questions. A. Long term solution schedule : 1. Long term solution LED reliability test 1000hr completed on 6/26. 2. Provde LED sample for Eagle bulit on 6/30. 3. 7/1~7/5 Eagle sample bulit for Long term solution LED reliability test . 4. 7/6~7/10 send back to Taiwan. (Eagle ,Long term solution LED sample. 5. 7/10~7/30 Long term solution LED reliability test. 6. 8/3 : Provde reliability test to ALT. B. Total STB SN range used bellow LED material DC190730 and DC190818 : Pls help check this data: Total SN used DC190730 : 42.890 pcs and DC190818 : 40.757 pcs Total : 83.646pcs Thanks |
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Hi Dennis please update also below lot. - D190725, D190817 Thanks SON |
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Hi Dennis Please answer the my question below 0001129:0006536 [ALT] I think this is to be an LED design defect and progression defect. Please let us know about out-of-warranty LED defect STB? free or need to charge? also, We think that the FII have to cover until applied long-term solution LED MP. the short term solution still has a risk due to design weakness even if filtered short term solution Thanks SON |
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Hi Dennis & Tiffanie, 1. We would like to know what the NEW LED MP date will be? 2. What is the L/T of NEW LED? If the sample LED provide on 6/30, does that means that Everlight will be ready and prepare raw material for MP phase? 3. In Fii point of view for SWAN project pre-MP 1K what kind of LED should be used, please advise, thanks. 4. How about out-of-warranty product that has LED issues, what kinds of Compensation that Fii or Everlight will proceed with? 5. Shot-term solution product has some possibility to have this kind of issues too, please define the compensation condition of it, thanks. |
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I'd like to update the short term solution schedule and update the total STB S/N. A. short term solution schedule : 1. 6/8~6/15 Eagle sample bulit for short term solution LED reliability test . 4. 6/16~6/22 send back to Taiwan. (Eagle ,short term solution LED sample. 5. 6/24~7/13 short term solution LED reliability test. 6. 7/15 : Provde reliability test to ALT. B. STB SN range used bellow LED material D190725, D190817 |
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Provide BFX-AT100 (T99X171.00) LED Issue Reliability Test Plan for ALT review. |
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Provide BFX-AT100 (T99X171.00) LED Hardware measurement Test report(long term solution) for ALT review. The actual test results still has color shift, and the reason is caused by different bin codes. |
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HI Cooper Kung 0001129:0007577 Please test again same bin code *DUT3 : silver glue = cold white = bin code 239 *DUT4~6 : insulation glue = warm white = bin code pw10 ->> 239 |
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I'd like to update the 8D report and plz let me know if any questions. This is report update Everlight LED reliability test 1000 hours result. PASS ( please check page 19) |
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Hi Dennis Lu, Could you add revision history of 8D Report ? We are difficult to find parts that are changed. It is more clear to discuss. |
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Long term solution schedule update : 1. LED sample ETA 7/4 -> 7/9 (Vietnam) 2. 7/10~7/15 Eagle sample bulit for Long term solution LED reliability test . 3. 7/16~7/20 send back to Taiwan. (Eagle ,Long term solution LED sample). 4. 7/21~8/15 Long term solution LED reliability test. 5. 8/16 : Provide "Eagle Long term solution" reliability test report to ALT. |
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Hi Philip and SH, Reply 0001129:0007579 As per I explain in SWAN daily meeting, Everlight is not able to determine when they are able to provide bin code 239 insulation glue LED sample in the future. Therefore, I suggest that we provide Everlight's production distribution report to illustrate the comparison of the characteristics of silver glue and insulating glue in mass production as a reference. Please refer attached report and let us know if you have any questions. Thanks! Regards, Sean |
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Hi Sean. as your report, The LED R/G/B wavelengths are not exactly the same, but they look similar. ALT can not to confirm LED change, this is SKB designer part role. So, Please send the sample (changed LED) 1set to designer confirm. I will check together. Thanks SON |
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Hi SH, So, you only need one set of Eagle sample (change to long term LED sample) for SKB designer confirm? We can also provide you some of insulating glue LED samples once you need more Eagle samples for comparison. Please let me know if you have any questions. Thanks! Regards, Sean |
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HI Sean Please send below - the one set of Eagle sample (change to long term LED sample) - 40~50 pcs insulating glue LED samples (long term LED) Thanks SON |
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Hi SH, OK, We can prepare one set of Eagle sample and 50pcs insulating glue LED samples to you. BTW, can we use ALT's FedEx account? Hi Cooper, As discussed, please follow it up. Thanks. Regards, Sean |
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Hi Mr. Sean Chiang, I think that we always pay delivery cost for all project. But I think FII should pay for delivery cost that it caused by Foxconn. In case of this LED issue, it is not ALT's fault. So I think FII should pay it. I know it takes time, but please tell me how long it will take to send the samples at your cost. |
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Hi Mr.Yoon, I understand your point. Let me check with team and get back to you. Regards, Sean |
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Hi SH, Here is LED short term solution Reliability test and MTBF test The result is pass please see the attached. Thanks, Cooper |
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Hi Sean Thankyou for test report. but, the customer MTBF target is 50,000 Hours (5 years). Not 17,500 Hours (2 years). it is same as long term solution MTBF test Please update the MTBF test and test report Thanks SON |
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Hi SH, 1. OK, we will continue to perform the MTBF to 5 years for short term LED solution. The report will be updated by end of Aug. 2. Update the reliability test schedule of long term solution LED as attachment. The test will be completed by 8/25. Please check it and let us know if there is any further questions. Regards, Sean |
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Hi SH, Here is LED reliability test (short term + long term) reports, Regards, Cooper |
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HI Cooper and Sean thank you for update the test report and reported no abnormal. but, from the test report photos, the light seems to have changed to a light purple. could you please check the test report photos and update again? Thanks SON |
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@HI Cooper and Sean Please update my feedback 0001129:0008018 Thanks SON |
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Hi SH, Our QA team will update test report photos next week and try to make the photos look consistent as much as possible Thanks, Cooper |
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Hi SH, updates test report photos as attached, FYI Thanks, Cooper |
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HI Mr. Yoon, Please refer to attached file for the batch shipped out on 10/8 & 10/12. (Total 40Kpcs) It includes the LED DC and SN. Short Term Solution from 2021/04/16; D/C 210416 Long Term Solution from 2021/06/20; D/C 210620 Thank you. Best Regards, Carey Lu |
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HI Mr.Yoon, Please refer to attached file for the Everlight LED D/C record. After checking with factory, they mix the short term and long term solution LED from Aug production till Oct production. For short term solution D/C, the stock were used up in Oct. But please be noted that there are 120pcs 2nd source control run DUT mix with short term solution D/C LED left in the warehouse and plan to rework and ship in Dec. PS. Short Term Solution from 2021/04/16; D/C 210416 Long Term Solution from 2021/06/20; D/C 210620 Best Regard, Carey Lu |
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Hi Tom and Sean Could you please check LED datasheet? in schemetic, LED VCC is Pin 4. but LED datasheet LED VCC is Pin 1 which one is correct? Thanks SON image.png (167,474 bytes) image-2.png (63,671 bytes) |
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Hi Cooper, Please check this issue and reply to SH asap. Thanks. Regards, Sean |
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Hi SH, The symbol we use for FII system is different from the pin define of this LED in previously, But the circuit design is correct. Regards, Cooper |
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Hi Sean and Miya, as we talked today, - schematic library is old version, but PCB artwork library is correct as LED datasheet. Action item ( due date : 5/12) - schematic update : LED library - 8D report about mis match LED library between schematic and LED datasheet. Thanks SON |
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Hi SH, Attached is schematic and 8D report, FYI Regards, Cooper |
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Hi Sean and Cooper I checked the LED Pin modified schematic. but about 8D report, ALT was request that issued by FII, Not a vender. it was caused by library management on the OrCad. So, please check and report again Thanks SON |
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Hi SH, Attached is FII 8D report, FYI Regards Cooper |
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Hi Sean and Cooper and Miya Thank you for update the LED 8D report but, I think FII was some misunderstood My point was "mismatch the LED library between schematic(Orcad) and LED datasheet And PCB artwork library(PADs)" So, Please update 8D report at FII HW library management below subject : To prevent library mismatch Problem Description : mismatch the LED library between schematic(Orcad, VCC Pin 4) and LED datasheet (VCC Pin 1) And PCB artwork library(PADs, VCC Pin1) Thanks SON |
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Hi SH and Lonnie, Please refer to the attached file for Fii's RD report on the LED schematics symbol mismatch issue. We will add an internal check list to ensure that RD will apply for the dedicated symbols and footprints for new parts and review such issues during the design phase to avoid the same issues happening agan in the future. Regards, Sean |
- yk.jung ( (ALTech) Younkwang Jung ) developer
