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Lakeport Tooling Kit Review and CIP

Lakeport Tooling Kit Review and CIP. Prepared by : ASM BP Product Team Date : 17 th May, 2005. Introduction. Intel feedback in April regarding the difficulty to setup Lakeport tooling. ASM already advised the CIP in April-18 and pending to verify the alignment jig by WW23

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Lakeport Tooling Kit Review and CIP

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  1. Lakeport Tooling Kit Review and CIP Prepared by : ASM BP Product Team Date : 17th May, 2005

  2. Introduction • Intel feedback in April regarding the difficulty to setup Lakeport tooling. ASM already advised the CIP in April-18 and pending to verify the alignment jig by WW23 • 2 to 3 weeks delay may be encountered due to manufacturing loading • Recently, Intel-PG expressed concern on the declining in performance of Lakeport tooling • On one hand ASM reviews the Lakeport tooling performance data. On the other hand, ASM summarized the problems found in past two months and advised the CIP done / in progress << New Lakeport alignment jig.

  3. Lakeport performance data (Intel-PG) Enable low pressure reference clamp Enable global alignment Replace with stronger damper spring • Remark: • Yield as shown in table is average yield of the workweek • Actual virgin yield (pre-reflow) does not take non-machine related defects (likes FM) into account • Actual yield (post-reflow) does not take non-machine related defects (likes ICOS drop unit) into account

  4. Lakeport performance data (Intel-PD) Enable low pressure reference clamp Replace with stronger damper spring • Remark: • Yield as shown in table is average yield of the workweek • Reflow yield includes both BP related and non BP related defects such as oven related defects

  5. Lakeport performance data

  6. Problem definition and solutions • Problem 1: • Package tilting by impact of reference clamp (package tilt was detected by sensor) • Cause: • Damper spring not strong enough to provide damping to reference clamp stroke • Follow-up Action: • Replace with stronger damper spring (spring force increased by ~1.5X) <Done> • Apply low pressure to reference clamp cylinder prior to high pressure to further smoothen the reference clamp stroke <Done> • Outcome: • Reference clamp stroke becomes smooth and hardly cause package tilt. • Issue closed

  7. Problem definition and solutions • Problem 2: • Reference clamp pivot shaft set screw (M3) loosen. Pivot shaft partially displaced out of the shaft hole and thus reference clamp could reach the correct stopping position • Failure mode • Merge ball and missing ball after reflow • Cause: • Suspected workmanship problem in assembling of the set screw Reference clamp Set screw Pivot shaft displaced

  8. Problem definition and solutions • Follow-up Action: • FSE checked and fixed the remaining set screws immediately <Done> • ASM also conducted study on the appropriate tightening torque for the M3 set screw <Done> • ASM found 3kgf*cm tightening torque can prevent screw from loosen based on ~80000 cycles accelerated test • ASM also found 10kg*cm tightening torque will tend to cause damage to screw head • ASM thus suggested 7kgf*cm tightening torque (~133% safety margin) for the set screw • Tightening torque requirement (7kgf*cm) added to quality procedure of clamp set assembling • Outcome: • Repeated case not found after screw fixing for 3 weeks • Issue closed

  9. Problem definition and solutions • Problem 3: • Cylinder motion not smooth and reference clamp could not reach correct stopping position. • Failure mode • Merge balls after reflow. • Causes: • It is not related to synchronization of individual clamps • The reference clamp can align the package as long as it stop at correct position prior to the moving clamp stroke • Air pressure probably not the cause • According to FSE, the problem cylinder can still reach the operating pressure. Also, no observable damage in O-ring was found. Thus, air pressure leakage due to wear off O-ring is probably not be the root cause • FM causes jamming of piston motion • FM was found on the problem cylinder. ASM suspected the presence of FM causes jamming

  10. Problem definition and solutions • Follow-up action: • FSE cleaned up the FM on cylinder. Cylinder motion resumed to normal <Done> • Replaced with strong damping spring to allow for faster piston motion <Done> • Enable global alignment to avoid globally misaligned package from transferring to reflow oven <Done> • Current global alignment still need improvement to achieve more accurate result. ASM vision engineer pending of working visa approval to fix the problem in field (Advised to be early June) • On the other hand, ASM built cylinders of different clearance with respect to the housing surface to study the jamming behavior by adding substrate fiber particles FM on cylinder

  11. Problem definition and solutions • Outcome: • Keep on monitoring the outcome of actions taken • Vision engineer pending to upgrade the global alignment feature in early June (pending for working visa approval) • Cylinder jamming experiment still in progress. Pending to have preliminary results in two weeks (WW23)

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