I recently conducted a Quality Audit, which encompassed site-wide activities and documentation compliance of UNISEM, Batam Indonesia and UNISEM, Ipoh Malaysia integrated circuit manufacturing plants.The audit methodology included personal interviews, observation, document/record reviews and Custom Silicon Solutions Audit check list. The Audit included the review of the following: process flow, Travelers, Training program, the process for Change Order approvals, Material Receiving and Shipping, Calibration tracking/records, Wafer saw process and the ESD control program.
I found that the Unisem Ipoh and Unisem Batam Quality Management system complies with ISO 9001. The reviewed procedures and observation conclude that the Unisem corporate direction is dedicated to Quality control. The personnel interviews during the audit found that Operators and Quality Control personnel work to a high degree of efficiency. 10 to 1 ratio (operators to QC) on the manufacturing floor enhances product reliability. All operating procedures (machine setup), and engineering specifications are clearly defined and followed.
Audit results found that the Unisem ESD control program complies with ANSI/ESD S20.20. Monitoring of the proper use and handling of equipment and devices were observed. For example; Ionizers wrist straps, grounded floors, ESD lab furniture and the monitoring and recording of the Temperature and Humidity. During the wafer saw operation the Co2 Bubbler is always active. There is a constant monitoring device in the wafer saw to find chip outs and saw integrity. The utilization of an automated pick and place machine eliminates the human contact risk of an ESD event. Particle Count, DI water and Temperature/Humidity statistical analysis is recorded, displayed and readily available upon request.The Training department operates at a high level of proficiency. Training records and procedures are controlled and employee training status is updated routinely. The employee ID system identifies operating qualification and due dates.
All relevant observations were discussed and agreed as understood with appropriate personnel.
Overall Unisem proved to provide high quality products and services with excellent quality.
To top off my visit I played a round of golf at the Clearwater Sanctuary Golf Resort in Malaysia.