CONTROL PLAN

SAE Circuits Colorado, Inc.

Part or Process Name

Proces
s

Contract review

200

Pre-Process CAM
Engineering

400

500
600

700

800
900

Characte
r

or

Serial
Number

Method
Product

Process

Incoming material

Material Release

Contract
Advanced Order Form Reliew

Computer
Computer

Copper Clad
Laminate

Production Traveler
Silver Film Plots

Engineerin
g
ENDOC001

Material Certs - Filed

Material
Receipt

SHDOC002

Material
Receipt

SHDOC002

Prepreg & Copper

Foil

Material Certs Filed

Core Laminate

Material Thickness

2
Core Laminate Prep

TSC Chem Clean

Module

Chemical Clean

Dry Film - Image

Dupont HRL-24
Laminator

Laminate Dry Film

Exposure Units

Expose Image

Resist Strip
AOI Innerlayer Cores

1000 Oxide Alternative

1100 Lamination

Step Test for Develop

Cores Only DFDOC001

TSC Developer

Develop order

Cores Only DFDOC002

TSC Resist Stripper

Mania AOI

Custom Oxide Line

Lay-up

First Article Panel

Etch Panels

1
1

Resist Strip Panels

I/L Cores

Coat All I/L Cores

Layup Cores, Prepreg

& Foil

Swatch

Department

Content Frequency

File Certs in QA File Cabinet

1
Piece/Lot
Cores Only DRDOC001 Micrometer
#
Copper
1
Thickness Gage - Piece/Lot
Cores Only DRDOC001 Electronic
#
Visual Operator
All
Cores Only WPDOC010 Inspection
Panels
Visual Operator
All
Cores Only DFDOC001 Inspection
Panels
Visual 1st
Operator
Article Cores Only DFDOC001 Inspection
AOI

TSC Developer &

Test Coupon

Chemcut I/L Etcher

Technique

Control Method

PDDOC008

Engineerig
FA
ENDOC003

Base Copper Foil

Thickness

Etch Cores

Reaction to Plan

Product/Proc
Evaluated
ess
/Measurement
Criterion
/Tolerance

Production Tool

100

300

Production
Equipment

Operation Description

Serial
Number

Rev: Jan 09, 2013

Visual - Step test

coupon
Setup
Visual Operator
All
Inspection
Panels

Scope - Measure
I/L Etch
WPDOC013 Line Width
Visual Operator
I/L Etch
WPDOC013 Inspection
Visual Operator
Resist Strip WPDOC014 Inspection
Line Widths,
AOI
ENDOC004 Opens, Shorts

Every Lot #

Recheck and Reject if applicable

Every Lot #

Recheck and Reject if applicable

All Panels

Analytical Lab Records - Chem Concentration

All Panels
Every P/N

Sign Traveler

Every Order Adjust speed as necessary for test result

All Panels

Dry Film Develop Log

Recheck and Reject if applicable

1st
Recheck, adjust speed and perform
Article Every Lot # Record Start & Finish Line Width on Traveler a new FA if necessary
All
Panels

Sign Traveler

Recheck and Reject if applicable

All
Panels Every Order Sign Traveler

Recheck & reprocess if necessary

All
Panels Every Order Sign Traveler

Reject & Restart as applicable

Visual for
complete
coverage Operator
All
Oxide Alt. WPDOC002 Inspection
Panels Every Order Sign Traveler
Per
Traveler
Book Thickness - All
Layup Inst LMDOC001 Micrometers
Books
Every Load Sign Traveler

1 of

Recheck and Reject if applicable

Reject and rework as applicable

N/A

SAE Control Plan

Rev: 01-09-13

Part or Process Name

Proces
s

Operation Description

Serial
Number

Production
Equipment

Characte
r

or

Serial
Number

Process

Reaction to Plan

Criterion
/Tolerance

Technique

Control Method

Swatch

Department

Content Frequency

Lamination Books

Panel Thickness Lamination LMDOC001 Micrometers

Sample

Log Low & High Thickness Measurement on

Every Order traveler - Complete LAMLOG001

Recheck Measurements & Reject if

Applicable - Notify Process
Engineer

Lamination Books

Panel Thickness Lamination LMDOC001 Micrometers

Sample

Log Low & High Thickness Measurement on

Every Order traveler - Complete LAMLOG001

Recheck Measurements & Reject if

Applicable - Notify Process
Engineer

All Panels

Flash
removal

Panel Size LMDOC001 Calipers

Every Order Complete RTFRM011 - Sign Traveler

Recheck and Reject if applicable

Pinning for Drill

All Single & D/S

Panels - MLB has
separate tooling not
requiring pinning

Pin

Visual -Operator All

DRDOC001 Inspection
Panels

Every Order Sign Traveler

N/A

Excellon HVP Driil

Excellon HVP Driil

All Panels
All Panels (1 Lyr thru
14 Lyr)

1st Article
Hole Sizes &
Drill
DRDOC002 Locations
Drill
Hole Sizes &
Production DRDOC002 Locations

1st
Article
Bottom
Panel

All Panels (1 Lyr thru

14 Lyr)

1st Article
Hole Sizes &
Drill
DRDOC002 Locations

1st
Article

Xray

All Panels (1 Lyr thru

14 Lyr)

Drill
Hole Sizes &
Production DRDOC002 Locations
Visual Operator
Debur
WPDOC003 Inspection

Bottom
Panel

Ind Spindles Sign Traveler

Recheck and Reject if necessary

All
Panels

Every Order Sign Traveler

Recheck and Reprocess as

necessary

Lamination - TMP
Lam Press (2 plates)
Flash removal Excellon XL-5
Router

Excellon Mark VI
Drills
Excellon Mark VI
Drills
1300 Debur

Product

Production Tool
Lamination - TMP
Lam Press (6 plates)

1200 Drill

Method
Product/Proc
Evaluated
ess
/Measurement

Chemcut Debur

1400 Electroless Copper

IPS Electroless
Copper

1500 Dry Film - Image

Dupont HRL-24
Laminator

Exposure Units

Drilled Panels

Backlight (BL)
Coupons,
Weight Gain
Coupons,
Weight Loss
Coupons Balance Scale
Desmear (MLB's) and Desmear &
and
Electroless Copper
Electroless
Metallurgical
Plate all Panels
Copper
WPDOC004 Scope
Visual Operator
Laminate Dry Film
Cores Only DFDOC001 Inspection
Visual Operator
Expose Image
Cores Only DFDOC001 Inspection

TSC Developer &

Test Coupon

Step Test for Develop

Cores Only DFDOC001

TSC Developer

Develop order

Cores Only DFDOC002

Copper Plate

Tin Plate

All
Through
Hole
All
Through
Hole

Eidshun Electroplate
1600 Electrolytic Copper Plate Line

All
Panels

Xray

Ind Spindles Sign Traveler

Cuposit List WPFRM007 - Sign Traveler

Recheck and Reject if applicable

All
Panels All Panels
1st
Article AOI
Every P/N

Sign Traveler

Recheck and Reject if applicable

Every Order Adjust speed as necessary for test result

All Panels

CMI - PTX 200

Portable
Electronic
WPDOC006 Caviderm
Sample Every Load
Visual
for
WPDOC006 Specified Time Coverage Every Load

Recheck and Reject if necessary

Verify Hole Location using Glenbrook Xray

for MLB Panels and Pin Gage Hole Sizes

BL
Coupons
(2 per
shift),
Weight
Loss &
Gain
Coupons 1 daily - Daily &
Visual
Visual all
for Voids panels

Visual - Step test

coupon
Setup
Visual Operator
All
Inspection
Panels

2 of

Verify Hole Location using Glenbrook Xray

for MLB Panels and Pin Gage Hole Sizes

Dry Film Develop Log

Recheck and Reject if applicable

Minimum deposition of 1.2 mils is required

Recheck and add more plate time if
before accepting deposition rate and removing necessary until 1.2 mils minimum
requirement is satisfied
order from copper plate
N/A

N/A

SAE Control Plan

Rev: 01-09-13

Part or Process Name

Proces
s

Operation Description

Serial
Number

Production
Equipment

Characte
r

or

Serial
Number

Method
Product

Process

Reaction to Plan

Product/Proc
Evaluated
ess
/Measurement
Criterion
/Tolerance

Tape Connecttors

Manual tape Process

Selrex Tabplate

Ni/Au Tabplate

Technique
Visual Operator
Connectors WPDOC011 Inspection
1st Article 1st Article CMI 900
Ni/AU
Flourescence XThickness WPDOC001 Ray

Selrex Tabplate

Ni/Au Tabplate

Tab Plate
Panels

1800 Resist Strip

Chemcut 547-30XL
Resist Strip Module

Resist Strip Panels

1900 Etch Copper

Chemcut CS2000
Etcher

Chemcut CS2000
Etcher

Body Plate - Connector

1700 Tabs (Ni/AU)

2000 Tin Strip

2100 ENIG (Reliavia)

2200 Soldermask

Production Tool

Chemcut CS2000
Tin Strip Module

Custom ENIG Line

Chemical Clean TSC Chem Clean
Module

DP-1500 Soldermask
Coater
ORC HMW680GW
Exposure Unit (S/M
Expose) & VCM
S/M Developer

ORC HMW680GW
Exposure Unit (S/M
Expose) & VCM
S/M Developer
Grieve & Precision
Quincy Ovens Soldermask Thermal
Cure
Standard - Connector
2300 Tabs (Ni/AU)

1
1

WPDOC001 Visual & Xray

Visual Operator
Resist Strip WPDOC008 Inspection

Scope - Measure
WPDOC009 Line Width
Visual Outer
Operator
Etch Panels
Layer Etch WPDOC009 Inspection
Visual Operator
Tin Strip Panels
Tin Strip WPDOC007 Inspection
CMI 900
Flourescence XRay for
deposition Visual Opeartor
Plate Panels
ENIG
WPDOC015 Inspection
Visual Soldermask
Operator
Chemical Clean Panels App
SMDOC004 Inspection
First Article Etch

Soldermask Coat
Panels

Expose & Develop

Soldermask - 1st
Article Panel

Expose & Develop

Soldermask - All
Panels

Thermal Cure
Soldermask

Tape Connecttors

Manual tape Process

Selrex Tabplate

Ni/Au Tabplate

O/L Etch

Solvent Loss
Test - Visual Soldermask
Operator
App
SMDOC001 Inspection

3 of

Department

Content Frequency
N/A

1st
Article
Xray
Sample
1%
Order

All Tab
Plate Panels Tab Dimension Height per Print

N/A

Analytical Lab records (Chemistry) and CMI

Every Order Report for Ni/Au Deposition

Recheck and Reject if necessary

Every Order

All
Panels

Every Order Sign Traveler

1sr
Article

Recheck, adjust speed and perform

Every Order Record Start & Finish Line Width on Traveler a new FA if necessary

All
Panels

Sign Traveler - All rework to be noted on

Every Order traveler

Recheck and reprocess if

applicable

Recheck and Reject if necessary

All
Panels
Every Order Sign Traveler
Readings
(5
minimum
) - Visual
Operator
Analytical Lab records (Chemistry) and CMI
Inspectio Every Order Report for ENIG Deposition, Sign Traveler

Recheck and Reject if necessary

All
Panels

Recheck and Re-clean if necessary

Every Order Sign Traveler

Solvent
Loss Test
Once
Daily,
Visual
All
Record Solvent Loss Data on SMFRM001,
Panels
Every Order Sign Traveler

1st Article Soldermask

Supervisor or
1st
App
SMDOC005 QA
available
Stepas
test
1/2 way Article
through order,
Visual Operator
Inspection - Eye
Soldermask
Loupe as
All
App
SMDOC005 necessary
Panels
Visual Operator
Soldermask
App
SMDOC005 Inspection
Visual Operator
Connectors WPDOC011 Inspection
1st Article 1st Article CMI 900
Flourescence XNi/AU
Thickness WPDOC001 Ray

Control Method

Swatch

Every Order Sign Traveler for 1st Article

Recheck and reprocess if

applicable

Recheck and Strip S/M and recoat

if necessary

Recheck and Reject if necessary

Record Step test Results on SMFRM002, Sign

Every Order Traveler
Recheck and Reject if necessary

All
Panels

Every Order Sign Traveler

Recheck and Reject if necessary

N/A

All Tab
Plate Panels Tab Dimension Height per Print

N/A

1st
Article

Analytical Lab records (Chemistry) and CMI

Every Order Report for Ni/Au Deposition

Recheck and Reject if necessary

SAE Control Plan

Rev: 01-09-13

Part or Process Name

Proces
s

Operation Description

Serial
Number

Hot Air Solder Level 2400 (HASL)

Production
Equipment

Characte
r

or

Serial
Number

2600 Score

Process

Reaction to Plan

Criterion
/Tolerance

Technique

Control Method

Swatch

Department

Selrex Tabplate

Ni/Au Tabplate

Tab Plate
Panels

WPDOC001 Visual & Xray

Content Frequency
Xray
Sample
1%
Order
Every Order Sign Traveler

Argus PreClean 5520

& Fluxer Unit 3215

Pre-Clean & Flux 1st

Article Panel

HASL

WPDOC012 N/A

N/A

HASL

1st Article Panel

- CMI 900 XRay for Solder
Thickness - Pin 1st
WPDOC012 Gage Hole Sizes Article

Daily Check N/A

Recheck and Reprocess panel as

necessary

N/A

N/A

N/A

Recheck and Reject if necessary

N/A

Avalon Avtec 4000

HASL Module

HASL - 1st Article

Panel

Argus PreClean 5520

& Fluxer Unit 3215

Pre-Clean & Flux - All

Panels
HASL

WPDOC012 N/A

N/A

N/A

HASL - All Panels

HASL

Visual Operator
WPDOC012 Inspection

All
Panels

Sign Traveler - CMI Report for HASL

Every Order Thickness

Recheck and Reprocess panel as

necessary

1st
Article

Every Order

Adjust Screen tension as necessary

N/A

Hand Screen
Operation

Legend - 1st Article

Legend

1st Article Visual by

SMDOC002 Operator

Hand Screen
Operation

Legend

Legend

Visual Operator
SMDOC002 Inspection

All
Panels

Every Order Sign Traveler

Recheck and Reject if necessary

Gireve Ovens Legend Cure

Legend Cure

Legend

SMDOC002 N/A

All
Panels

Every Order Sign Traveler

N/A

Every Order 1st Article Approval Signed on Traveler

Recheck and Reject if necessary

All
Panels

Every Order Sign Traveler

Recheck and Reject if necessary

1st
Article
Panel

Every order 1st Article Approval Signed on Traveler

Recheck and Reject if necessary

Accu-Score AS-200

Accu-Score AS-200

2700 Rout

Product

Production Tool

Avalon Avtec 4000

HASL Module

2500 Nomenclature (Legend)

Method
Product/Proc
Evaluated
ess
/Measurement

Excellon XL-3, XL5 & Mark V

Driller/Router
Machines

V-Score 1st Article

V-Score Panels

V-Score

V-Score

Rout 1st Article Panel Rout

RTDOC003

RTDOC003

RTDOC004

1st Article VScore, Measure

depth using
Accu-Score
Digital V-Score
Checker,
measure X & Y 1st
Dimensions
Article
using Calipers Panel
Check Score
Depth by
measuring with
Accu-Score
Digital V-Score
Checker,
Measure X & Y
Dimensions
using Calipers
Verify 1st
Article Rout
Dimensions
using Caliper for
Specified
Dimensions per
Print

4 of

SAE Control Plan

Rev: 01-09-13

Part or Process Name

Proces
s

Operation Description

Serial
Number

Production
Equipment

Characte
r

or

Serial
Number

Method
Product

Process

Criterion
/Tolerance

Production Tool

Excellon XL-3, XL5 & Mark V

Driller/Router
Machines
Barnaby Beveler
(edge beveling),
Delta Drill Press
(Countersink/Counte
rbore), Upright Belt
Sander (Nub
Removal)

Reaction to Plan

Product/Proc
Evaluated
ess
/Measurement

Rout - All Panels

Final Fabrication

Rout

Rout

Technique

RTDOC004

Verify Rout
Dimensions
every third run
using Caliper for
Specified
Every
Dimensions per Third
Print
Run

RTDOC002

Verify Bevel,
Countersink/Cou
nterbore and
Nub Removal as
necessary to
meet print
dimensions

All
Boards
as
applicabl
e
Every Order Sign Traveler

Recheck and Reject as necessary

All
Boards

Every Order Sign Traveler

N/A

All
Boards

Every Order
as applicable Test Cert Provided with every order

N/A

Complete QA Holes/Defect Chart Appropriate 1st Article Documentation

Every order specified by customer when applicable

Recheck and Reject as necessary

Final Board
Wash/Clean

Final Fabrication

Rout

RTDOC002

2800 Electrical Test

Subcontracted Flying Probe, Dual

Grid, 9090 Tester

Electrical Test

Electrical
Test

SubContracted

Pass-Fail Tags

2900 Final QA Inspection

Various Pin Gages,

Calipers,
Micrometers,
Granite Surface
Plate, Scopes, Eye
Loupes, Halo
Inspection Lamps

verify all
dimensions,
notes and
1st
Final
requirements per Article
Inspection - 1st Article Inspection QADOC003 Print
Board

Inspection - All Boards

- Sample Plan may be
used at 2.5 AQL level
per ANSI/ASQC Z1.4
1993 Standard based
upon complexity of
Final
product
Inspection QADOC003

3000 Immersion Silver

Controlled Impedance
3100 Testing

Customer Sterling
Silver Line

Polar CITS-500 TDR

Visual
Inspection by
QA Department
Inspectors
1 piece
deposition
thickness
checked on CMI
900
Flourescence XRay, VisualOperator
Inspection All
Silver Coat - All Panels Silver Plate WPDOC018 Boards

Test Coupons

Department

Content Frequency

Visual Operator
Inspection

Various Pin Gages,

Calipers,
Micrometers,
Granite Surface
Plate, Scopes, Eye
Loupes, Halo
Inspection Lamps

Control Method

Swatch

ENDOC004
Impedance & Equipment Test CI with
Instructions TDR
testing

5 of

All Zero Correction Factor adjustments must

be recorded on RTFRM011 form, Sign
Every order Traveler

Recheck and Reject if necessary

All
Boards
as
applicabl
e
Every order Sign Traveler

Recheck and Reject as necessary

1 Piece
Measure
ment for
depositio
n, All
Boards
Visual
Every Order Sign Traveler

Recheck and Reject as necessary

Applicable
Coupons Orders

Sign Traveler, Print CI Test report and place in

Traveler Package
Recheck and Reject as necessary

SAE Control Plan

Rev: 01-09-13

Part or Process Name

Proces
s

Operation Description

Serial
Number

3200 Packaging and Ship

Production
Equipment

Characte
r

or

Serial
Number

Method
Product

Process

Criterion
/Tolerance

Production Tool

CII Vacuum Sealing

Equipment, AIE455FI Impulse MBB
Foot sealer, Vacuum
Seal Amine Free
Bubble Wrap, Scc
2000MQPL Type1
Moisture Barrier
Bags, Desiccant
Material, Humidity
Indicator Strips,
Single & Double
Wall Boxes, Clear
bags, Bubble Pak

Reaction to Plan

Product/Proc
Evaluated
ess
/Measurement

Package and Ship

Ship

SHDOC001

Technique

Department

Content Frequency

Count product,
measure weight
of boxes with
scale, Identify
Product
Markings on
Boxes and
Documentation Visual Shipping Clerk All
Inspection
Boards

6 of

Control Method

Swatch

Every Order Sign Traveler

SAE Control Plan

Rev: 01-09-13