Yesterday we published the final report for the Delphi complaint C1506774. Today I had a call with them on the report. The problem is bigger than we knew it to be!!
Since November 23rd they have seen 269 electrical rejects in their line. Apparently all of these showed similar spots on the top of the solder joint, with a leakage current which causes the electrical behavior. Attached are two files with their production data, unfortunately our lot information is not in there.
I have made an extraction from Roots. All deliveries of this type amount to 1434k, since October 1st. Delphi received 504k, so roughly 35%. I do not understand why only they see this phenomenon.
Questions to be answered ASAP:
• What are the results of the shiftly buy-off? Did we see any rejects there yet? The above figures would suggest that we must have seem some rejects.
• Did we see an increase in rejects with the decreased boundary gap or is that visible in another way?
• From the roots extraction I copied underneath deliveries of December 11th. These reels might have seen our corrective actions, as the last one was implemented on that same day. Please check urgently if these reels were packed before or after the implementation of our actions. When they are packed after the implementation and our actions are effective, then these reels should be clean.