Professional Documents
Culture Documents
on May/22
SZ Media
Jul 15, 2016
07/01 update
D0: Awareness Of The Problem By Qian Hu
Symptom or event : MPK EC8295(Delta TDP Final Function) error code trigger by MAP4 on
May/22 at Final test process from 0.5% to 7%. Observed disk sputter date(Apr/14)
dependency
Reported date: 31 May 2016
Immediate response :
Establish the team/Media investigation
On-hold all sputter date Apr/14 MPK parts in Media site.
Hong Yu SZ Yield
Ti Zhang SZ QC
Qian Hu SZ PE
Problem statement: MPK EC8295(Delta TDP Final Function) error code trigger by MAP4 on
May/22 at Final test process from 0.5% to 7%. Observed disk sputter date(Apr/14) dependency
Fail disk lube start/end time for phase2 and phase4 is close, comparing with other process.
Shipping cassette(1.27mm thickness) is common between phase2 and phase4, and unique from
other products during that time period.
Phase Wash Sputter Lube FTP UV Test Bagging
2 Check MPK media inventory, on hold all affected parts SZ Media May.31/2016 Done
5 HDD PRB stop load AR8 affected disks HDD PRB Jun.28/2016 Done
6 Immediately alert to GSP for Jaguar risk assessment SZ Media Jun.28/2016 Done
7 HDD GSP stop load Jaguar affected disks HDD GSP Jun.28/2016 Done
9 Sort and scrap return shipping cassettes for all product SZ Media Jul.15/2016 Done
from impact period
Why-Why Analysis
Why does this cause occur?
Occurrence cause : Suspected disk was cross-contaminated by Mobil maintenance oil which contained high Si level.
HDD PRB TD and MSL result found Si-Smear on the failed head from EC8295 fail drive
Disk dTDP_OD dTDP_ID
HDDSN PROC PFCD PHD HDDASMDATE LI TI MSL result SEM image Remark
lot (Final-Func) (Final-Func)
EDX
Refer EDX on
6800 8295 5 20160522144737 LG 97 6417 - - Si-smear
head#4**
**EDX on bad head in the same drive can refer Si-smear on other heads.
Exclude
Bad
sputter
period
High dTDP on disk
sputter date Apr/14
indicated media was
contaminated
Oil
Sputter date Apr.14 3:00pm~9:00pm is suspected based on the following information applied
for
spindle
s
MPK failure from sputter date Apr.14 3:00pm~9:00pm
Each type shipping cassette transfer two times per shift on Apr.14 for all product, no accurate time traceability
Lift station PM during 8:30am ~16:30 on Apr.14, cleaning was performed during 16:00~19:00.
Si Source Hunting
Many different analyses were conducted looking for evidence of Si present on Mars-KP Media from affected timeframe,
with no obvious differences found between affected and control samples
TOF-SIMS analysis of extractions showed higher levels of siloxanes on the clear inner poly bag from the affected lot,
relative to the control bag, as well as higher levels on the affected cassette relative to the control cassette.
Peaks associated with Irgafos 168 (a common anti-oxidant/process stabilizer) were also observed on the affected
metallized bag, and on the affected cassette.Do not believe this is related to Si smear issue.
WD
Confidential
2016 Western Digital Corporation All rights reserved 11
07/08 update
D4: Identify And Evaluate Root Causes By Tony
Si Source Hunting GCMS Outgassing result
Sample Name Outgas (ug/g) Siloxane (ng/g) Silane (ng/g) Remark
Siloxane containing materials were found to have been used in and around the production factory during the
affected timeframe
While the silicone sealant for toilet maintenance contains very high siloxane, the timing does not match the
problem vintage timeframe so we find no clear linkage to the issue. Also, toilet maintenance was done in sister
building across street from media mfg building (connected by tunnel)
New Mobil lubricant oil that had been transferred to a smaller container/bottle prior to use contains high siloxane,
and was used during maintenance of the elevator during the affected timeframe.
2016 Western Digital Corporation All rights reserved 2016 Western Digital Corporation All rights reserved 4/10/17 12
07/14 update
Hypothesis root
Corrective Actions Owner CP Status
cause
Only use maintenance grease on monthly lift PM Sam Huang Jun.15 Done
Hypothesis root
Corrective Actions Owner CP Status
cause
Media was cross-
contaminated by
Mobil maintenance Only use maintenance grease on monthly lift PM Sam Huang Jun.15 Done
oil which detected
high Si level
Siloxanes
Spec of PE
Outgas
Sample Name
(ug/g)
Siloxane (ng/g) Bag for Silane (ng/g)
reference(n
g/g)
Mobil XHP222 grease
703.062 4.639 10 Not detected
01
Mobil XHP222 grease
922.398 6.465 10 Not detected
02
FTIR and GCMS result shows Si level of Mobil XHP222 maintenance grease is acceptable
2016 Western Digital Corporation All rights reserved 14
07/15 update
Hypothesis root
Corrective Actions Owner CP Status
cause
Media was cross-
contaminated by
WW contamination control team revisit updated lift
Mobil maintenance Dong Wang Jul.19 Ongoing
station PM procedure
oil which detected
high Si level
Experiment Plan:
Facility select 3 lifts including the affected lifts to decontamination
Conduct updated PM on above lifts
Pick up shipping cassette for GCMS testing, before and after maintenance every 4 hours for 6 data points
of each. (Total 12 data points per lift)
Experiment execution plan: Week of Jul 19
GCMS result CP: Jul 29
Hypothesis root
Corrective Actions Owner CP Status
cause
Enhance training unbag
operators about the risk of cross
Media was cross- Optimize Dong Wang Jul.04 Done
contamination and improper
contaminated by shipping handling.
Mobil maintenance cassette unbag
oil which detected activity in lift Optimize cleaning cassette (and
high Si level station other consumables) unbag flow
Xiaohui Zeng Jul.14 Done
to reduce risk of cross
contamination
Training Record
1.Move the shipping cassette from pallet 2.Move the rack with shipping cassette 3.Open outer PE bag w/ double gloves
in corridor to the rack in elevator by from elevator to outer transfer room by in outer transfer room by C/R operator
unpacking room operator A C/R operator B with double gloves B
Notes
1)Operator B can not touch inner bag
2)Operator C take out inner bag from operator B
3)Operator C take off outer gloves and pull the
shipping cassette to C/R
4)Put cassettes removed outer bag to rack B by
4.Move the shipping cassette w/outer PE operator C
bag by operator B to another C/R
operator C between outer and inner
transfer room
2016 Western Digital Corporation All rights reserved 17
07/13 update
0.2m air particle level at transfer room shows obvious improvement for new
unbag procedure comparing to previous unbag procedure
Surface particle level for operators gowning shows obvious improvement for new
unbag procedure comparing to previous unbag procedure
LPC level for operators gloves shows obvious improvement for new unbag
procedure comparing to previous unbag procedure
Hypothesis root
Preventive Actions Owner CP Status
cause
Review scope: <<WI-HGST-01Facility Warehouse Management
Procedure>> & <<WI-HGST-09 Facility Maintenance Working
Facility material
Instruction>>
storage/handling
Sam
enhancement to Focus areas: a) Material control (Approved/designated); b) Storage Jul.20 Ongoing
Huang
prevent cross- (Separation, area/material condition, EOL control etc.); c) Handling
contamination (Distribution, usage condition, temporary storage & disposal etc.)
Method: a) Update the instructions; b) Re-train technicians
Review scope: Clean room environment relative system (MAU, Air-
shower, C/R Exhaust etc.)
Media was cross- Review facility
contaminated by Focus areas: a) materials/tools (approved/designated, Si free material
PM to eliminate
Mobil maintenance etc.); b) Maintenance method (PCN/C & C approval process, Sam
risk of impacting Jul.29 Ongoing
oil which detected particle/outgas avoidances, cross-contamination rules; release for use Huang
clean room
high Si level standard etc.)
environment
Method: a) Pull the facility PM list; b) Review and update in PM system
(Maximo); c) Re-train technicians
Employee clean room cosmetic contamination control training Jun.19 Done
Extend contamination monitoring to SZ shipping cassette cleaning
Overall Jul.E Ongoing
vendor facility Prakash.
contamination
Cross functional audits for grease from CC, QA, Facility, EE, ELM inside Von
improvements Jul.E Ongoing
and outside CR
Extend material purchase control to non-clean room used item Sep. E Ongoing
Hypothesis root
Preventive Actions Owner CP Status
cause
Media was cross- Employee clean room cosmetic contamination control training Jun.19 Done
contaminated by Overall
Extend contamination monitoring to SZ shipping cassette cleaning Dong
Mobil maintenance contamination Jul.E Ongoing
vendor facility Wang
oil which detected improvements
high Si level Extend material purchase control to non-clean room used item Sep. E Ongoing
Fail rate shows down trend after cosmetic contamination control implemented