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Introduction
The sudden 15% increase in defect rates for Intel's 10nm SuperFin transistors is a critical issue that demands immediate attention. This analysis will systematically identify, validate, and address the root cause while considering both short-term and long-term implications for Intel's product line and market position.
I'll approach this problem by first clarifying the context, then ruling out external factors before diving deep into the product specifics, metric breakdown, and data analysis. From there, I'll form and validate hypotheses, conduct a root cause analysis, and propose a comprehensive resolution plan.
Framework overview
This analysis follows a structured approach covering issue identification, hypothesis generation, validation, and solution development.
Step 1
Clarifying Questions (3 minutes)
Why it matters: Process changes often lead to quality fluctuations. Expected answer: Yes, there have been minor tweaks to improve yield. Impact on approach: If yes, we'll focus on recent changes; if no, we'll look at other factors.
Why it matters: Ensures we're dealing with a real issue, not a measurement artifact. Expected answer: No changes to QC processes. Impact on approach: If changed, we investigate measurement; if not, we focus on actual defects.
Why it matters: Helps narrow down potential causes and affected areas. Expected answer: Increase is seen across multiple lines but varies in severity. Impact on approach: Uniform increase suggests systemic issue; localized suggests equipment or process problem.
Why it matters: External factors can significantly impact product quality. Expected answer: No major changes in suppliers or reported quality issues. Impact on approach: If yes, we investigate supply chain; if no, we focus on internal factors.
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