Synthetic example. Every value is made up to show the format.
Lessons · Issues
Issues What did go wrong, why, and what fixed it?
4 issues
1 with a fix in place
1 embargoed Yield lost to each issue, biggest first, with the running share. Only issues whose yield impact the file states. Stick drift traced to flux under the potentiometer Public iss:stick-drift-flux ext:controller:stick-drift sensor solder
Seen on field, simulated · caught at field, test
Conditions Hand soldering with flux-core wire next to an open potentiometer housing; worse after months of use Yield impact 1.2% Engineering judgement, not measured. Medium confidence.Evidence: src:reviews, src:repair-guide field return share attributed to drift in the review sample Root cause Flux migrates into the carbon track and changes wiper resistance Engineering judgement, not measured. Medium confidence.Evidence: src:ct-run-1, src:repair-guide proposed design-change Replace soldered pins with an FPC connector on the stick module
implemented sop-update Cap iron dwell at 2 s, no extra flux, inspect with 10x loupe
Yield before 97.8% Engineering judgement, not measured. Low confidence.No evidence listed. after 98.6% Engineering judgement, not measured. Low confidence.No evidence listed.
#solder #field-return
Battery connector unseats after a 1.2 m drop Public iss:battery-unseat connector-unseat fpc-connector battery connector-mate
Seen on simulated, dvt · caught at reliability-test
Conditions Tight z-height over the connector; the top shell rib lands 0.3 mm above it Yield impact 0.9% Engineering judgement, not measured. Low confidence.Evidence: src:ct-run-1 drop-test fallout in the simulated build Root cause No preload on the connector and no seat check at mating Engineering judgement, not measured. Medium confidence.Evidence: src:ct-run-1 proposed fixture-change Closing fixture presses the connector while the shell closes
proposed sop-update Tug test after mating, 2 N, at sta:a3
#tight-space #drop
Shoulder-button gap opens past 0.30 mm on cavity 2 Embargoed until 2028-06-01 iss:shoulder-gap gap-flush housing button inspect
Seen on pvt · caught at fqc
Conditions Cavity 2 of the top-shell tool; worse in the first hour after a mould start Yield impact 1.7% Engineering judgement, not measured. Low confidence.Evidence: src:caliper-run-1 Root cause Uneven cooling bows the shoulder wall outward on cavity 2 Engineering judgement, not measured. Low confidence.Evidence: src:caliper-run-1 trialled process-change Raise mould temperature 8 C and extend cooling 2 s on cavity 2
Yield before 98.3% Engineering judgement, not measured. Low confidence.No evidence listed. after 99.1% Engineering judgement, not measured. Low confidence.No evidence listed.
#tooling #cosmetic
RF power low when the LRA sits against the antenna keep-out Public iss:rf-detune rf-detune antenna motor-haptic connector-mate
Seen on simulated · caught at test
Conditions The LRA pocket allows 2 mm of play toward the antenna Yield impact 0.6% Engineering judgement, not measured. Low confidence.Evidence: src:eol-sample
Root cause Metal LRA can within 5 mm of the chip antenna detunes it Engineering judgement, not measured. Medium confidence.No evidence listed. proposed design-change Add a rib so the LRA can't move toward the antenna
#rf #placement