PCBA Tech - Causes and solutions of PCBA's SMT material loss

The factors existing in the loss of SMT materials of PCB board manufacturers can be comprehensively analyzed by people, machines, materials, and methods as follows:

First, human factors

1. When the technical operators of smt patch processing install the material, the material is lost when the belt is too long and the material is pressed too much; there is a problem of material loss;

Solution: PCB board manufacturers provide professional technical operation training for smt technical personnel. When smt technical operators are loading materials, keep two or three vacancies, press the material to the material window and see that the material is OK, so that you can check the FEEDER gear position and tape tension .

2. After the FEEDER is installed, there is debris on the TABLE which causes it to be out of place and unable to fetch materials when shaking;

Solution: PCB board manufacturers provide professional technical training for smt technology related personnel. When smt technology operators install FEEDER, check the machine TABLE and FEEDER base for sundries, and clean the machine TABLE when turning and pulling.

3. The material tray of the smt equipment is not installed on the FEEDER, causing the chuck and FEEDER TAPE to float and throw materials;

Solution: PCB board manufacturers need to strictly require the smt technical operator to install the material tray on the FEEDER when changing the material.

4. Failure to remove the coiled material in time causes tension changes, non-coiling, poor feeding, and FEEDER TAPE floats and throws;

Solution: PCB board manufacturers strictly require the operator to clean the tape when changing materials

5. Loss caused by reversing the board, jumping the wrong board, wiping the board, etc.;

Solution: The smt patch processing plant strictly requires the smt technical operator to operate according to the work instruction, and mark the position of the board, the direction of the board and the precautions on the instruction book.

6. Wrong material location and P/N cause wrong material;

Solution: PCBA processing plants need to train smt technical operators to check the material P/N and machine alarm display, and the position of the discharge table.

7. The quantity of materials is wrong, the PCBA is excessive, and the material tray is lost by mistake;

Solution: Require material staff to enter and exit all materials on the production line, PCBA must count the quantity and register on-duty to check the production quantity and the stock quantity.

8. The packaging parameters in the edited program are set incorrectly, and the number of feeding times used does not match the packaging PITCH, resulting in throwing;

Solution: Modify the PACKED DATA according to the material packaging.

9. Before the smt chip processing operation, the mounting position and station setting error in the program edited by the smt technical operator caused the wrong material;

Solution: Check the BOM and drawings when doing the program, and re-check the BOM and drawings after posting the first inspection board.

10. During the PCB processing and production process, FEEDER, NOZZLE, and material throwing technicians failed to follow up the throwing material in time, and the data caused a large amount of throwing material;

Solution: require smt patch processing and line technicians to monitor the operating conditions of the machine in real time, and when the machine alarms, it must be processed and observed on site. The hourly dumping report must be signed by the smt technician to confirm and write the improvement measures. If there is a signature to confirm that it has not been processed within two hours, the reason must be analyzed and reported to the assistant engineer for processing.

11. The feeder cover is not fastened, and the feeder is loaded without checking the feeder

Solution: The smt placement factory requires the smt technical operator to work according to the WI requirements, check the FEEDER before and after the installation, and the technician and management check and confirm.

12. FEEDER is randomly stacked to cause deformation, and FEEDER STOPPER is randomly disassembled and placed in disorder;

Solution: The patch processing factory must require the smt technical operator to place all FEEDER on the FEEDER car. It is strictly forbidden to stack or place it randomly.

13. The bad FEEDER failed to be repaired and reused in time, resulting in throwing materials;

Solution: The PCB factory requires that all bad FEEDER of the smt technical operator must be clearly marked and sent to the FEEDER repair station for repair and correction.

Second, the machine factor

1. The suction nozzle is deformed, blocked, damaged, insufficient vacuum pressure, and air leakage, causing the material to be sucked, incorrectly reclaimed, and the recognition fails and the material is thrown.

Solution: PCBA processing plant requires smt technicians to check smt equipment every day, test NOZZLE center, clean suction nozzle, and maintain smt equipment regularly as planned.

2. Insufficient spring tension, uncoordinated suction nozzle and HOLD up and down lead to poor picking;

Solution: Regularly maintain smt equipment as planned, check and replace vulnerable parts.

3. Deformation of HOLD/SHAFT or PISTON, bending of the suction nozzle, and shortening of suction nozzle abrasion, resulting in poor material picking;

Solution: The equipment in the smt workshop of the PCB board manufacturer is regularly maintained as planned, and the vulnerable parts are checked and replaced.

4. The reclaiming material is not in the center of the material, and the reclaiming height is not correct (generally press 0.05MM after touching the part), resulting in deviation, incorrect reclaiming, offset, and the identification does not match the corresponding data parameters And the recognition system is discarded as invalid material;

Solution: PCB manufacturers regularly maintain smt equipment as planned, check and replace vulnerable parts, and calibrate the origin of the machine.

3. Material reasons

1. Substandard products such as dirty, damaged, irregular incoming materials, and oxidation of the PCB components cause poor recognition.

Solution: feedback IQC to communicate with suppliers to replace materials.

2. The components are magnetized, the components are packaged too tightly, and the material frame has too much friction on the components, which makes it impossible to absorb them.

Solution: feedback IQC to communicate with suppliers to replace materials.

3. The component size or package size, spacing, and direction are not uniform to cause poor picking and poor recognition.

Solution: feedback that IQC communicates with the supplier to replace the material, and the packaging and body shape of the same P/N material must be checked when the material is received.

4. The components are magnetized and the material tape is too viscous, and the material adheres to the material tape when the tape is wound.

Solution: The person in charge of the relevant job position of the PCB board manufacturer feedback IQC to communicate with the supplier to replace the material.

Four, operation method

1. The wrong package type FEEDER is used, the groove for the paper tape and the flat groove for the tape cause the material to be unavailable;

Solution: Train the smt technical operator to identify the choice of material packaging and FEEDER.

2. Use wrong FEEDER with different specifications, 0802FEEDRE for 0603 materials, 0804FEEDER for 0402 materials, Ø1.3MM material caps for 0603 materials, Ø1.0MM material caps for 0402 materials, Ø1.0MM material caps for 0805 materials, wrong FEEDERPITCH Unexpected

Solution: PCB board manufacturers train smt technical operators to identify the size and shape of the material body and the choice of FEEDER material cover.

3. The smt technical operators of PCB board manufacturers do not work according to the standards of the work instructions.

Solution: pac board manufacturers strictly require the work in accordance with the standard work instructions, regularly assess the operating skills of smt technicians, and manage supervision and evaluation.