PCBA Tech - About SMT patch processing process exception handling

Purpose

In order to effectively track the root cause of SMT process abnormal problems, clarify the rights and responsibilities of each related department, improve the efficiency of abnormal accident handling, and reduce complaints;

definition

SMT (Surface Mounting Technology): surface mount technology;

SMT patch processing process is abnormal: due to the lack of technicality of SMT equipment (program) parameters, poor raw materials (main materials, auxiliary materials), design errors and other factors, the process control fails, the production efficiency cannot reach the predetermined target, and the SMT product quality exceeds All events of the IPC acceptance standard are called SMT process abnormalities;

Duties

Engineering Department: Analyze the cause of abnormal process, determine the nature of the abnormal accident, and provide suggestions for improvement;

R&D department: explain design principles and revise design schemes;

Quality Assurance Department: Provide quality data reports, feedback complaints handling opinions, and assign responsibilities;

Quality Planning Department: track the timely closure and phase control of problems at each stage, and for process problems, combined with engineering analysis and risk assessment, assist in promoting R&D and improvement;

After-sales service department: feedback customer information, investigate and track the status of client products;

Project Management Department: Overall coordination and supervision of project team members to promote the resolution of problems, to ensure the progress of the project;

1. Manufacturability design leads to the processing flow of abnormal process

1.1. If process abnormalities caused by manufacturability design are found, the outsourcing factory will summarize the problem points and output a trial production report, and the NPI in the factory will send the trial production report to the project team. In response to the manufacturability design problems reported in the "Trial Production Report", the engineering confirms whether the revision is to be made and provides analysis and evaluation opinions to R&D;

1.1.1. If R&D has no objection to the analysis opinions of the project, the R&D will implement the revision, the quality plan will track the revision progress, and the project will be responsible for the revision confirmation;

1.1.2. If there is a dispute between the analysis opinions of the project and the requirements of R&D and design, the project manager and quality plan will evaluate and resolve them;

2. Process abnormal handling process in the production process

2.1. When process abnormalities are found in production, the XX plant NPI needs to confirm the status of the production line in time, and the plant PQE promptly provides the "Outsourcing Factory Abnormal Problem Feedback Form", and the project is responsible for judgment based on the "Outsourcing Factory Abnormal Problem Feedback Form", Confirm and provide improvement suggestions, PQE decides whether to maintain production or stop the line according to the abnormal risk level;

2.2. Classification and treatment of process abnormalities in the production process

2.2.1. Handling of abnormal process caused by poor incoming materials

2.2.1.1. Incoming bad information feedback

2.2.1.1.1. For abnormal process accidents caused by poor incoming materials, the PQE in the XX factory shall be responsible for the information feedback of abnormal incoming materials, and notify SQE to contact the supplier to cooperate with the improvement of the production line;

2.2.1.2. Analysis of the causes of poor incoming materials

2.2.1.2.1. Resident PQE leads the analysis of outsourcing factories and suppliers to the production line, and provides analysis results;

2.2.1.2.1.1. If the outsourcing factory and the supplier agree with each other and confirm the analysis results agreed by both parties, then the project will give a risk assessment opinion based on the analysis results of both parties, and provide it to PQE for reference, and PQE will decide whether to change the material Or overcome production;

2.2.1.2.1.2. If there is a disagreement between the outsourcing factory and the supplier, and the analysis result agreed by both parties is not reached, the project will make a judgment and analysis based on the abnormal feedback information, and provide the analysis opinion to PQE for reference, and PQE will coordinate SQE to solve it;

2.2.2. Treatment of process abnormalities caused by missing processing technology data

2.2.2.1. Handling of missing Gerber data content

2.2.2.1.1. The NPI stationed in the factory will notify the project team by email, and the SMT process engineer will confirm it. If the situation is true, the R&D will be responsible for the file upgrade and send it to the outsourcing factory, and the NPI will be responsible for tracking until the problem is closed;

2.2.2.2. Treatment of missing content in "Process Control Matters"

2.2.2.2.1. Shanghai NPI is responsible for the file upgrade and send it to the outsourcing factory, and the stationed NPI supervises the outsourcing factory to adjust the process according to the upgraded file to maintain production;

2.2.3. SMT equipment (program) problems lead to the treatment of process abnormalities

2.2.3.1. Treatment of process abnormalities caused by equipment performance degradation

2.2.3.1.1. When the performance of the SMT equipment of the outsourcing factory is not adequately maintained and upgraded in a fixed period, resulting in abnormal process accidents, engineering intervention is required to evaluate the performance of the equipment, and the outsourcing factory is instructed to Transform according to the inherent parameters of the equipment, and then confirm the equipment performance index (CPK) to meet the prerequisite of the process capability of XX products;

2.2.3.2. Treatment of process abnormalities caused by sudden equipment failures

2.2.3.2.1. Process abnormalities caused by sudden equipment failures during the production process are controlled internally by the outsourcing factory;

2.2.3.3. SMT patch program error leads to the processing of abnormal process

2.2.4. Treatment of abnormal process caused by the opening method of the steel mesh

2.2.5. Handling of abnormal process caused by auxiliary fixture (carrier dispensing fixture)

2.2.5.1. The outsourcing factory is responsible for the proofing and adjustment of auxiliary fixtures, the XX project is responsible for outputting specific requirements and evaluation opinions, and the PQE is responsible for handling the quality problems caused;

3. Process for handling process abnormal complaints

3.1. In response to complaints about process abnormalities, quality, engineering, and R&D need to be coordinated and dealt with;

3.1.1. Engineering and R&D are responsible for the cause analysis and status confirmation of process abnormalities;

3.1.2. Quality planning is responsible for the coordination and tracking of process abnormal complaints until the clear certainty of the cause of the abnormality;

3.1.3. PQE, based on the analysis conclusions of R&D and engineering, instructs the outsourcing factory to provide improvement measures, and track follow-up production until the problem is closed; if a third-party verification is required, PQE will be responsible for coordinating the processing of the outsourcing factory and provide analysis report;

3.2. Process for handling internal complaints of process abnormalities

3.2.1 Handling of complaints about process abnormalities during R&D and commissioning

3.2.1.1. First, R&D will conduct qualitative analysis of functions and signals, reserve bad samples (no repairs have been made) and fill in the "PCBA Welding Abnormal Problem Contact Form" and submit it to the quality plan, and then the quality plan will contact the engineering analysis judge;

3.2.2. Handling of complaints about process abnormalities in the assembly stage of the complete machine

3.2.2.1. The after-sales service is responsible for collecting the back-end information, the PQE is responsible for summarizing the production data of the outsourcing factory, and the project is responsible for analysis and judgment;

3.3. Process for handling customer complaints of abnormal process

3.3.1 Abnormal information collection and feedback

3.3.1.1. After-sales is responsible for collecting and feeding back customer information. The customer operation process (such as PCBA status, packaging and transportation methods, operation methods, etc.) must be described in detail in the "Customer Complaint Handling Form", and clear pictures and explanatory texts should be attached;

3.3.1.2. PQE is responsible for summarizing the production data of the outsourcing factory, and providing bad samples (no repairs have been made), contacting engineering and R&D for analysis;

3.3.2 Analysis and treatment of abnormal causes

3.3.2.1. PQE organizes a meeting to determine whether the reasons for customer complaints are sufficient and whether the complaint requirements are reasonable;

3.3.2.1.1. If the reason for the complaint is established, it is obviously manifested as a customer complaint caused by an abnormal process, the PQE is responsible for urging the outsourcing factory to review and submit the follow-up improvement plan, and the project is responsible for the confirmation of the improvement plan;

3.3.2.1.2. If the reason for the complaint is insufficient and the cause of the abnormality is relatively vague, the quality planning committee shall inform the research and development department to conduct a qualitative analysis of functions and signals, and fill in the "PCBA Welding Abnormal Problem Contact Form"; the project is based on the "PCBA Welding" Analyze the Abnormal Problem Contact Sheet and give a judgment conclusion;