PCB Technical - ​PCB factory implements TPM

TPM (Total Productive Maintenance) was formally formed in Japan. For more than 40 years, it is still one of the preferred management models for equipment-intensive enterprises and has been practiced tirelessly in many industries.

PCB factory, complex process, long production process, including cutting, filleting, edging, baking sheet, inner layer pretreatment, coating, exposure, DES (development, etching, film removal), punching, AOI inspection, VRS Repairing, browning, lamination, pressing, drilling targets, gongs, drilling, copper plating, laminating, printing, text, surface treatment, final inspection, packaging and other processes, most of the processes must rely on equipment to complete Therefore, in recent years, more and more choose to implement TPM.

The TPM framework of Guanzhi consists of "two cornerstones" and "eight pillars". The “two cornerstones” are “5S” and “group activities”; the “eight pillars” are “talent training”, “independent maintenance”, “case improvement (focus improvement)”, “professional maintenance”, “quality improvement”, and “eight pillars”. "Initial improvement", "Business improvement", "Environment and safety". There are no two identical leaves in the world. Even for different PCB manufacturers in the same industry, the key points of implementing TPM may not be exactly the same, but the following key points are generally given priority by PCB manufacturers.

This year alone, PCB factories have had a major fire tragedy. "Fire is the natural enemy of the PCB industry" and "the industry with the highest fire frequency". Some people sigh so. If we look back at the development history of the PCB industry for more than 30 years, it can be said that Zhu Rong has followed all the way, and many world-renowned PCB factories have been burned by the fire. Against this historical background, "Golden Mountain and Silver Mountain, fire protection is the backing" has become more and more important. Therefore, when implementing TPM, PCB factories should first consider the prevention of equipment fires. There have been so many fires along the way. To sum up, electroplating and etching are the processes that are most likely to cause fires; the main reasons are improper chemical treatment, poor temperature control, and wire escape. It is recommended to use D=LEC or other methods to carry out safety risk analysis on production equipment, and then take corresponding preventive measures, and carry out effect tracking and verification.

The vast majority of domestic PCB factories still adopt the post-maintenance model, that is, "repair only if it is broken, not repair if it is not broken", and generally do not have the awareness of "pursuing zero equipment failure". The resulting equipment shutdowns one after another and operation with diseases It is ubiquitous, and one of the most common faults is the card board (unsmooth delivery). Moreover, it is not uncommon for equipment production lines with a unit price of several hundred thousand to several million yuan to deteriorate and have to be scrapped after only three to five years. It is recommended to organically integrate and subdivide "autonomous maintenance", "professional maintenance" and "initial improvement", design a controlled maintenance system covering the entire life cycle of equipment, and form prevention of "repair by maintenance" through the participation of all employees Maintenance mechanism to gradually realize zero failure of equipment.

Quality maintenance refers to the maintenance and improvement of equipment based on the quality of the product so that the equipment can produce qualified products.

Because PCBs rely on equipment for production, fewer PCB factories systematically carry out quality maintenance, but PCB itself has higher quality requirements, so the one-time pass rate of general PCB factories is low, and the total failure rate of each process is accumulated., It can be as high as 10% or more; the failure rate of a single process can be as high as 2% to 4% (such as exposure, development). It is recommended to analyze the correlation between poor quality and equipment status, and then take targeted improvement measures. When carrying out quality maintenance, we should also pay attention to related factors such as improving the skill and proficiency of personnel.

With the advent of the era of small batches, multiple varieties, and high production costs, the loss of line suspension caused by production changes has attracted more and more attention. Take CNC molding machine as an example. Generally, one changeover takes 50 to 90 minutes, and one or two batch numbers are changed a day. The efficiency loss caused by it cannot be underestimated. There are also processes such as inner layer exposure, text printing, solder mask printing, dry film exposure, and drilling. The changeover time ranges from ten minutes to tens of minutes. It is recommended to implement rapid production changeover activities in order to gradually reduce the changeover time of the above-mentioned processes to less than 10 minutes.

In PCB factories, there are many undesirable statuses such as leaking, dripping, corrosion, etc.; at the same time, because PCB factories often adopt workshop-divided production methods, there are more handling between workshops and between processes. . To vigorously promote 5S, we should focus on improving the cleanliness of the equipment body and improving the efficiency of handling (logistics).

Although China's PCB industry is the world's largest in terms of scale, it still lags behind the world's advanced level in terms of overall industrial management. Successful examples have shown that the management improvement effect of TPM on PCB factories is more obvious. However, if we can further grasp the main points in combination with the actual situation, it will not be difficult to achieve a multiplier improvement effect.