PCB Technical - How does PCBA handle abnormal incoming materials?

How to deal with abnormal incoming materials from SMT patch processing plant?

1. Purpose

PCBA processing factory return staff return material inspection methods and procedures, effective control of bad materials in the PCBA processing process, to ensure the smooth production of PCBA and customer satisfaction, this standard is specially set.

2. Scope of application

This work instruction is applicable to all PCBA processing plants for return inspection

3. Definition

1) Poor incoming materials

The materials provided by customers or suppliers are inherently defective and do not meet product quality standards or production process requirements.

2) Production damage

Due to improper operation in the PCBA production process, the materials have defects that do not meet the product quality standards or production process requirements.

4. Responsibilities

1) The IQC returner is responsible for the inspection of the returned materials, and keeps relevant records of the inspection timely and accurately.

2) The IQC returner is responsible for the identification of the responsibility status after the return inspection.

5. Content

1) General material inspection

A. To perform the return operation on the production line, the physical material code, model, quantity, bad content, supplier, and bad mark must be confirmed on the body of the bad material.

B. The production line personnel output the production return form and send it to the IQC returner.

C. The IQC returner inspector checks the actual material identification and the physical object according to the return form, and determines who is responsible according to the defective phenomenon marked on the part. If the actual cause of the material defect is found to be inconsistent with the return form, it will be returned to the production line for renewal. confirm.

2) Inspection of returned materials for four major items

A. When the production line performs the return operation, it is necessary to distinguish the model, part number, supplier, and quantity. The engineering department shall confirm the defect and confirm the signature.

B. The production line material clerk outputs the production return order and sends it to the IQC return clerk.

C. The responsibility for bad materials is judged as production damage. If the IQC returner does not find any bad appearance during the appearance inspection, it will be judged to be bad, and the relevant records will be recorded in the "Four Major Items Return Report".

D. Questions that cannot be judged need to be reported to the superior MQE for confirmation.

3) Nesting (good product) return inspection

A. When the production line executes the return action, it is necessary to distinguish the model and part number.

B. The IQC returner inspector conducts an appearance inspection on the material to confirm whether the material is good;

C. When the IQC returner inspector confirms the return of the nesting material, first confirm whether there is a substitute material for this model. If there is a substitute material, the IQC returner inspector needs to confirm the material number on the document and the material Indicate whether the material number and actual material number are the same to determine whether the return material of the production line is correct.

D. If the quantity of materials is below 15PCS, the IQC returner inspector will perform full inspection. If the quantity of materials is above 15PCS, the IQC returner inspector will perform random inspections in accordance with GB/T2828.1 (0.65/1.0);

E. If the IQC returner inspector finds that the production line has returned mixed materials during the nesting process, immediately re-differentiate the nesting return production line;

4) Processing of inspection results

A. According to the inspection results, the IQC returner should truthfully fill in the relevant data on the production return form, affix the special seal of the IQC returner for return, and affix the unqualified product label on the judged material. Indicate the material number, bad phenomenon, and responsibility.

B. After the inspection is completed, the IQC returner needs to make the recorded "Four Major Return Reports" into an electronic file, and send it to the relevant personnel by email every Monday morning, and at the same time file the paper file.

5) PCBA&LCD, TP return

A. PCBA return: In principle, the supplier is required to go to the site for judgment; if the supplier cannot be there, it will be judged by IQC. After the IQC judgment, it must be confirmed by the customer in the factory. If the customer in the factory cannot be confirmed on site, they need to support IQC Decide the judgment result.

B. LCD return: When the defective LCD has accumulated to a certain number, the IQC engineer will notify the supplier to come to the company for on-site confirmation.

6) Bad material warning line

A. Bad incoming materials warning line: bad materials used without concession>3%

For materials with poor incoming materials that exceed the warning line, the IQC engineer must be notified, and the IQC engineer will issue a "Vendor Quality Improvement Contact Form" to notify the supplier, and process the inventory materials.

B. Warning line for poor operation: Four major materials>0.05%

For materials with poor operations that exceed the warning line, IQC informs the responsible unit and engineering department to request analysis and improvement.

7) Material scrap basis

A. The four major parts have the following defects to be scrapped due to production operations: the display screen is broken, the copper foil of the welding gold finger cable is dropped, the FPC is broken, and the surface is obviously hard scratched;

B. The shell material has the following defects as a result of the production operation to be scrapped: beating, breaking, perforating, severely deforming, buckling broken;

C. The production operation leads to the assembly and use of poor performance of electronic devices, which are scrapped.