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The factors of SMT material loss, we can first conduct a detailed analysis through the man-machine material method as follows:
1. Human factors
1. When the material is installed, the tearing tape is too long and the material is too much to cause loss of material;
Solution: Train the operator to reserve two or three vacancies when loading the material, press the material to the material window and see the material OK, so that you can check the FEEDER gear position and the tape tension.
2. After the FEEDER is installed, there is debris on the TABLE which causes it to be out of place, shaking and not fetching materials;
Solution: Train the operator to check the machine TABLE and FEEDER base for debris when installing FEEDER, and clean the machine TABLE when turning it.
3. The material tray is not installed on the FEEDER causing the chuck and FEEDER TAPE to float and throw materials;
Solution: Strictly require the operator to load the tray on the FEEDER when changing the material.
4. Failure to remove the coiled material in time, causing tension changes, non-coiling, poor feeding, and FEEDER TAPE floating and throwing materials;
Solution: Strictly require the operator to clean the tape when changing materials
5. Loss caused by reversing the board, jumping the wrong board, rubbing the board, etc.;
Solution: Strictly require the operator to operate according to the work instruction, and mark the position of the board, the direction of the board and the matters needing attention on the instruction book.
Causes and solutions of SMT material loss
SMT material loss factors and solutions
6. Reading the wrong material location and P/N cause wrong material;
Solution: Train the operator to check the material P/N, the machine alarm display, and the position of the discharge table.
7. The quantity of materials is wrong, 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 not set correctly, and the number of feeding times used does not match the packaging PITCH, resulting in throwing;
Solution: Modify PACKED DATA according to material packaging.
9. Wrong placement and station setting in the edited program cause wrong material;
Solution: Check the BOM and drawings when making the procedure, and re-check the BOM and drawings after posting the first inspection board.
10. During the 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: It is required that the follow-up technician must monitor the machine's operating status in real time, and must handle and observe on-site when the machine alarms. The hourly dumping report must be signed by the technician to confirm and write improvement measures. If the report has not been processed for 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: require the operator to work according to WI requirements, and check FEEDER before and after installation. Technician and management check and confirm.
12. FEEDER is randomly stacked to cause deformation, FEEDER STOPPER is randomly disassembled and placed in disorder;
Solution: The operator is required to place all FEEDER on the FEEDER car. It is strictly forbidden to stack or place it randomly, and it is strictly forbidden to dismantle the FEEDER accessories randomly.
13. The bad FEEDER failed to be repaired and reused in time to cause throwing;
Solution: The operator is required to clearly identify all bad FEEDER and send it to the FEEDER repair station for repair and correction.
2. Machine factors
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: require technicians to check the equipment every day, test the NOZZLE center, clean the suction nozzle, and maintain the equipment regularly as planned.
2. Insufficient spring tension, uncoordinated suction nozzle and HOLD up and down lead to poor picking;
Solution: Regularly maintain the 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 wear, resulting in poor material picking;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts.
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 identification does not match the corresponding data parameters And the recognition system is discarded as invalid material;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts, and correct the origin of the machine.
5. The vacuum valve and the vacuum filter element are dirty, and the vacuum pipe channel is blocked by foreign matter. The vacuum is not enough when sucking, and the operating speed of the equipment causes poor feeding;
Solution: require technicians to clean the nozzle every day and maintain the equipment regularly as planned.
6. The positioning of the machine is not horizontal and the vibration is large, and the resonance of the machine and the FEEDER causes poor feeding;
Solution: Regularly maintain the equipment as planned, and check the equipment level to fix the support nuts.
7. Worn and loose screw rods and bearings cause vibration and stroke changes during operation, resulting in poor material picking;
Solution: It is strictly forbidden to blow the inside of the machine with an air gun to prevent dust, debris and components from sticking to the screw. Regularly maintain equipment as planned, check and replace vulnerable parts.
8. Motor bearing wear, barcode reader and amplifier aging cause the machine origin to change, the operating data is inaccurate, and the material is poor;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts, and correct the origin of the machine.
9. The vision, laser lens, and suction nozzle reflective paper are not clean, and there are debris that interferes with the camera's recognition and causes poor processing;
Solution: require technicians to check the equipment every day, test the NOZZLE center, clean the suction nozzle, and maintain the equipment regularly as planned.
10. Identification of improper selection of light source, aging of the luminous intensity of the lamp, and insufficient grayscale resulting in poor processing;
Solution: Regularly maintain the equipment according to the plan, test the brightness of the camera and the brightness of the lamp, check and replace the vulnerable parts.
11. Poor handling caused by aging, carbon deposits, abrasion and scratching of reflective prisms;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts.
12. Insufficient air pressure, leakage of vacuum causes insufficient air pressure and the material cannot be retrieved, or it falls on the way to paste after picking it up;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts.
13. The feeder gland is deformed and the spring tension is not enough to cause the material tape to not be stuck on the ratchet wheel of the feeder, and the tape is not thrown;
Solution: The operator is required to clearly identify all bad FEEDER and send it to the FEEDER repair station for repair, correction, inspection and replacement of vulnerable parts.
14. Camera loosening and aging cause poor recognition and throwing materials;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts.
15. Feeder ratchet gears, driving claws, positioning claws are worn, electrical failures, and feeding motors are poor, causing the feeder to feed poorly, or poorly and throwing materials;
Solution: require the operator to clearly identify all bad FEEDER and send it to the FEEDER repair station for repair, correction, inspection and replacement of vulnerable parts
16. The abrasion of the machine's feeding platform causes FEEDER to become loose after installation and poor feeding;
Solution: Regularly maintain the equipment as planned, check and replace vulnerable parts.
Causes and solutions of SMT material loss
SMT chip processing products
3. Material reasons
1. Unqualified products such as dirty, damaged, irregular incoming materials, and oxidation of pins cause poor identification.
Solution: feedback IQC to communicate with suppliers to replace materials.
2. The components are magnetized, the components are packed 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 IQC to communicate with the supplier to replace the material. When receiving the material, the packaging and body shape of the same P/N material must be checked.
4. The component is magnetized and the material tape is too viscous, and the material adheres to the material tape when the tape is wound.
Solution: feedback IQC to communicate with suppliers to replace materials.
5. The suction surface of the component is too small, resulting in poor picking.
Solution: feedback IQC to communicate with suppliers to replace materials and reduce the machine's operating speed.
6. The material aperture of the component is too large, and the component size is not consistent with the package size, which will cause the material to stand upright, turn over, and position incorrectly during feeding, resulting in poor material retrieval.
Solution: feedback IQC to communicate with suppliers to replace materials.
7. The error between the feeding hole and the feeding hole of the material belt is large, and the suction position changes after the material is changed.
Solution: feedback IQC to communicate with suppliers to replace materials.
8. The tension of the coiled material is not uniform, it is too soft and easy to stretch without coiling; it is too brittle and easy to break and the material cannot be taken.
Solution: feedback IQC to communicate with suppliers to replace materials.
9. Incoming material packaging is not standardized, and bulk packaging cannot be machined.
Solution: feedback IQC to communicate with suppliers to replace materials.
4. Operation method
1. The wrong package type FEEDER is used, the groove for paper tape and the flat groove for tape cause the material to be unavailable;
Solution: Train operators to identify the choice of material packaging and FEEDER.
2. Use wrong FEEDER with different specifications, 0802FEEDRE for 0603 materials, 0804 FEEDER for 0402 materials, ?1.3MM material cover for 0603 materials, ?1.0MM material cover for 0402 materials, ?1.0MM material cover for 0805 materials, wrong FEEDERPITCH Unexpected
Solution: Train the operator to identify the size and shape of the material body and the choice of FEEDER material cover.
3. The personnel do not work according to the standard work instructions.
Solution: Strictly require the work in accordance with the standard work instructions, regular assessment of operating skills, management supervision and evaluation.
4. Poor splicing, bending of the material belt, too tight coiling belt tension, and poor material reclaiming caused by the hole of the material belt not on the gear;
Solution: Strictly require work in accordance with the standard work instructions, training and assessment of operating skills, management supervision and evaluation.
5. The tension of the coil is not enough, and the coil is not installed according to the standard;
Solution: Strictly require work in accordance with the standard work instructions, training and assessment of operating skills, management supervision and evaluation.
6. After the material is installed, there are vacancies that cause the material to be unavailable;
Solution: Strictly require work in accordance with the standard work instructions, training and assessment of operating skills, management supervision and evaluation.
Five, production environment
1. The high temperature and insufficient humidity in the workshop cause dust and static electricity when the material is dried.
Solution: Monitor the temperature and humidity of the workshop in real time, add air conditioners and humidifiers.
2. The humidity in the workshop and warehouse is high, and the material absorbs moisture in the air, causing poor material retrieval
Solution: Real-time monitoring of temperature and humidity in workshops and warehouses, adding air conditioning and ventilation equipment.
3. The workshop has poor airtightness and poor dust-proof facilities. Too much dust causes the machine to be easily dirty and vacuum blocked.
Solution: It is strictly forbidden to use air guns to blow machine electrical equipment and materials, and add carpet dust removal at the door of the workshop.
4. Insufficient loading platform and FEEDER carts cause non-standard loading and FEEDER damage and deformation.
Solution: increase the loading platform and FEEDER cart, and operate strictly according to WI requirements.
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