QT-00056 Ver40 SMT 產(chǎn)品更換工作指引

1、SUZHOUSMT 產(chǎn)品更換工作指引SMT Changeover instruction信息分類： 三階文件文件編號: QT-00056版本:4.0頁碼:11 of 111.Product Revision 產(chǎn)品版本Product Name產(chǎn)品名稱Applicable Product BOM Revision適用的產(chǎn)品BOM版本N/AN/A2.Change history更改記錄Updated Ver.最新版本Effective date 生效日期Prepared by起草人Brief of Amendments更改內(nèi)容摘要1.02012/5/27Yongxing ZhuNew Issue2.

2、02012/9/7Yongxing ZhuAdd AOI and SPI process3.02012/11/26Yongxing ZhuOptimize changeover process4.0Dirk ZhuAdd handed placement process3.Purpose目的Know clearly how to change over product, in order to guide operators to change over product correctly and achieve quickly change over goal.明晰SMT產(chǎn)線轉(zhuǎn)型操作,以指導(dǎo)

3、轉(zhuǎn)型員工正確操作,達到快速轉(zhuǎn)型目標(biāo).4.Scope范圍All related changeover personnels.所有與生產(chǎn)線轉(zhuǎn)型相關(guān)人員.5.Definitions定義5.1 Changeover: The process that production line changes from one product to another product.轉(zhuǎn)型的定義:是指生產(chǎn)線從一個產(chǎn)品切換到另一個產(chǎn)品的操作過程.5.2 Changeover Time: Start time for the last PCB for the previous product begin to load

4、into the reflow, end time for the first PCB for the next product has passed the reflow.轉(zhuǎn)型時間的定義:轉(zhuǎn)型時間以爐前上一個型號最后一片板子進爐開始，到下一個型號第一片板子進爐結(jié)束5.3 Changeover operators: The person who joins in changeover directly, its recommended that 5 people to finish a standard changeover operation, here be defined as: OP-

5、1,OP-2,OP-3,OP-4,OP-5. OP-1 is DEK operator, OP-2 and Op-3 are placement operators, OP-4 is visual inspection before reflow, OP-5 is offline setting up team. 轉(zhuǎn)型人員的定義:這里所定義的轉(zhuǎn)型人員是指直接參與轉(zhuǎn)型操作的人員,一個標(biāo)準的轉(zhuǎn)型操作建議由5人完成,這里分別定義為OP-1,OP-2,OP-3,OP-4,OP-5,其中OP-1為DEK操作員,OP-2和OP-3為貼片機操作員,OP-4為爐前人員,OP-5為離線上料組.6.Respons

6、ibilities職責(zé) Planner is responsible for sending production schedule to technicians 24hours early. Planner提前24小時把生產(chǎn)計劃發(fā)給技術(shù)員.Technician is responsible for optimizing several products together according to production schedule 12hours early and make setup list, support any deviation on line.技術(shù)員根據(jù)計劃提前12小時打

7、包優(yōu)化程序并做套料單,在線支持任何異常.Line leader is responsible for personal coordinate and problem feedback.班組長負責(zé)人員協(xié)調(diào)與問題反饋.Warehouse is responsible for releasing materials to the preparation member 8hours early according to work order. The setup list should contain informations: product module, WISE version, line n

8、umber, placement machine name, table number, part number, storage location, BOM requirement quantity for this work order and actual sending quantity, Take the materials according to the Feeder list in good order and points good feeder position .庫房根據(jù)工單提前8小時發(fā)料給產(chǎn)線備料員，備料單上包括以下信息：產(chǎn)品型號、版本、線別、貼片機設(shè)備名稱、Table

9、區(qū)號、料號、庫位、BOM、工單需求數(shù)量、發(fā)料數(shù)量，備料員取料時按照Feeder list排好順序并分好站位；Off line setup center setting up (or tear down) leader is responsible for printing the setup list, mark the MSL components in the setup list, support if any deviation and monitoring and keep records of deviations.離線上料(或下料)的領(lǐng)班負責(zé)打印上料單,在上料單上標(biāo)記濕度敏感元器

10、件,支持任何異常,檢查并記錄異常.DEK printer operator is responsible for preparing magazine loader/ stacker, Pick and inspect stencil ,squeegees, PCB, paste or glue, Take old stencil/squeegees and clean ,Change program acc. to product change over check list, Fix tooling / check tooling ,Full print inspection cycle

11、acc. To instruction, SPI check , Running the production (paste and cleaning replenishment) , Daily maintenance acc. To instruction DEK印刷機作業(yè)員負責(zé)準備自動存儲送料裝置，領(lǐng)取并檢驗鋼網(wǎng)，刮刀，PCB, 錫膏或紅膠，清洗鋼網(wǎng)和刮刀，根據(jù)產(chǎn)品更換確認表調(diào)用程序，維修和檢驗工具，量產(chǎn)時根據(jù)指引要求檢查印刷的周期，SPI檢查，運行生產(chǎn)，每日保養(yǎng).Pick and place operator is responsible for monitoring and reco

12、rding PuR, Cph /2hsupport if any deviation and keep records of deviations.貼片機作業(yè)員負責(zé)每隔兩小時監(jiān)控和記錄吸取率和每小時產(chǎn)能，支持任何異常和記錄異常.Reflow operator is responsible for monitoring the process, feedback defects to team leader.回流爐作業(yè)員負責(zé)監(jiān)控制程, 并及時把缺陷反饋給工段長.AOI operator is responsible for recording DPMO, and feedback defects

13、 to the team leader.AOI作業(yè)員負責(zé)記錄每百萬件的缺陷數(shù)，并及時把缺陷反饋給工段長.7.Description描述7.1 Off line setup center setting up離線上料7.1.1 Print setup list according to QF-00070 SMT Product Change Over Check List, check all the materials for the changeover product are arrived in line, check PCB part number version and quanti

14、ty. 打印上料單根據(jù)QF-00070 產(chǎn)品更換記錄表，確認轉(zhuǎn)型產(chǎn)品的所有物料已到產(chǎn)線，確認PCB的料號,版本和數(shù)量.7.1.2 Pick up empty feeders and tables, check all the feeders and tables are in good overall condition. and put the feeders in the correct position according the setup list.拾取空的供料器和供料車，確認供料器與供料車都處于好的狀態(tài).并根據(jù)上料單把供料器放在供料車的正確位置上.7.1.3 Set the com

15、ponents into the feeders carefully avoiding component loss or damage,1st component on tape to the correct pick up position裝料時要小心操作，避免物料損耗或損壞，第一個料要裝在正確的取料位置.7.1.4 Adjust the feeder settings according the feeder list，Check that all feeders have correct pitch and that the pick up angles are correct .If

16、 pick up angle, material packing size or feeder type is different from the setup list, operator should inform technician to check and adjust in time, if need to change program, technician should record the program changing list and check the changing position components placement orientation for the

17、 first PCB before reflow.根據(jù)上料單，調(diào)整供料器的設(shè)置，確認所有的供料器的供料間隔，吸料角度都是正確的.如果吸料角度，材料封裝尺寸或供料器類型與上料單不同，作業(yè)員應(yīng)及時通知技術(shù)員確認和調(diào)整,如果需要更改程序，技術(shù)員應(yīng)做好程序更改記錄并確認爐前首板該料的貼裝方向.7.1.5 Put all hand mounted components to a separate container, Make sure all needed components are omitted in the program, Write a note to go along in the co

18、ntainer which tells what components are hand mounted and what are their positions. 把所有手貼的物料裝到一個單獨的容器中，確保在程序中所有手貼物料都被忽略,記錄什么物料需手貼，及其貼裝位置.7.1.6 For MSD, Tray, stick packing etc. cant loaded in advance, operator need mark on the setup list , MSD material will be loaded in half an hour early before chan

19、geover.對于濕敏元件，托盤物料，管裝料等不能提前上料的，上料組成員需要在上料單上作出標(biāo)注, 濕敏元件在轉(zhuǎn)型前半小時上料.7.1.7 Verify all components with the barcode reader. For not traceability product, only scan part number barcode, for traceability product, need scan two barcodes: part number, unique ID.確認所有的物料都已掃料.不需要追蹤的產(chǎn)品，只掃料號條碼，需要追蹤的產(chǎn)品，掃兩個條碼：料號和唯一身份標(biāo)

20、識號碼.7.1.8 Splice all needed components in advance. 把需要接料的料盤全部提前接好.7.1.9 After a table is complete mark the set-up-list with date, time and name.完成離線上料的供料車，作業(yè)員在上料單上簽上日期，時間和名字.7.1.10 Take all completed tables to near the line marked areas in blue to wait for production.把所有已完成的供料車推到產(chǎn)線附近的有藍色標(biāo)記的區(qū)域等待轉(zhuǎn)型.7.

21、1.11 As the production moves forward, remember to move the next setup to the nearer marked areas. 由于生產(chǎn)在向前發(fā)展，記得移動下單的物料向更近的標(biāo)記區(qū)域.7.1.12 Assist in other jobs if needed. 如果需要準備其他工單.7.1.13 Make sure that the setup area is clean. 確保上料區(qū)域的清潔.7.2 Off line setup center tear down離線下料7.2.1 Pick up tables going t

22、o tear down from marked areas. 把供料車移到下料標(biāo)記區(qū)域.7.2.2 Remove the components from feeders. Remember to leave enough cover tape. (approx 50cm). 拆料，保留下約50cm長的料帶.7.2.3 Take the components back to their warehouse positions. 把料送還倉庫.7.2.4 Empty the cover tape waste containers of all feeders. 清除所有供料器廢料帶倉.7.2.5

23、Check and clean all feeders and tables from loose components. 檢查并清除所有供料器和供料車上的散料.7.2.6 Daily maintenance tasks: clean the pick up window of the feeder, empty the waste bins (tables), clean the tables (clean the tracks, clean the magnetic surface of the S tables). 每日維護任務(wù)：確認并清潔供料器的取料窗口，清空供料車的垃圾箱，清潔供料車

24、（軌道和S型供料車的磁鐵表面）.7.2.7 Assist in other jobs if needed. 如果需要準備其他工單.7.2.8 Make sure that the tear down area is clean. 確保下料區(qū)域的清潔. 7.3 Printer印刷機7.3.1 The paste or glue is took out in advance four hours by operator, check its type and fill in the time of extraction.操作員生產(chǎn)前4個小時取出錫膏或紅膠,確認錫膏或紅膠型號并填寫取出時間.填寫QF

25、-00066 錫膏使用記錄.7.3.2 Check the PCB part number and version according to product change over check list, check PCB quantity according to work order.根據(jù)產(chǎn)品更換記錄表檢查PCB料號及版本,根據(jù)工單確認PCB數(shù)量.7.3.3 In order to check the front and rear squeegees printing quality, paste plastic protective film on the two PCBs in ad

26、vance half an hour. 為確認前后刮刀的印刷品質(zhì),提前半小時在2塊板子上粘貼塑料保護膜.7.3.4 Print all the left PCBs and place them on the conveyor for last product in advance in order to changeover quickly. 為快速轉(zhuǎn)型,提前印刷完上一工單產(chǎn)品剩余的板子并放在軌道上.7.3.5 Select squeegee, stencil and solder（or glue）according to changeover checklist before product

27、 changeover, Before setting up a production run and after stencil and squeegee cleaning, the stencil and squeegee quality must be inspected. If any of the stencil apertures are dented or damaged contact technician. If a stencil contains dried solder paste or adhesive, the cleaning procedure must be

28、followed to remove the material. If the material remains on the stencil or in the apertures after cleaning, contact technician appropriate for corrective action.產(chǎn)品轉(zhuǎn)型前根據(jù)產(chǎn)品更換檢查表選擇刮刀,網(wǎng)板和錫膏(或紅膠),在設(shè)定某產(chǎn)品生產(chǎn)之前及鋼網(wǎng)和刮刀清潔之后都必須檢查.如果鋼網(wǎng)刮刀損壞,聯(lián)系技術(shù)員.如果鋼網(wǎng)上有干燥的錫膏或膠, 需按清潔步驟去除.如果清潔以后殘留物仍然殘留在鋼網(wǎng)或網(wǎng)孔上，聯(lián)系技術(shù)員采取適當(dāng)改善措施.7.3.6 Sel

29、ect product program, confirm whether squeegee speed, pressure, wipe frequency, separation speed and distance are correct or within the limits of WI according to changeover checklist.根據(jù)產(chǎn)品更換確認表選擇產(chǎn)品程序，確認刮刀速度，壓力，清洗頻率,脫模速度與距離是否正確或在指引要求的范圍內(nèi).7.3.7 Adjust rail width and confirm whether need add support pin

30、according to product changeover checklist.調(diào)整軌道寬度并根據(jù)產(chǎn)品更換確認表確認是否需要支撐.7.3.8 Print two PCBs with pasting plastic protective film, and check both front and rear squeegees printing quality. If acceptable, wipe stencil automatically, then print two bare PCBs without pasting plastic protective film；if unacc

31、eptable, operator should adjust print parameter, reprint different PCBs with pasting plastic protective film till its ok, for the problem operator cant solve in five minutes, inform technician to adjust. Operator use SPI to check printing quality for the before 3 pieces of PCBs, if no alarm, waiting

32、 for mount machine to produce, if alarm, technician need check and adjust printing parameter if need, sign his name on the product changeover checklist.印刷兩片粘有塑料保護膜的板子,確認前后刮刀印刷品質(zhì).如果可接受,自動擦拭鋼網(wǎng), 然后印刷兩片沒有粘貼塑料保護膜的板子；如果不可接受,作業(yè)員調(diào)整印刷參數(shù),重印不同粘有塑料保護膜的板子直到可接受,作業(yè)員5分鐘內(nèi)不能解決的問題,通知技術(shù)員調(diào)整.作業(yè)員使用SPI檢查前三片板的印刷品質(zhì),如果不報警,等待貼

33、片機生產(chǎn),如果報警,技術(shù)員需確認，調(diào)整印刷參數(shù)如需要,并在產(chǎn)品更換確認表上簽字.7.3.9 Operator need use SPI to check 3 pieces of PCBs printing quality once an hour according to SPI WI when normally produce and make SPC record，if SPC alarm, inform technician to check and adjust.正常生產(chǎn)中,根據(jù)SPI操作指引作業(yè)員需要每小時使用SPI檢查3塊板的印刷品質(zhì)并做SPC記錄,如有報警，通知技術(shù)員確認調(diào)整.7

34、.3.10 Half an hour early when be about to finish the current product, operator need prepare the next batch product, ensure related stencil, squeegees, PCB and solder (or glue) etc. for the next batch product are already and are all meet the product change over check list requirement. 在當(dāng)前產(chǎn)品快結(jié)束時,提前半小時

35、，確認下單產(chǎn)品所使用到的鋼網(wǎng)，刮刀，PCB和錫膏(或紅膠)等都已準備好，且都符合產(chǎn)品更換確認表的要求.7.3.11 When finish current product, operator must check production quantity, if the same as the work order quantity requirement, preparing for changeover, remove and clean the stencil or squeegees from the machine. stencil must be cleaned by stencil

36、 automatically cleaning machine, squeegee cleaning by hands. For glue stencil cleaning result must be checked with line leader, write stencil and squeegee cleaning record. 當(dāng)完成當(dāng)前產(chǎn)品時，作業(yè)員必須確認該產(chǎn)品的生產(chǎn)數(shù)量，如果和工單要求數(shù)量一致，準備轉(zhuǎn)型，移走鋼網(wǎng)或刮刀，鋼網(wǎng)必須用自動鋼網(wǎng)清洗機清洗，刮刀手動洗，對于紅膠鋼網(wǎng)清洗結(jié)果需產(chǎn)線領(lǐng)班確認合格，填寫QF-00152 鋼網(wǎng)和刮刀的清洗記錄.7.3.12 Make sur

37、e that the process area is clean. 確保工作區(qū)域清潔.7.4 Mount machine貼片機7.4.1 Move offline tables near the corresponding area in advance half an hour before changeover. 轉(zhuǎn)型前半小時把離線的供料車放在貼片機對應(yīng)的附近區(qū)域.7.4.2 After finish the last PCB for the previous product on the first placement machine, The line leader announces

38、 changeover begins, all the related persons are ready to changeover, then the offline team and the first placement operator start to change table together, and check that the area in the machine is clean, Empty all component loss containers，Everyone is responsible for one side till finish changeover

39、, if the second placement machine operator has spare time also join in.上個型號最后一片板子完成第一臺貼片機貼片，產(chǎn)線leader通知轉(zhuǎn)型開始，所有轉(zhuǎn)型相關(guān)人員準備到位，離線上倆組和第一臺貼片操作員一起便開始更換Table,確認機器Table該區(qū)域清潔，清空拋料盒，每人負責(zé)一側(cè)，直到全部切完,如果第二臺機作業(yè)員有時間也要參與轉(zhuǎn)型. 7.4.3 The offline team firstly scan machine material area label and secondly scan table side “TID”

40、 label, Complete offline Table and product Setup binding. Meanwhile the first placement operator start to download program according to changeover checklist, Click SETTING UP on in OIS, then change correct nozzle if needed, adjust right conveyor width and PCB barcode scanner position (if need tracea

41、bility), Apply support pins if needed, Make sure you are using the correct fiducials，Click SETTING UP off in OIS and Click NORMAL OPERATION，Make the first assembly for the first placement machine, no stopping.先掃描機器的物料區(qū)域區(qū)碼，再掃描Table側(cè)面的“TID”條碼，完成離線Table與產(chǎn)品Setup綁定.同時第一臺貼片操作員根據(jù)產(chǎn)品更換檢查表傳程序,設(shè)置OIS為SETTIING U

42、P模式, 更換正確的吸嘴如果需要,調(diào)整正確的軌道寬度和PCB條碼掃描器位置（如果需要追蹤）,提供支撐如果需要, 確認使用正確的基準點，在OIS單擊關(guān)閉SETTING UP，單擊NORMAL OPERATION，第一臺貼片機打首件,不停機.7.4.4 When the second placement machine also finish the last PCB for the previous product, the same changeover method as the first placement machine, if the first placement machine

43、operator has spare time also join in. For irregular materials, linear feeder or tray component, need check its pick up position in advance. 當(dāng)?shù)诙_機也完成上單產(chǎn)品的最后一片板時，使用與第一臺機同樣的轉(zhuǎn)型方法進行轉(zhuǎn)型，如果第一臺機的作業(yè)員有時間也要參與轉(zhuǎn)型.對于異形料，震動feeder或托盤料需要提前確認吸料位置.7.4.5 For mass production products, if finish the first PCB assembly, th

44、e line continue produce without stopping, If the current product is NPI or ECN or has BGA component, only produce one PCB, just produce till QA finish checking the first assembly. 對于量產(chǎn)產(chǎn)品,如果完成首件,產(chǎn)線繼續(xù)生產(chǎn)不停機,如果是新品,有變更或有BGA元件,只能生產(chǎn)一塊板子,直到QA確認完首件才可繼續(xù)生產(chǎn).7.4.6 Splicing the component reels without stopping ma

45、chine when produce，need double check splicing position in order to avoid the cutoff tape , pick up error and upside down defect etc. 生產(chǎn)中須不停機續(xù)料, 需要對接料位置重點確認，避免斷帶，吸取錯誤，翻件等不良.7.4.7 Operator monitor and record PuR, Cph per 2h, if low PuR allowed corrective actions: check feeder conditions/settings. 作業(yè)員每

46、隔兩小時記錄一次吸取率和置件數(shù)，如果低的吸取率，允許的正確操作：確認供料器位置和設(shè)置.7.5 Reflow oven 回流爐7.5.1 Load product program according to changeover checklist. 調(diào)程序根據(jù)產(chǎn)品更換檢查表.7.5.2 Confirm whether the temperature, speed and blow speed are the same as product reflow temperature parameter setup list. 確認爐溫，速度和風(fēng)速是否和爐溫參數(shù)一覽表（QF-00064或者QF-0029

47、9）一致.7.5.3 Automatically adjust rail width, must check both front and rear rail width with bare PCB, ensure the PCB can smoothly run on the rail, check whether need center support pin, for the first side need to active center support pin, for the second side, dont need, except special requirement fo

48、r product changeover checklist .自動調(diào)整軌道寬度，拿裸板確認前后軌道寬度，確保板子可以在軌道上順暢通行，確認是否需要中央支撐，生產(chǎn)第一面時，需要打開中央支撐，生產(chǎn)第二面時，不需要打開,除非產(chǎn)品更換確認表有特殊要求.7.5.4 Please fill in changeover checklist and reflow each zones temperature check list after each product finish changeover. 每次產(chǎn)品更換之后填寫產(chǎn)品更換檢查表和回流爐各溫區(qū)爐溫檢查記錄表（QF-00039或者QF-00273）.

49、有手擺料根據(jù)QF-00276 SMT手貼料清單填寫QF-00040 SMT手擺料記錄表并找QA和技術(shù)員簽字確認7.5.5 Open the reflow heating door to cool down quickly if needed, Before the temperature reached its setting up, no stopping production, load the PCAs into the magazines carefully, when reflow temperature is ready, manually place it on the conveyor before reflow. 打開加熱蓋子快速降溫如果需要，在爐溫達到設(shè)定之前，不停止SMT生產(chǎn)，先小心收到周轉(zhuǎn)箱里，爐溫ok后再手動放回爐前軌道.7.5.6 Visual inspection for the first PCBs placement and solder quality, any placement and printing issue, feedback to t