Shulou(Shulou.com)06/02 Report--

Know it, know why, solve the practical problems in production in order to be handy. In the electronic assembly enterprises with high frequency of product upgrading and fast production process, it is not easy for production managers to successfully complete the work of finding, checking and dealing with problems in a limited time.

Know it, know why, solve the practical problems in production in order to be handy. In the electronic assembly enterprises with high frequency of product upgrading and fast pace of production process, production managers want to find, inspect and deal with problems in a limited time, among which the biggest obstacle often occurs in checking the problem link, that is, the lack of sufficient historical data to determine the problem.

For example, in the surface mount process of motherboard components, there are always some kind of performance problems of semi-finished products periodically, but because there is no detailed information such as processing equipment, raw materials and processing time recorded with the work order, there is no summary of these periodic performance problems, but only take a piece-by-piece check method for all the problems of the day every day. This requires a lot of resources and time to check one by one on a large scale, such as equipment parts, personnel, historical environment, etc., and the result is often that it takes time to deal with the problem.

The above only reflects from a small point that if electronic assembly enterprises can not do a good job in traceability management, the limited ability to deal with and improve problems will bring difficulties to production management. Furthermore, if these problematic products cause customer complaints after shipment, doing a good job of RMA to avoid the recurrence of problems is an important means to restore customer confidence, at this time more efficient and accurate problem determination system is needed. Therefore, the traceability management of electronic assembly enterprises is also an important part of the whole manufacturing management.

Three key points of production traceability to improve process analysis ability

From the perspective of the categories of historical data needed for production problem analysis and inspection, in order to do a good job of production traceability, the data that need to be collected can be divided into three categories, namely: process data, product data, material (raw material) data. The process data is to collect the data of the whole production process from the point of view of the four elements of production: human, machine, law and ring. It contains a wide range of contents, such as the operation of the equipment, maintenance, throwing status, operators and production-related information, the temperature, humidity, purification of the manufacturing workshop, QA personnel regular sampling of the project data and so on. Typical applications of these data in engineering and manufacturing analysis in the electronic manufacturing industry may include: finding out whether a batch of substandard products are caused by an operator by retrieving the operator's historical operation information; looking at the manufacturing records of a certain equipment history, understanding that some periodic defects are caused by abnormal wear and tear of equipment parts, etc.

Product data refers to the quality-related data produced in the process of processing and testing in the production process from raw materials to finished products. From a statistical point of view, this kind of data can be divided into measurement value (Parameter Date) and count value (Numerical Data). From a more intuitive point of view, for example, the product electrical performance test data generated by testing equipment can be classified as metrological data, while the judgment data of good or bad products produced in the same process can be classified as counting data. These product data are very useful in production site monitoring and engineering analysis. For example, real-time SPC (Statistical process Control) monitoring must rely on these data to report the fluctuation of product performance and the change of yield in real time, and to make early warning of anomalies. The historical product performance test data are often an important basis for engineering analysis of major product quality problems.

Material data refers to all data related to the raw materials used in the finished product. The reason why we separate the material data from the other four major production factors is not only because the material data runs through the procurement and manufacturing business, but also because from the application point of view, materials are not only a huge part of the cost of the electronic assembly industry, but also a frequent source of quality problems. The material data of manufacturing enterprises need to be collected not only from the procurement and storage process, but also from the manufacturing process. In the simplest sense, the manufacturer must have the basic information of the raw material, such as supplier, material category (number), raw material batch, characteristic data, etc. When the material is transported from the warehouse or line warehouse to the production line, the process of transforming the raw material into a product component begins. In this process, the raw material is sent to which station, when it is assembled on which product, and when it has been repaired. Details such as when it has been repaired should be recorded, and these data will be often used in quality analysis.

In the actual electronic assembly process, because the production rhythm is very tight, a manual processing process may end in about 10 seconds. Although automatic detection procedures such as AOI testing are carried out automatically, the detection data generated is massive, so it is unrealistic to rely on manual detailed recording of the above three types of data. At the same time, it is unrealistic to rely on the automatic control system that comes with the equipment to record the data. It often has the characteristics of incomplete, non-intuitive, manual reprocessing and so on. Therefore, enterprises that record production data manually or semi-automatically are often faced with insufficient production data available for analysis when checking production problems, or have original data, but checking a small problem requires a lot of manpower and time to salvage useful information from the original data.

Sharp weapon to improve traceability of MES system

Insufficient data or too much invalid data will affect the efficiency and accuracy of problem analysis. Before proposing a solution to this problem, we have to thank the invention of the 1946 computer. Today, these small square boxes are replacing manual work with tens of thousands or even tens of thousands of times the efficiency. The effective way to solve the contradiction between manual work and the amount of data mentioned above is to apply the computer-based information tool MES (Manufacturing execution system).

MES system, an enterprise application system, with the development of European and American manufacturing industry, MES was defined by MESA International (MES International Federation) in the early 1990s: MES can optimize the management of the whole production process from order to product completion through information transmission. With the gradual formation of the pattern that China has become the factory of the world, the application of MES has been widely used in Chinese electronic assembly enterprises in recent years. Through information tools combined with the successful application experience of other enterprises, many enterprises that implement MES have tasted the benefits brought by the improvement of production traceability.

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