设备管理_如何降低喷锡后防焊白化

如何降低喷锡后防焊白化 專題成員 姓名職稱 學歷 組長：劉益利副工程師大 學 組員：張啟煌副工程師專 科 王玉琪現場組長專 科 皮賢明現場組長專 科 李志清現場組長專 科 1.前言: 隨著客戶對PCB的品質要求越來越嚴格，相對地在外觀上也越來越要求完美。所以電路板廠無不在原物料、機械設備、製作條件上，想盡各種方法來改善，以滿足客戶需求。良好的外觀品質，更能取得客戶的信賴，以奠定後續定單能源源不絕。2.選題理由: 防焊油墨在噴錫後產生白化現象，雖然於功能上不影響，但是在外觀上出現瑕疵，使得客戶產生疑慮，甚至不允收。所以利用DOE的手法找出最佳生產條件，以降低防焊油墨在噴錫後產生白化現象。 3.品質問題現況分析: 月 份-3 7月-2 8月-1 9月0 10月1 11月2 12月3 1月白 化 不良率0.0513 (5.13%)0.0484 (4.84%)0.0324 (3.24%)0.0312 (3.12%)0.0171 (1.71%)0.0025 (0.25%)(0指開始作專題之月份) 4.製程說明: 防焊前處理印刷預烤曝光顯影後烘烤噴錫前處理IR預熱浸Flux噴錫浮床噴錫後清洗出料檢視因本廠出現防焊白化以Curtain Coating比例較高，因此選擇以Curtain Coating印刷方式找出白化成因。 5.特性要因分析: 6.第一階段實驗配置及解析: 6.1實驗因子及水準對照表:6.2配置方式及交互作用: 6.2.1採L16215方式配置 6.2.2點線圖:6.3實驗解析(1)白化 6.3.1防焊特性(1)白化實驗配置及數據: FACTORABABFIDADCACeGHAHIGFGDATAROW/COL1234567891011121314153111111111111111142111111122222222031112222111122228411122222222111110512211221122112296122112222112211071222211112222110812222112211112229212121212121212110212121221212121811212212112122121712212212121211212513221122112211221614221122121122112115221211212212112016221211221121221 6.3.2防焊特性(1)白化實驗平均值比較表： COLFACTORSIAVE(L1)AVE(L2)1A14.253.752B0.254.1253.8753AB6.253.3754.6254C16535F255.252.756J110.251.3756.6257H0.254.1253.8758D2.253.6254.3759I6.253.3754.62510G43.54.511K93.254.7512CD2.254.3753.62513JK6.254.6.253.37514HI44.53.515FG14.253.75 6.3.3防焊特性(1)白化變異數分析: ANOVA：在合併後 FACTORSiDFVF(%)J110.251110.2538.587555.3571*F251258.7511.4138*C161165.66.77466*K9193.153.16642AB6.2516.252.18751.71889I6.2516.252.18751.74889A1110.350.95729B0.2510.250.08751.34388e2072.85714217.4889St=194t=82.5110 6.3.4防焊特性(1)白化貢獻率分析: J (板溫)E (曝光能量)C (預烤溫度)K (水洗溫度)ABI (後烤溫度)A (下墨量)B (油墨黏度)E (誤差值)貢獻率55.36%11.41%6.77%3.17%1.75%1.75%0.96%1.34%17.49%累積 貢獻率55.36%66.77%73.54%76.71%78.46%80.21%81.17%82.51%100.00% 6.4實驗解析(2)壓痕 6.4.1防焊特性(2)壓痕實驗配置及數據: FACTORABABFIDADCACeGHAHIGFGDATAROW/COL123456789101112131415211111111111111111211111112222222203111222211112222041112222222211111.551221122112211221.5612211222211221107122221111222211081222211221111228921212121212121210102121212212121213112122121121221210.5122122121212112127132211221122112218.5142211221211221121152212112122121122.5162212112211212216.4.2防焊特性(2)壓痕實驗平均值比較表： COLFACTORSIAVE(L1)AVE(L2)1A74.390620.755.06252B0.3906253.06252.753AB0.3906252.753.06254C66.015624.93750.8755F26.265621.6254.18756J0.3906253.06252.757H0.3906252.753.06258D0.1406252.812539I0.7656253.1252.687510G1.2656253.18752.62511K0.3906252.753.062512CD1.8906252.68753.12513JK1.8906253.252.562514HI0.7656252.68753.12515FG1.8906253.252.56256.4.3防焊特性(2)壓痕變異數分析: FACTORSiDFVF(%)A74.39062174.39062144.272741.9483*C66.01562166.01562128.030337.1927*F26.26562126.2656250.9393914.6215*JK1.89062511.8906253.6666660.78076FG1.89062511.8906253.6666660.78076G1.26062511.2656252.4545450.42587K0.39062510.3906250.7575750.07097J0.39062510.3906250.7575750.07097e3.60937570.5156254.10788St=176.1093t=95.8921 6.4.4防焊特性(2)壓痕貢獻率分析: A (下墨量)C (預烤溫度)F (曝光能量)JKFGG (靜置時間)K (水洗溫度)J (板溫)E (誤差值)貢獻率41.95%37.19%14.62%0.78%0.78%0.43%0.07%0.07%4.11%累積貢獻率41.95%79.14%93.76%94.54%95.32%95.75%95.82%95.89%100.00% 6.5實驗解析(3)銅面氧化 6.5.1防焊特性(3)銅面氧化實驗配置及數據: FACTORABABFIDADCACeGHAHIGFGDATAROW/COL123456789101112131415311111111111111112211111112222222243111222211112222541112222222211112512211221122112256122112222112211271222211112222114812222112211112209212121212121212010212121221212121011212212112122121012212212121211212013221122112211221014221122121122112115221211212212112016221211221121221 6.5.2防焊特性(3)銅面氧化實驗平均值比較表 COLFACTORSIAVE(L1)AVE(L2)1A42.253.3750.1252B01.751.753AB0.251.8751.6254C11.525F0.251.6251.8756J11.527H2.251.3752.1258D11.529I2.251.3752.12510G121.511K2.252.1251.37512CD01.751.7513JK0.251.8751.62514HI121.515FG0.251.8751.625 6.5.3防焊特性(3)銅面氧化變異數分析: FACTORSiDFVF(%)A42.25142.25147.87576.2987*I2.2512.257.8753.57142*H2.2512.257.8753.57142*K2.2512.257.8753.57142*C1113.51.29870D1113.51.29870G1113.51.29870J1113.51.29870e270.2857147.78220St=55t=92.20776.5.4防焊特性(3)銅面氧化貢獻率分析: A (下墨量)I (烘烤溫度)H (後烤時間)K (水洗溫度)C (預烤溫度)D (預烤時間)G (靜置時間)J (板溫)E (誤差項)貢獻率76.30%3.57%3.57%3.57%1.30%1.30%1.30%1.30%7.79%累積貢獻率76.30%79.87%83.44%87.01%89.00%89.61%90.91%92.21%100.00% 7.Cross Table 因子特性質ABCFJHDIGK結論防焊白化C2F2J11.A2、B2、C2、F2、J1、H1、I1、G1、K2為 Cross Table分析後之較佳條件，其中遇多特 性質，有衝突時以其貢獻率%來取捨。 2.本次實驗之二面多特性質經分析後，第二階 段實驗中取A2、B2、D1、H1、I1、G1、K2 為常數項，C、F、J三因子為繼續做第二階 段實驗。 3.本次實驗之二個多特性質經分析後，顯著因 子無交互作用。顯著性*貢獻率6.77%11.41%55.36%底片壓痕A1C2F1顯著性*貢獻率41.95%37.19%14.83%銅面氧化A2H1I1K2顯著性*貢獻率76.3%3.75%3.75%3.75%結 論A2C2F2J1H1I1K2 8.第二階段實驗配置及解析: 8.1計劃構想: 由Cross Table結論得知C、F、J為顯著因子,希望在第二階段少因子多水準中尋找出最佳量產條件 8.2因子水準對照表:因子代號水準交互作用123預烤溫度CC21C22C23曝光能量FF21F22F23噴錫後處理前板溫JJ21J12J13 8.3點線圖:8.4實驗常數:1.下墨量 5. 後烘烤溫度 2.油墨黏度 6. 曝光靜置時間 3.預烤時間 7.噴錫後水洗溫度 4.後烘烤時間 8.5第二階段實驗防焊噴錫後白化實驗配置及數據: factorJFeeCeeeeeeeedataROL/COL12345678910111213012231231312123022123123123123031111111111111041222222333111052123231231231061333333222111073213213321132081111333333333091111222222222010231223112331201133212131323210123213321132213013223112323131201412223331112220152231312123231016231231223112301721233123123120183321321213132019122211122233302013332221113330211333111333222022332113232121302331322132132130242312123312231025321313221332102631323213213210273132132132132 8.6防焊噴錫後白化實驗變異數分析: FACTORSiDFVF(%)C020J020F020e0200St0t= 8.7第二階段實驗防焊曝光底片壓痕實驗配置及數據: factorJFeeCeeeeeeeedataROL/COL12345678910111213012231231312123022123123123123031111111111111241222222333111052123231231231161333333222111173213213321132181111333333333091111222222222110231223112331211133212131323210123213321132213213223112323131201412223331112221152231312123231016231231223112321721233123123121183321321213132119122211122233302013332221113331211333111333222122332113232121302331322132132130242312123312231025321313221332112631323213213211273132132132132 8.8防焊曝光底片壓痕實驗變異數分析: FACTORSiDFVF(%)F0.66666620.3333330.666662.77777J0.66666620.3333330.666662.77777C0.66666620.3333330.666662.77777e10200.5St=12t=8.33333 8.9第二階段實驗防焊下銅面氧化實驗配置及數據: factorJFeeCeeeeeeeedataROL/COL123456789101112131.1122312313121231.1221231231231231.2311111111111111.2412222223331111.1521232312312311.1613333332221111.1732132133211321.1811113333333331.2911112222222221.21023122311233121.21133212131323211.11232133211322131.21322311232313121.114122233311122211522313121232311.11623123122311231.21721233123123121.21833213212131321.11912221112223331.120133322211133312113331113332221.12233211323212131.12331322132132131.12423121233122311.12532131322133211.22631323213213211.2273132132132132 8.10防焊下銅面氧化變異數分析: FACTORSiDFVF(%)F0.00962920.0048141.192661.61538J0.00518520.0025920.642203C0.00074020.0003700.091747.61538e0.080740200.00403787.7692St=0.096296t=12.2307 9.第二階段實驗結論: 操作條件對照表實驗因子因子代號原始作業條件最佳作業條件下墨量AA120g/m2A220g/m2油墨黏度BB110secB215sec預烤溫度CC12.5C25預烤時間DD1D2曝光能量FF150mj/cm2F2100mj/cm2曝光後靜置時間GG1G1後烘烤時間HH1H1後烘烤溫度II110I210噴錫後板溫JJ110J215噴錫熱水洗溫度KK110K215由第二階段實驗與兩個多特性質分析後,獲得最佳作業條件 10.再現性結果確認 1、製 程：防焊 2、再現性實施期間：1999/12/272000/1/9 3、再現性生產記錄： 生產批數：420批 生產總批數：100800 Working Panel4、再現性品質記錄：1999/12/272000/1/19無白化現象發