QT-00056 Ver40 SMT 产品更换工作指引.doc

SUZHOUSMT 产品更换工作指引SMT Changeover instruction信息分类： 三阶文件文件编号: QT-00056版本:4.0页码:11 of 111.Product Revision 产品版本Product Name产品名称Applicable Product BOM Revision适用的产品BOM版本N/AN/A2.Change history更改记录Updated Ver.最新版本Effective date 生效日期Prepared by起草人Brief of Amendments更改内容摘要1.02012/5/27Yongxing ZhuNew Issue2.02012/9/7Yongxing 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产线转型操作,以指导转型员工正确操作,达到快速转型目标.4.Scope范围All related changeover personnels.所有与生产线转型相关人员.5.Definitions定义5.1 Changeover: The process that production line changes from one product to another product.转型的定义:是指生产线从一个产品切换到另一个产品的操作过程.5.2 Changeover Time: Start time for the last PCB for the previous product begin to load into the reflow, end time for the first PCB for the next product has passed the reflow.转型时间的定义:转型时间以炉前上一个型号最后一片板子进炉开始，到下一个型号第一片板子进炉结束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-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. 转型人员的定义:这里所定义的转型人员是指直接参与转型操作的人员,一个标准的转型操作建议由5人完成,这里分别定义为OP-1,OP-2,OP-3,OP-4,OP-5,其中OP-1为DEK操作员,OP-2和OP-3为贴片机操作员,OP-4为炉前人员,OP-5为离线上料组.6.Responsibilities职责 Planner is responsible for sending production schedule to technicians 24hours early. Planner提前24小时把生产计划发给技术员.Technician is responsible for optimizing several products together according to production schedule 12hours early and make setup list, support any deviation on line.技术员根据计划提前12小时打包优化程序并做套料单,在线支持任何异常.Line leader is responsible for personal coordinate and problem feedback.班组长负责人员协调与问题反馈.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 number, 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 .库房根据工单提前8小时发料给产线备料员，备料单上包括以下信息：产品型号、版本、线别、贴片机设备名称、Table区号、料号、库位、BOM、工单需求数量、发料数量，备料员取料时按照Feeder list排好顺序并分好站位；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.离线上料(或下料)的领班负责打印上料单,在上料单上标记湿度敏感元器件,支持任何异常,检查并记录异常.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 acc. To instruction, SPI check , Running the production (paste and cleaning replenishment) , Daily maintenance acc. To instruction DEK印刷机作业员负责准备自动存储送料装置，领取并检验钢网，刮刀，PCB, 锡膏或红胶，清洗钢网和刮刀，根据产品更换确认表调用程序，维修和检验工具，量产时根据指引要求检查印刷的周期，SPI检查，运行生产，每日保养.Pick and place operator is responsible for monitoring and recording PuR, Cph /2hsupport if any deviation and keep records of deviations.贴片机作业员负责每隔两小时监控和记录吸取率和每小时产能，支持任何异常和记录异常.Reflow operator is responsible for monitoring the process, feedback defects to team leader.回流炉作业员负责监控制程, 并及时把缺陷反馈给工段长.AOI operator is responsible for recording DPMO, and feedback defects to the team leader.AOI作业员负责记录每百万件的缺陷数，并及时把缺陷反馈给工段长.7.Description描述7.1 Off line setup center setting up离线上料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 quantity. 打印上料单根据QF-00070 产品更换记录表，确认转型产品的所有物料已到产线，确认PCB的料号,版本和数量.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车，确认供料器与供料车都处于好的状态.并根据上料单把供料器放在供料车的正确位置上.7.1.3 Set the components into the feeders carefully avoiding component loss or damage,1st component on tape to the correct pick up position装料时要小心操作，避免物料损耗或损坏，第一个料要装在正确的取料位置.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 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 first PCB before reflow.根据上料单，调整供料器的设置，确认所有的供料器的供料间隔，吸料角度都是正确的.如果吸料角度，材料封装尺寸或供料器类型与上料单不同，作业员应及时通知技术员确认和调整,如果需要更改程序，技术员应做好程序更改记录并确认炉前首板该料的贴装方向.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 container which tells what components are hand mounted and what are their positions. 把所有手贴的物料装到一个单独的容器中，确保在程序中所有手贴物料都被忽略,记录什么物料需手贴，及其贴装位置.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 changeover.对于湿敏元件，托盘物料，管装料等不能提前上料的，上料组成员需要在上料单上作出标注, 湿敏元件在转型前半小时上料.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.确认所有的物料都已扫料.不需要追踪的产品，只扫料号条码，需要追踪的产品，扫两个条码：料号和唯一身份标识号码.7.1.8 Splice all needed components in advance. 把需要接料的料盘全部提前接好.7.1.9 After a table is complete mark the set-up-list with date, time and name.完成离线上料的供料车，作业员在上料单上签上日期，时间和名字.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车推到产线附近的有蓝色标记的区域等待转型.7.1.11 As the production moves forward, remember to move the next setup to the nearer marked areas. 由于生产在向前发展，记得移动下单的物料向更近的标记区域.7.1.12 Assist in other jobs if needed. 如果需要准备其他工单.7.1.13 Make sure that the setup area is clean. 确保上料区域的清洁.7.2 Off line setup center tear down离线下料7.2.1 Pick up tables going to tear down from marked areas. 把供料车移到下料标记区域.7.2.2 Remove the components from feeders. Remember to leave enough cover tape. (approx 50cm). 拆料，保留下约50cm长的料带.7.2.3 Take the components back to their warehouse positions. 把料送还仓库.7.2.4 Empty the cover tape waste containers of all feeders. 清除所有供料器废料带仓.7.2.5 Check and clean all feeders and tables from loose components. 检查并清除所有供料器和供料车上的散料.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). 每日维护任务：确认并清洁供料器的取料窗口，清空供料车的垃圾箱，清洁供料车（轨道和S型供料车的磁铁表面）.7.2.7 Assist in other jobs if needed. 如果需要准备其他工单.7.2.8 Make sure that the tear down area is clean. 确保下料区域的清洁. 7.3 Printer印刷机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.操作员生产前4个小时取出锡膏或红胶,确认锡膏或红胶型号并填写取出时间.填写QF-00066 锡膏使用记录.7.3.2 Check the PCB part number and version according to product change over check list, check PCB quantity according to work order.根据产品更换记录表检查PCB料号及版本,根据工单确认PCB数量.7.3.3 In order to check the front and rear squeegees printing quality, paste plastic protective film on the two PCBs in advance half an hour. 为确认前后刮刀的印刷品质,提前半小时在2块板子上粘贴塑料保护膜.7.3.4 Print all the left PCBs and place them on the conveyor for last product in advance in order to changeover quickly. 为快速转型,提前印刷完上一工单产品剩余的板子并放在轨道上.7.3.5 Select squeegee, stencil and solder（or glue）according to changeover checklist before product 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 followed to remove the material. If the material remains on the stencil or in the apertures after cleaning, contact technician appropriate for corrective action.产品转型前根据产品更换检查表选择刮刀,网板和锡膏(或红胶),在设定某产品生产之前及钢网和刮刀清洁之后都必须检查.如果钢网刮刀损坏,联系技术员.如果钢网上有干燥的锡膏或胶, 需按清洁步骤去除.如果清洁以后残留物仍然残留在钢网或网孔上，联系技术员采取适当改善措施.7.3.6 Select 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.根据产品更换确认表选择产品程序，确认刮刀速度，压力，清洗频率,脱模速度与距离是否正确或在指引要求的范围内.7.3.7 Adjust rail width and confirm whether need add support pin according to product changeover checklist.调整轨道宽度并根据产品更换确认表确认是否需要支撑.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 unacceptable, 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 for mount machine to produce, if alarm, technician need check and adjust printing parameter if need, sign his name on the product changeover checklist.印刷两片粘有塑料保护膜的板子,确认前后刮刀印刷品质.如果可接受,自动擦拭钢网, 然后印刷两片没有粘贴塑料保护膜的板子；如果不可接受,作业员调整印刷参数,重印不同粘有塑料保护膜的板子直到可接受,作业员5分钟内不能解决的问题,通知技术员调整.作业员使用SPI检查前三片板的印刷品质,如果不报警,等待贴片机生产,如果报警,技术员需确认，调整印刷参数如需要,并在产品更换确认表上签字.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.正常生产中,根据SPI操作指引作业员需要每小时使用SPI检查3块板的印刷品质并做SPC记录,如有报警，通知技术员确认调整.7.3.10 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. 在当前产品快结束时,提前半小时，确认下单产品所使用到的钢网，刮刀，PCB和锡膏(或红胶)等都已准备好，且都符合产品更换确认表的要求.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 automatically cleaning machine, squeegee cleaning by hands. For glue stencil cleaning result must be checked with line leader, write stencil and squeegee cleaning record. 当完成当前产品时，作业员必须确认该产品的生产数量，如果和工单要求数量一致，准备转型，移走钢网或刮刀，钢网必须用自动钢网清洗机清洗，刮刀手动洗，对于红胶钢网清洗结果需产线领班确认合格，填写QF-00152 钢网和刮刀的清洗记录.7.3.12 Make sure that the process area is clean. 确保工作区域清洁.7.4 Mount machine贴片机7.4.1 Move offline tables near the corresponding area in advance half an hour before changeover. 转型前半小时把离线的供料车放在贴片机对应的附近区域.7.4.2 After finish the last PCB for the previous product on the first placement machine, The line leader announces 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, if the second placement machine operator has spare time also join in.上个型号最后一片板子完成第一台贴片机贴片，产线leader通知转型开始，所有转型相关人员准备到位，离线上俩组和第一台贴片操作员一起便开始更换Table,确认机器Table该区域清洁，清空抛料盒，每人负责一侧，直到全部切完,如果第二台机作业员有时间也要参与转型. 7.4.3 The offline team firstly scan machine material area label and secondly scan table side “TID” 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 traceability), 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.先扫描机器的物料区域区码，再扫描Table侧面的“TID”条码，完成离线Table与产品Setup绑定.同时第一台贴片操作员根据产品更换检查表传程序,设置OIS为SETTIING UP模式, 更换正确的吸嘴如果需要,调整正确的轨道宽度和PCB条码扫描器位置（如果需要追踪）,提供支撑如果需要, 确认使用正确的基准点，在OIS单击关闭SETTING UP，单击NORMAL OPERATION，第一台贴片机打首件,不停机.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 operator has spare time also join in. For irregular materials, linear feeder or tray component, need check its pick up position in advance. 当第二台机也完成上单产品的最后一片板时，使用与第一台机同样的转型方法进行转型，如果第一台机的作业员有时间也要参与转型.对于异形料，震动feeder或托盘料需要提前确认吸料位置.7.4.5 For mass production products, if finish the first PCB assembly, the 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. 对于量产产品,如果完成首件,产线继续生产不停机,如果是新品,有变更或有BGA元件,只能生产一块板子,直到QA确认完首件才可继续生产.7.4.6 Splicing the component reels without stopping machine when produce，need double check splicing position in order to avoid the cutoff tape , pick up error and upside down defect etc. 生产中须不停机续料, 需要对接料位置重点确认，避免断带，吸取错误，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. 作业员每隔两小时记录一次吸取率和置件数，如果低的吸取率，允许的正确操作：确认供料器位置和设置.7.5 Reflow oven 回流炉7.5.1 Load product program according to changeover checklist. 调程序根据产品更换检查表.7.5.2 Confirm whether the temperature, speed and blow speed are the same as product reflow temperature parameter setup list. 确认炉温，速度和风速是否和炉温参数一览表（QF-00064或者QF-00299）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 for product changeover checklist .自动调整轨道宽度，拿裸板确认前后轨道宽度，确保板子可以在轨道上顺畅通行，确认是否需要中央支撑，生产第一面时，需要打开中央支撑，生产第二面时，不需要打开,除非产品更换确认表有特殊要求.7.5.4 Please fill in changeover checklist and reflow each zones temperature check list after each product finish changeover. 每次产品更换之后填写产品更换检查表和回流炉各温区炉温检查记录表（QF-00039或者QF-00273）.有手摆料根据QF-00276 SMT手贴料清单填写QF-00040 SMT手摆料记录表并找QA和技术员签字确认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. 打开加热盖子快速降温如果需要，在炉温达到设定之前，不停止SMT生产，先小心收到周转箱里，炉温ok后再手动放回炉前轨道.7.5.6 Visual inspection for the first PCBs placement and solder quality, any placement and printin