QT-00056Ver20 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:2.0页码:7 of 71.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1.0ZhuyongxingNew Issue2.0ZhuyongxingAdd AOI and SPI3.Purpose目的 Setup the guidelines for SMT changeover work.建立产品更换工作指南.4.Scope范围This instruction used for SMT line.适用于SMT生产线.5.Definitions定义Change over: The process that production line changes from one product to another product.6.Responsibilities职责 Off line setup center setting up leader is responsible for printing the setup list, reprint in case of mismatch, mark the MSL components in the setup list, support if any deviation and monitoring and keep records of deviations.离线上料的领班负责打印上料单，重新打印如果丢失，在上料单上标记湿度敏感元器件，支持任何异常和检查并记录异常.Off line setup center tear down leader is responsible for removing finished tables from the line, take out the components from the feeders, pack and mark MSL components，support if any deviation and monitoring and keep records of deviations, keep records of deviations, daily maintenance tasks: check and 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).离线下料的领班负责从产线移走已经完成的供料车，从供料器上拆卸料盘，清除供料器内的散料，包装并记录湿度敏感元器件, 支持任何异常和检查,并记录异常. 每日维护任务：确认并清洁供料器的吸料窗口，倒空供料车的垃圾桶，清洁供料车的轨道和S型供料车的磁铁表面.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离线上料设置7.1.1 Print setup list according to product change over check list, check all the materials for the change over product are arrived in line, including to PCB part number and version. 打印上料单根据产品更换记录表，确认转型产品的所有物料已到产线，包括PCB的料号和版本.7.1.2 Pick up feeders, tables, check the condition of feeders and tables. and put the feeders in the correct position according the setup list.拾取供料器和供料车，确认供料器与供料车的状态.并根据上料单把供料器放在供料车的正确位置上.7.1.3 Adjust the feeder settings according the setup list，check pick up position，pick up angle, pitch and feeder type. If pick up angle, material packing size or feeder type is different from the setup list, operator should inform SMT technician to check and adjust in time, if need to change program, SMT 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，确认吸取位置，吸取角度,间隔和供料器类型.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SMT 技术员确认和调整,如果需要更改程序，SMT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.7.1.4 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 change over.对于湿敏元件，托盘物料，管装料等不能提前上料的，作业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.7.1.5 For not traceability product, only scan part number barcode, for traceability product, need scan three barcodes: part number, unique ID and quantity.不需要追踪的产品，只扫描料号条码，需要追踪的产品，扫描三个条码：料号，唯一身份标识号码和数量.7.1.6 After finish off line setup, operator sign with the name, time and date on the setup list, and put the setup list on the its each table.完成离线上料后，作业员在上料单上签上名字，时间和日期,把上料单放在各自的供料车上.7.1.7 Take the finished table next to the line to the area marked in blue.把已完成的供料车推到产线附近的有蓝色标记的区域.7.2 Printer印刷机7.2.1 The paste or glue is took out 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.7.2.2 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.7.2.3 In order to check the front and rear squeegees printing quality，paste plastic protective film on the two PCBs in advance. 为确认前后刮刀的印刷品质，提前在2块板子上粘贴塑料保护膜.7.2.4 Select squeegee，stencil and solder（or glue） according to change over check list before product conversion.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）.7.2.5 Select product program，confirm squeegee speed, pressure and wipe frequency according to change over check list.根据产品更换确认表选择产品程序，确认刮刀速度，压力，清洗频率是否正确.7.2.6 Adjust rail width and confirm whether need add support pin according to product change over check list.调整轨道宽度并根据产品更换确认表确认是否需要支撑.7.2.7 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 PCB with pasting plastic protective film till its ok, for the problem operator cant solve in ten miniutes, technician need 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, operator or technician need adjust printing parameter and need sign his name on the product change over check list.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，作业员十分钟内不能解决的问题，技术员需调整.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，作业员或技术员需调整印刷参数,并在产品更换确认表上签字.7.2.8 Operator need use SPI to check 3 pieces of PCBs printing quality once an hour according to SPI WI when normally production.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.7.2.9 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.7.2.10 When finish current product, operator must check production quantity, if the same as the work order quantity requirement, preparing for next product, 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，准备下一个产品，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，填写钢网和刮刀的清洗记录.7.3 Mount machine贴片机7.3.1 Check the boards name according to change over check list, transmit program from Line computer to mount machine, then change nozzle and adjust rail width , confirm whether need to add support according to product changeover check list.机台作业员根据产品更换检查表确认panel名字,将程序从主控电脑传到机器,更换吸嘴和调整轨道宽度并根据产品更换确认单确认是否需要支撑.7.3.2 Off line setup center team and machine operator load the off line setup center tables into the machine, scan machine tables ID label and off line tables label.离线上料组和机台操作员将离线的供料车安装到机器里，扫描机器供料车位置的身份识别号码条码和离线供料车的身份识别号码的条码.7.3.3 Use scanner to check component according to fix component scan system operation instruction. 根据上料扫描系统操作指引使用扫描枪确认物料.7.3.4 Splicing the component reels without stopping machine. 不停机续料.7.3.5 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.7.4 Reflow oven 回流炉7.4.1 Select product program according to changeover checklist. 根据产品更换检查表，选择生产用的程序.7.4.2 Confirm whether the temperature, speed and blow speed are the same as product reflow temperature parameter setup list (QF-00064). 确认炉温，速度和风速是否和产品更换检查表一致(QF-00064).7.4.2 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 change over check list .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,除非刹产品更换确认表特殊要求.7.4.3 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