The factors of SMT material loss, we can first conduct a detailed analysis through the human-machine material method ring as follows:

 

1. Human factors

1. When installing materials, the tearing belt is too long, and too much pressing material causes material loss and loss;

Solution: train the operator to keep two or three empty spaces when loading, press the material to the material window and see that the material is OK, so that you can check the position of the FEEDER gear,

 

Tape tension.

2. After the FEEDER is installed, there are sundries on the TABLE, which cause it to be out of place, and the material cannot be obtained by shaking;

Solution: Train the operator to check whether there is debris on the machine TABLE and the FEEDER base when installing the FEEDER, and clean the machine TABLE when turning and pulling.

3. The material tray is not installed on the FEEDER, causing the chuck and FEEDER TAPE to float and throw materials;

Solution: It is strictly required that the operator must install the tray on the FEEDER when changing the material.

4. Failure to remove the coil tape in time causes tension changes, non-reel tape, poor feeding, FEEDER TAPE floating high throwing material;

Solution: Strictly require the operator to clean the tape when refueling

5. Putting the wrong board, jumping the wrong board, wiping the board, etc. cause loss;

Solution: Strictly require the operator to operate according to the work instructions, and mark the jigsaw position, feeding direction and precautions on the instructions.

 

 

6. Wrong material position and P/N cause wrong material;

Solution: Train the operator to check the material P/N and machine alarm display, and the position of the discharge table.

7. The quantity of materials is wrong, there are more PCBAs, and the materials are wrongly made and the tray is lost;

Solution: Require material personnel to enter and exit all materials in and out of the production line, and PCBA must count the quantity and register on duty to check the production quantity and the quantity in stock.

8. The packaging parameter setting in the edited program is incorrect, and the feeding times used do not match the packaging PITCH, resulting in material throwing;

Solution: Modify PACKED DATA according to the material packaging.

9. The placement position and station setting in the edited program are wrong, resulting in wrong material;

Solution: Check the BOM and drawings when doing the program, and reconfirm and check the BOM and drawings after posting the first inspection board.

10. During the production process, FEEDER, NOZZLE, and material throwing technicians did not follow up the throwing materials in time, and the data caused a large amount of throwing materials;

Solution: It is required that the line technicians must monitor the running status of the machine in real time, and when the machine alarms, it must be handled and observed on site. hourly report

 

The form must be signed and confirmed by the technician and written improvement measures. If there is a signed confirmation that has not been processed within two hours, the reason must be analyzed and reported to the assistant engineer.

 

reason.

11. The feeder cover is not fastened, and the feeder is loaded without checking the feeder

Solution: Ask the operator to work according to the requirements of WI, and check the FEEDER before and after installation. Technician and management check to confirm.

12. The FEEDER is stacked casually to cause deformation, and the FEEDER STOPPER is disassembled and placed randomly;

Solution: The operator is required to place all the FEEDERs on the FEEDER cart. It is strictly forbidden to stack or place them randomly, and it is strictly forbidden to dismantle the FEEDER accessories along the line.

13. Bad FEEDER is not sent for maintenance and reused in time, causing throwing;

Solution: The operator is required to clearly mark all bad FEEDERs and send them to the FEEDER maintenance station for repair and correction.

 

 

 

Second, the machine factor

1. The suction nozzle is deformed, blocked, damaged, insufficient vacuum pressure, and air leakage, which will cause the material to not be able to be sucked, the material to be taken incorrectly, and the material to be thrown out if the identification fails.

Solution: Technicians are required to check the equipment every day, test the NOZZLE center, clean the suction nozzle, and maintain the equipment regularly according to the plan.

2. Insufficient spring tension, inconsistency between the suction nozzle and the HOLD, resulting in poor feeding;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

3. The deformation of HOLD/SHAFT or PISTON, the bending of the suction nozzle, and the shortening of the suction nozzle wear lead to poor feeding;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

4. The retrieving material is not in the center of the material, and the retrieving height is incorrect (generally, it is determined by pressing down 0.05MM after touching the part), resulting in deviation, and retrieving the material

 

If it is not correct, there is an offset, and it does not match the corresponding data parameters during identification, it will be discarded as invalid by the identification system;

Solution: regularly maintain the equipment according to the plan, check and replace vulnerable parts, and correct the origin of the machine.

5. Vacuum valve, vacuum filter core is dirty, there are foreign objects blocking the vacuum air pipe channel is not smooth, and the instantaneous vacuum is not enough when the suction is caused by the operating speed of the equipment.

 

Bad retrieving;

Solution: Technicians are required to clean the suction nozzles every day and maintain the equipment regularly according to the plan.

6. The positioning of the machine is not horizontal and the vibration is large, and the resonance between the machine and the FEEDER causes poor material retrieving;

Solution: Maintain the equipment regularly according to the plan, and check the level of the equipment to fix the support nuts.

7. The wear and looseness of screw rod and bearing cause vibration during operation, change of stroke and poor material retrieving;

Solution: It is strictly forbidden to blow the inside of the machine with an air gun to prevent dust, sundries and components from adhering to the screw. Maintain equipment regularly according to plan, check

 

and replace vulnerable parts.

8. The wear of the motor bearing, the aging of the code reader and the amplifier cause the origin of the machine to change, the operating data is inaccurate and the material is not retrieved properly;

Solution: maintain the equipment regularly according to the plan, check and replace the vulnerable parts, and correct the origin of the machine.

9. The vision, laser lens, and reflective paper of the nozzle are not clean, and there are sundries that interfere with camera recognition, resulting in poor handling;

Solution: Technicians are required to check the equipment every day, test the NOZZLE center, clean the nozzles, and maintain the equipment regularly according to the plan.

10. Identify improper selection of light sources, aging lamps, luminous intensity, and insufficient gray scale, resulting in poor processing;

Solution: regularly maintain the equipment according to the plan, test the brightness of the camera and the brightness of the lamp, check and replace the vulnerable parts.

11. The reflective prism is aging and has carbon deposits, wear and scratches, resulting in poor handling;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

12. Insufficient air pressure, vacuum leaks cause insufficient air pressure and the material cannot be picked up or dropped on the way to paste after picking up;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

13. The cover of the feeder is deformed and the spring tension is not enough, so that the tape is not stuck on the ratchet gear of the feeder, and the tape is not wound and thrown;

Solution: The operator is required to clearly mark all bad FEEDERs and send them to the FEEDER repair station for repair, calibration, inspection and replacement of vulnerable parts

 

.

14. The camera is loose and aging, resulting in poor identification and throwing materials;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

15. The feeder ratchet gear, driving claws, positioning claws are worn out, electrical failures, and feeding motors are defective, resulting in poor feeding of the feeder or failure to take out materials.

 

Good and discarded;

Solution: The operator is required to clearly identify all bad FEEDERs and send them to the FEEDER maintenance station for maintenance, calibration, inspection and replacement of vulnerable parts.

16. The wear of the feeding platform of the machine causes the FEEDER to loosen after installation and cause poor material retrieving;

Solution: Regularly maintain the equipment according to the plan, check and replace vulnerable parts.

 

 

3. Material reason

1. Unqualified products such as dirty and damaged components, irregular incoming materials, and oxidation of pins cause poor recognition.

Solution: Feedback to IQC to communicate with the supplier to replace the material.

2. The component is magnetized, the component packaging is too tight, and the material frame has too much friction on the component, which makes it impossible to absorb it.

Solution: Feedback to IQC to communicate with the supplier to replace the material.

3. The component size or package size, spacing, and direction are not consistent, resulting in poor material picking and poor identification.

Solution: Feedback to IQC to communicate with the supplier to replace the material. When incoming materials must check the packaging and body shape of the same P/N material.

4. The component is magnetized and the material tape is too sticky, and the material adheres to the material tape when the tape is rolled.

Solution: Feedback to IQC to communicate with the supplier to replace the material.

5. The absorbable surface of the component is too small, resulting in poor material retrieving.

Solution: Feedback to IQC to communicate with suppliers to replace materials and reduce machine speed.

6. The hole diameter of the component containing the component is too large, and the size of the component does not match the size of the package, causing the material to stand on its side, turn over, and the position is incorrect during feeding, resulting in poor material retrieving.

Solution: Feedback to IQC to communicate with the supplier to replace the material.

7. The error between the feed hole and the feed hole of the material belt is large, and the suction position changes after refueling

Solution: Feedback to IQC to communicate with the supplier to replace the material.

8. The tension of the coiled tape is not uniform. If it is too soft, it will be stretched and will not be coiled;

Solution: Feedback to IQC to communicate with the supplier to replace the material.

9. The packaging of incoming materials is not standardized, and bulk packaging cannot be mounted by machines.

Solution: Feedback to IQC to communicate with the supplier to replace the material.

 

 

 

4. Working method

1. Wrong different packaging models FEEDER, grooves for paper tapes, flat grooves for tapes, resulting in failure to get materials;

Solution: Train the operator to identify the choice of material packaging and FEEDER.

2. Use the wrong specification FEEDER, 0802FEEDRE for 0603 material, 0804FEEDER for 0402 material, Ø1.3MM material cover for 0603 material,

 

0402 materials use Ø1.0MM material caps, 0805 materials use Ø1.0MM material caps, wrongly adjust the FEEDERPITCH, resulting in failure to get the material;

Solution: Train the operator to identify the size and shape of the material body and the choice of FEEDER material cover.

3. Personnel do not operate according to the standard operation instructions.

Solution: Strictly require standard operations in accordance with the operation instructions, regularly assess operating skills, and manage supervision and assessment.

4. Poor splicing of materials, bending of the material belt, too tight tension of the coil material belt, and failure of the material belt hole to fit the gear, resulting in poor material retrieving;

Solution: Strictly require standard operation according to the operation instruction, training and assessment of operational skills, management supervision and assessment.

5. The tension of the coil tape is not enough, and the coil tape is not installed according to the standard, resulting in no coil tape;

Solution: Strictly require standard operation according to the operation instruction, training and assessment of operational skills, management supervision and assessment.

6. After the material is installed, there is a space and the material cannot be obtained;

Solution: Strictly require standard operation according to the operation instruction, training and assessment of operational skills, management supervision and assessment.

 

5. Production environment

1. The high temperature and insufficient humidity in the workshop will cause dust and static electricity to dry out the material.

Solution: monitor the temperature and humidity in the workshop in real time, and add air conditioners and humidifiers.

2. The humidity in the workshop and warehouse is high, and the material absorbs moisture in the air, resulting in poor material retrieving

Solution: monitor the temperature and humidity of workshops and warehouses in real time, and increase air conditioning and ventilation equipment.

3. The workshop is not well sealed, and the dust-proof facilities are poor. Too much dust will cause the machine to be easily dirty and vacuum blocked.

Solution: It is strictly forbidden to use the air gun to blow the electrical equipment and materials of the machine, and add carpet dust removal at the workshop door.

4. Insufficient loading tables and FEEDER vehicles cause non-standard loading and FEEDER damage and deformation.

Solution: Add loading table and FEEDER car, and operate strictly according to WI requirements.