In the PCBA processing, high rework rate will not only increase production costs, but also may affect the product delivery time and customer satisfaction.
I. The main reasons for high rework rate
1. Production process problems
Soldering defects
Poor soldering process may lead to solder joints, short circuit or open circuit, which in turn leads to functional failure of the board.
Defective placement
During the placement process of SMT machine, if the components are not placed accurately or bonded securely, it will lead to problems during the testing or use of the board.
2. Problems with raw materials
Unqualified material quality
If using unqualified components or PCB boards, it may lead to high rework rate.
Poor material management
Poor material management may lead to improper storage of materials, which affects the performance and reliability of the materials, and in turn affects the production quality.
3. Equipment failure
Equipment aging
Production equipment with the increase in the use of time, there may be a decline in performance or failure, affecting the processing quality.
Inadequate equipment calibration
Equipment that is not calibrated regularly may lead to processing errors and quality problems.
4. Operator problems
Inadequate operation
Operators who do not operate in strict accordance with process procedures may lead to processing defects. For example, improper operation during welding may lead to weld joint problems.
Inadequate skills
Inadequate skill level and experience of the operator may lead to inaccurate process control, which may increase the rework rate.
5. Inadequate testing and inspection
Incomplete testing
Inadequate testing and inspection during the production process may result in defective products not being detected and handled in a timely manner, thus affecting product quality.
Unclear testing standards
Unclear or strict testing standards may result in products that do not meet quality requirements flow into the next production process.
II. Reduce the high rework rate of effective strategies
1. Optimize the production process
Improve the welding process
Use advanced welding technology, such as wave soldering or reflow soldering, optimize the welding parameters to ensure welding quality. Regular maintenance and calibration of welding equipment to maintain stable equipment performance.
Improve placement accuracy
Use high-precision placement equipment and technology to ensure accurate placement of components. Regular calibration and maintenance of placement equipment to avoid poor placement.
2. Strict control of raw materials
Select high quality materials
Purchase high quality raw materials from reliable suppliers and conduct strict quality inspection on incoming materials to ensure that they meet the specifications.
Improve material management
Establish a scientific material management system to ensure the correct storage and use of materials to avoid quality defects caused by material problems.
3. Strengthen equipment management
Regular maintenance and upkeep
formulate equipment maintenance and upkeep plan, regularly inspect and maintain the production equipment to ensure the normal operation of the equipment and reduce the problems of returning to repair caused by equipment failure.
Equipment calibration
Regularly calibrate the equipment to ensure processing accuracy and consistency. Calibration records should be complete to facilitate the tracking of equipment status and performance.
4. Enhance operator skills
Enhance training
Provide regular technical training to operators to improve their operating skills and quality awareness. The training should include process procedures, quality control and troubleshooting.
Implementation of standardized operation
Develop and implement standardized operating procedures to ensure that operators operate the equipment in accordance with the standards and reduce quality problems caused by human factors.
5. Complete testing and inspection
Comprehensive testing
Conduct comprehensive testing and inspection during the production process to detect and deal with defective products in a timely manner. The testing program should cover all key parameters to ensure that the product meets the quality requirements.
Clear inspection standards
Develop clear inspection standards and processes to ensure the accuracy and reliability of the inspection work. Inspectors should receive professional training to ensure that they have the necessary testing capabilities.
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Post time: Sep-10-2024