The causes and solutions of SMT material loss

The causes and solutions of SMT material loss

The factors causing SMT material loss can first be analyzed in detail through the human-machine-material-method-environment approach as follows:
I. Human factors
When installing materials, the tearing tape was too long and too much material was pressed, resulting in material loss and loss.
Solution: Train the operator to leave two or three empty Spaces when loading materials. Press the materials until they are in good condition at the material window. This way, the position of the FEEDER gear and the tension of the winding belt can be checked.
2. After the FEEDER was installed, there were debris on the TABLE, causing it to be out of place and shake, making it impossible to get the materials.
Solution: Train the operator to check whether there are any foreign objects 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 was not installed on the FEEDER, causing the chuck and FEEDER TAPE to float and throw materials.
Solution: Strictly require the operator to load the material tray onto the FEEDER when changing materials.
4. Failure to remove the roll TAPE in time leads to changes in tension, failure to roll the tape, poor feeding, and floating and throwing materials on the FEEDER TAPE.
Solution: Strictly require the operator to thoroughly clean the reel when changing materials
5. Losses caused by placing the board in the wrong direction, jumping the wrong board, or wiping the board, etc.
Solution: Strictly require the operator to operate in accordance with the operation manual, and mark the position of panel assembly, the direction of panel entry and precautions in the manual.
The causes and solutions of SMT material loss
Factors and Solutions for SMT material loss
6. Misreading the material station position or P/N leads to incorrect materials.
Solution: Train the operators to verify the P/N of the materials and the machine alarm display, as well as the position of the discharge meter.
7. Incorrect quantity of materials, excessive PCBA, and loss of the material tray due to incorrect feeding.
Solution: It is required that the material handler must count and record the quantity of all materials and PCBA when entering or leaving the production line, and verify the production quantity and inventory quantity during the shift.
8. The packaging parameters in the edited program were set incorrectly, and the number of feedings used did not match the packaging PITCH, resulting in material ejection.
Solution: Modify the PACKED DATA according to the material packaging.
9. The incorrect setting of the mounting position and station position in the edited program led to incorrect materials.
Solution: When programming, check the BOM and drawings. After pasting the first inspection board, reconfirm and check the BOM and drawings.
10. During the production process, due to FEEDER, NOZZLE, and material issues, the technician failed to follow up on the material discharge in a timely manner, resulting in a large amount of material discharge.
Solution: It is required that the line technicians must monitor the operation status of the machine in real time. When the machine alarms, they must handle and observe on site. The hourly material discharge report must be signed and confirmed by the technician along with improvement measures. If the material is not handled within two hours after being signed and confirmed, the reasons must be analyzed and reported to the assistant engineer for handling.
11. The Feeder cover was not fastened properly and the Feeder was not inspected before loading materials
Solution: Require the operator to operate in accordance with WI requirements and check the FEEDER both before and after installation. Technicians and management check and confirm.
12. Random stacking of feeders causes deformation, and random disassembly and placement of FEEDER stoppers.
Solution: It is required that the operator place all feeders on the FEEDER vehicle and strictly prohibit stacking or randomly placing them. When following the wires, it is strictly forbidden to disassemble FEEDER accessories at will.
13. Poor feeders were not sent for repair in time and were reused, resulting in material discharge.
Solution: All faulty feeders must be clearly marked by the operator and sent to the FEEDER repair station for maintenance and calibration.

Ii. Machine factors
The suction nozzle is deformed, clogged, damaged, the vacuum pressure is insufficient, and there is air leakage, resulting in the material not being sucked up properly, the material being taken out incorrectly, and the material being thrown out due to failure to pass the identification.
Solution: It is required that technicians must inspect the equipment every day, test the NOZZLE center, clean the nozzle, and maintain the equipment regularly as planned.
2. Insufficient spring tension, uncoordinated suction nozzle and HOLD, and uneven up and down movement result in poor material retrieval.
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
3. Poor feeding caused by deformation of HOLD/SHAFT or PISTON, bending of suction nozzle, wear and shortening of suction nozzle;
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
4. The material is not taken at the center of the material, and the height of the material taken is incorrect (generally, it is determined by pressing down 0.05MM after touching the part), resulting in misalignment. The material taken is incorrect and has a deviation. When identified, it does not match the corresponding data parameters and is discarded by the recognition system as invalid material.
Solution: Regularly maintain the equipment as planned, inspect and replace vulnerable parts, and calibrate the machine's origin.
5. The vacuum valve and vacuum filter element are dirty, or there are foreign objects blocking the vacuum air pipe channel, making it unsmooth. During suction, the instantaneous vacuum is insufficient to meet the operating speed of the equipment, resulting in poor material retrieval.
Solution: Technicians are required to clean the suction nozzles every day and maintain the equipment regularly as planned.
6. The machine is not positioned horizontally and vibrates greatly. The machine resonates with the FEEDER, resulting in poor material picking.
Solution: Regularly maintain the equipment as planned and check the horizontal fixing support nuts of the equipment.
7. Wear and loosening of the lead screw and bearings cause vibration during operation, changes in stroke and poor material taking.
Solution: It is strictly prohibited to blow the interior of the machine with an air gun to prevent dust, debris and components from adhering to the lead screw. Regularly maintain the equipment as planned, and inspect and replace the vulnerable parts.
8. Wear of motor bearings, aging of code readers and amplifiers cause changes in the machine's origin, and inaccurate operation data leads to poor material picking.
Solution: Regularly maintain the equipment as planned, inspect and replace vulnerable parts, and correct the machine's origin.
9. The visual, laser lens and the reflective paper of the nozzle are not clean, and there are impurities interfering with the camera's recognition, resulting in poor handling.
Solution: It is required that technicians must inspect the equipment every day, test the NOZZLE center, clean the nozzle, and maintain the equipment regularly as planned.
10. Poor processing is caused by improper selection of the light source, aging of the lamp tube, insufficient luminous intensity and gray scale.
Solution: Regularly maintain the equipment as planned, test the luminance of the camera and the brightness of the lamp tubes, and inspect and replace the vulnerable parts.
11. Poor treatment of the reflective prism due to aging, carbon deposits, wear and scratches.
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
12. Insufficient air pressure and vacuum leakage cause insufficient air pressure, resulting in the material being unable to be picked up or falling off during the process of pasting after being picked up.
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
13. The deformation of the feeder cover and the insufficient spring tension caused the material tape not to get stuck on the ratchet wheel of the feeder, resulting in the tape not being rolled up and the material being thrown out.
Solution: All faulty feeders must be clearly marked by the operator and sent to the FEEDER repair station for maintenance, calibration, inspection and replacement of vulnerable parts.
14. Loose or aged cameras cause poor recognition and material discharge.
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
15. Wear of the spines, drive claws, and positioning claws of the feeder, electrical failure, and malfunction of the feeding motor can cause poor feeding of the feeder, failure to collect materials or poor material discharge.
Solution: All faulty feeders must be clearly marked by the operator and sent to the FEEDER repair station for maintenance, calibration, inspection and replacement of vulnerable parts
16. The wear of the machine's feeding platform causes the FEEDER to loosen after installation, resulting in poor material retrieval.
Solution: Regularly maintain the equipment as planned, and inspect and replace vulnerable parts.
The causes and solutions of SMT material loss

SMT patch processing products
Iii. Material reasons
1. Substandard products such as dirty, damaged components, irregular incoming materials, and oxidized pins lead to poor identification.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
2. The components are magnetized, the packaging of the components is too tight, and the friction force between the material frame and the components is too large, causing the components to fail to be lifted.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
3. Inconsistent component sizes or package sizes, spacings, and orientations can lead to poor material picking and identification.
Solution: Feedback to IQC and communicate with the supplier to replace the materials. When incoming materials are sent, the packaging and body shape of the same P/N material must be inspected.
4. The components are magnetized and the tape is too sticky, causing the material to adhere to the tape during winding.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
5. The component's suction surface is too small, resulting in poor material retrieval.
Solution: Report to IQC and communicate with the supplier to replace the materials and reduce the operating speed of the machine.
6. The hole diameter of the material used to hold the components is too large, and the size of the components does not match the packaging size, resulting in the components being placed sideways, flipped over, or in an incorrect position during feeding, leading to poor material retrieval.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
7. The feeding hole of the material belt has a large error from the material hole, and the suction position changes after material change
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
8. The tension of the rolled material tape is not uniform. If it is too soft, it is prone to elongation and will not roll. It is too brittle to break easily and the material cannot be retrieved.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.
9. The packaging of incoming materials is not standardized, and bulk materials cannot be pasted by machines.
Solution: Feedback to IQC and communicate with the supplier to replace the materials.

Iv. Work Methods
1. Using the wrong packaging model of FEEDER, using grooves for the paper tape and flat grooves for the tape, resulting in the inability to retrieve the materials.
Solution: Train operators to identify material packaging and the selection of feeders.
2. Using the wrong specification of FEEDER For material 0603, use 0802FEEDRE; for material 0402, use 0804FEEDER; for material 0603, use Ø1.3MM feed caps; for material 0402, use Ø1.0MM feed caps; for material 0805, use Ø1.0MM feed caps. Adjusting the feeder pitch incorrectly results in no material being retrieved.
Solution: Train operators to identify the size and shape of the material body and the selection of FEEDER covers.
3. Personnel do not operate in accordance with the standards of the operation instruction manual.
Solution: Strictly require operation in accordance with the standards of the operation manual, regularly assess operational skills, and manage, supervise and evaluate.
4. Poor material receiving, bending of the material tape, overly tight tension of the rolled material tape, and the holes of the material tape not matching the gears cause poor material picking.
Solution: Strictly require operation in accordance with the standards of the operation manual, train and assess operational skills, and manage, supervise and evaluate.
5. The tension of the roll tape is insufficient, and the roll tape is not installed in accordance with the standard, resulting in no roll tape.
Solution: Strictly require operation in accordance with the standards of the operation manual, train and assess operational skills, and manage, supervise and evaluate.
6. There is an empty space after the materials are installed, resulting in the inability to retrieve the materials.
Solution: Strictly require operation in accordance with the standards of the operation manual, train and assess operational skills, and manage, supervise and evaluate.
V. Production Environment
The high temperature and insufficient humidity in the workshop cause the materials to dry, generating dust and static electricity.
Solution: Monitor the temperature and humidity in the workshop in real time, and add air conditioners and humidifiers.
2. The high humidity in the workshop and warehouse causes the materials to absorb water from the air, resulting in poor material handling
Solution: Monitor the temperature and humidity in the workshop and warehouse in real time, and add air conditioning and ventilation equipment.
3. The workshop has poor sealing and inadequate dust-proof facilities. Excessive dust causes the machines to get dirty easily and the vacuum to be blocked.
Solution: It is strictly prohibited to use air guns to blow on machinery, electrical facilities and materials. Add carpets for dust removal at the workshop entrance.
4. Insufficient loading platforms and FEEDER vehicles result in non-standard loading and damage or deformation of the FEEDER.
Solution: Add loading platforms and FEEDER vehicles, and operate strictly in accordance with WI requirements.