How to effectively control the loss of components in SMT ?
In SMTprocessing and production, the loss of components has always been a key factor affecting production costs and product quality. Due to the fact that the SMT process involves high-precision mounting, soldering and other links, component loss may come from multiple links such as mounting offset, poor soldering and material waste. How to effectively control component wear and tear has become the core issue for enhancing production efficiency and reducing costs.
Main reasons for component wear and tear in SMT
1. Insufficient placement accuracy: Insufficient precision or improper calibration of the placement machine may lead to problems such as component offset, erection, and flipping, resulting in defective products and component waste.
2. Unstable soldering process: Improper setting of the reflow soldering temperature curve, uneven solder paste printing, etc., may lead to false soldering, bridging or component damage.
3. Material management issues: Poor quality of incoming components, improper storage conditions or incorrect retrieval may lead to component failure or waste.
4. Insufficient equipment maintenance: Long-term lack of maintenance of equipment such as surface mount technology (SMT) machines and printers may lead to a decline in placement accuracy and increase component wear and tear.
How do we effectively control component wear and tear?
As a professional PCBA manufacturer, Asinda ensures the minimization of component loss during the SMT processing through a three-in-one approach of "technology + management + equipment"
1. High-precision placement, reducing placement defects
● Equipped with Yamaha YSM series high-speed surface mount machines, featuring 3D SPI (Solder Paste Inspection) and AOI (Automatic Optical Inspection), real-time monitoring of placement accuracy is carried out to ensure the precise position of component placement.
● Regularly calibrate the equipment, optimize the mounting parameters, reduce problems such as offset and monument erection, and lower the defect rate.
2. Optimize welding processes to enhance welding yield.
● Utilize a ten-zone nitrogen reflow furnace to precisely control the temperature curve, ensuring stable welding quality and reducing issues such as false welding and bridging.
● High-precision steel mesh and high-quality solder paste are used to ensure uniform solder paste printing and reduce component loss caused by poor soldering.
3. Strict material management to eliminate incoming material issues
● All components are sourced from the original factory or first-level agents. Before being ware-in-stock, they undergo AOI+X-RAY inspection to ensure the quality of incoming materials.
● Adopting an intelligent warehouse management system can prevent the problem of wrong materials and mixed materials, and reduce losses caused by material errors.
4. Preventive maintenance of equipment to ensure production stability: ● Daily equipment inspection, regular cleaning of the suction nozzles of the surface mount technology (SMT) machine, and replacement of worn parts to ensure long-term stable operation of the equipment.
● Real-time monitoring of equipment status through the MES system, early warning of potential faults, and reduction of component waste caused by equipment problems.
