In order to identify inefficiencies and non-conformities in production, to identify the root cause for high failure rate, we suggest to start with an in-depth audit.
Audit scheme and report are based on industry-leading technology company.
Project scheme is as follows:
Report, feedback and proposal
1. Check IQC department procedures for proper material.
2. Warehouse inspection for adequate ESD and MSD storage, and material stock control.
3. Concentrate on SMT department, procedures for quality assurance, for failure avoidance, for ESD and MSD handling.
4. Evaluate machine and factory capabilities. Evaluate process and quality for on-going order during audit. Advice on actual cases of SMT problems, if personnel can prepare a list of most common failures.
5. Assembly department (incl. HMT and DIP processes) inspected for overall quality, soldering skills, process flow, documentation, ESD, QA system and management structure
6. Evaluate factory's IPQC and OQC. IPQC department is often underestimated and not well-functioning
SMATE compiles audit report, and present report of observed non-conformities together with suggestions and solutions for optimization.
Earlier project has proven, factories will achieve better optimization working along SMATE than handling it alone.
Logically, many problems would not exists or already be solved, if factory had these skills in-house.
Based on findings from audit report and client request, we assist clients implementing optimizations, covering:
1. Management optimization
- Train managers and engineers, enhance their understanding of quality
- Enable team to perform internal audits.
- Clarify responsibilities
2. Procedures optimization
- Optimize procedures to control risks before and during production
- On-site support for root-cause analysis
- Focusing on SMT department and assembly line.
- Focusing on details, e.g. adequate handling of humidity and temperature
Smate recommends to schedule a small follow-up audit a few weeks later to make sure that the optimization is carried out.
By making specialist eye examinations, we look for root cause for issues in production.