People who make circuit boards know that the production process is very complex~~~
Cutting, fillet, edging, baking, inner layer pretreatment, coating, exposure, DES (development, etching, film removal), punching, AOI inspection, VRS repair, browning, lamination, pressing, target drilling, Gong edge, drilling, copper plating, film pressing, printing, writing, surface treatment, final inspection, packaging and other processes are countless.
It sounds great, but the process is so long that there are many problems that need to be paid attention to.
1： Equipment is a treasure and needs to be taken good care of
If you want to ask the circuit board factory what is the most valuable, the equipment will never fall out of the top three.
Millions of foreign high-end equipment are expensive, especially those that are expensive.
It is reasonable to say that such an expensive thing should be cherished.
However, in many circuit board factories, the "noble" equipment is treated casually: just use it hard and don't pay attention to maintenance and repair. It's really broken, so it's repaired and repaired.
This is like a boy who tries his best to marry a lovely girl home, and then doesn't cherish it. He calls her hard every day and asks her to do all the chores and important tasks such as washing, mopping, buying vegetables, cooking, making money at work, turning her into a yellow faced woman with yellow complexion.
People will be old and tired, and so will equipment. No matter how good a machine is, it can't stand the toss accumulated over time. Therefore, in factories that do not cherish equipment, there are often equipment downtime, and even equipment worth millions of dollars has deteriorated seriously and had to be scrapped in just three or five years.
Suggestion: organically integrate and subdivide "independent maintenance", "professional maintenance" and "initial improvement", design a controlled inspection and maintenance system covering the whole life cycle of equipment, and form a preventive maintenance mechanism of "maintenance instead of repair" through full participation, so as to gradually realize zero fault of equipment.
2： It is very important to save cost and change production quickly
At present, we have ushered in an era of small batch, multiple varieties and high production costs. For circuit board factories, the losses caused by changing production lines and stopping production lines are very significant. As soon as they stop production lines, a large amount of white money will disappear.
Take CNC molding machine as an example. Generally, the production change time is as long as 50 to 90 minutes at a time, and one or two batch numbers need to be changed a day. The efficiency loss caused by it can't bear to think about it.
In addition, there are internal exposure, text printing, anti welding printing, dry film exposure, drilling and other processes, and the production change time ranges from more than ten minutes to tens of minutes.
Suggestion: implement rapid production change activities to gradually reduce the production change time of the above processes to less than 10 minutes.
3： If the pass rate of products is not raised, the profits will fall
The product pass rate of famous enterprises in the circuit board industry will never be poor.
In contrast, some small enterprises with mediocre performance may not perform well in terms of product pass rate. The total unqualified rate of each process can be as high as 10% or more; The unqualified rate of single process can be as high as 2% to 4% (such as exposure and development). The pass rate of products is poor. If the added value of products is not high, the benefits of the factory will not look good.
The reason is that employees' weak awareness of product quality is one of the important factors. As shown in the table above, the manufacturing process of circuit board is very long. If one or two employees in each process are absent-minded and do not take product quality seriously, the one-time qualified rate of products will be low and the problem will be very serious.
Suggestion: analyze the correlation between poor quality and equipment status, and then take targeted improvement measures. When carrying out quality maintenance, we should also pay attention to improving the skill proficiency and other related factors of personnel.
4： It is necessary to carry out lean production according to the actual situation of the factory
In PCB Factory, it is difficult to avoid the bad phenomena such as leakage, leakage and corrosion of equipment. At the same time, because most PCB factories adopt workshop split production mode, there are more handling between workshops and between processes, which virtually increases many unnecessary costs.
Suggestion: vigorously promote lean production, and focus on the improvement of equipment cleanliness and handling (logistics) efficiency.
5： Safety is the top priority, and PCB factories must strictly prevent fire
Cost, equipment maintenance, pass rate and lean production are very important for a circuit board factory, but for all circuit board people, the first rule they should engrave in their mind should be: safe production!
Safety is above all else!
The production process of circuit board is long and complex, and there are many hidden dangers. If you don't pay close attention, it is likely to lead to great disaster.
Among them, the circuit board factory fire is the "devil" we circuit board people most hear but most often see.
"Fire is the natural enemy of PCB industry" and "the industry with the highest fire frequency", some people sigh. If we look back on the development history of the PCB industry for more than 30 years, we can say that the fire followed all the way, and many world-famous PCB factories were set on fire.
In this historical context, "Jinshan Yinshan, fire protection is the backing" is becoming more and more important. Therefore, in the production process, circuit board people must always pay attention to putting safety production first and strictly prevent fire!
Suggestion: according to the summary of insiders, electroplating and etching are the processes most likely to cause fire; The main reasons are improper treatment of chemicals, poor temperature control, wire fire and so on. It is suggested to use d = LEC or other methods to analyze the safety risk of production equipment, then take corresponding preventive measures, and track and verify the effect.
