Electronic Manufacturing Defect and Process Data Collection
Do you want to collect defects or/and process data?
Do you want to collect data by Serial Number or by Batch?
Does your touch up need to detect position of Reference Designation on PCB?
Do you prefer to use paper or computers?
DCollector is the answer. It allows collection of information in different modes and levels.
It can import information from different sources such as CAD, BOM (ERP, PLM etc), SMT machines etc. It can collect defects from ATE, AOI etc. It has many features, more than you can imagine.
Visual Manual Inspection
The use of advanced technologies for defect identification, such as AOI, ICT, boundary scan etc. has not yet completely replaced Visual Manual Inspection. In most production lines it is used to complement the automated processes either for inspection or correction of faults.
In many factories, the VMI process lack proper supporting tools for collecting the information and monitor the quality and productivity of inspectors although in many cases it is a bottleneck in the manufacturing process and the stage in the process where quality is most questionable.
DCollector is a data collection tool designed specifically for the electronic production industry and for the VMI process. Its main purpose is to allow efficient collection of defect data while increasing data accuracy and quality.
DCollector uses the PCB’s CAD data in order to present the PCB layout to the inspector. By doing so, it improves both efficiency and accuracy.
The inspector can easily locate the faulty component on the screen that assists him in locating it on the faulty board. Imagine trying to locate a faulty diode on a board containing hundreds of components. By typing the faulty designation, DCollector locates the component on the board and highlights it for the inspector, so he can easily locate it on the board. DCollector also presents the component’s Catalogue number, description etc.
After locating the suspected component, the inspector examines and potentially corrects the fault by soldering or replacing the component. Following the correction, the inspector can report the fault and the corrective action taken by clicking on the faulty component and selecting the relevant values from a drop down list.
The above process shortens inspection time and guarantees the correctness of the data due to the visual reference to the board and since integrity is enforced based on CAD and BOM data. Customers using DCollector have reported 30% increase in VMI productivity and close to zero errors in data collection.
In addition to shortening the inspection time DCollector enables managers to monitor the VMI quality and inspectors productivity.
The reported defects and corrective actions information are stored in a database. Faulty boards can be traced back to the inspector who failed to identify or fix the fault.
In addition DCollector generates reports about inspectors’ productivity (# of inspected boards per hour) and quality (# of repeated faults).
Figure 1. Component Information
DCollector as a Basic Part of MES (Manufacturing Execution System)
Proventus DCollector (as Part of MES) contains forms that enable import of defects (that can be collected using papers before). Also, DCollector contains features for collection process data (including of route settings, works management, etc.) and viewing it on online WIP (Work In Process) screen. In additionally, it allows export of management reports and raw reports by different parameters such as Yield reports, Bad components etc.
Figure 2. Reporting Defect
Also, it includes:
General instructions for product and work as textual and file attachment (for example PDF, Excel, Completed Folder and more)
Attached (as file or folder) Station/Stage instructions as a part of product route card and work rout card
Result collection as hard copy (or as file/folder) for each serial number:
User can attach files and folders directly in reporting form as a part of process. This information is collecting and can be requested in any time by serial number.
Traceability with serial management and collection of system configurations (tree of serials)
Product (Catalog Number and Revision) and Work management by creating in DCollecctor or by importing from ERP/PLM systems
Parallel processing - multiple parallel stations on same stage of process
and more ...
Graphical representation of inspected board
Point and click data collection
Speeds up inspection process
Improves data quality and integrity
Provides managers with tools for monitoring quality and productivity of VMI.
Can be used as a Part of MES
Can be implemented without changing the processes
Manager can follow what is happening on the production line
Internal and External (Customer) Reports
Identifying problematic components