The European Union's RoHS (Restriction of Hazardous Substances) Directive is in effect and has been followed with similar legislature in China, Korea, California and, likely, other states. Implementing RoHS lead-free requirements is a challenge throughout the entire supply chain. OEMs and CEMs, large and small, included, exempt or deferred — all electronic assemblers are affected.
If your facility's goal is to manufacture products that are compliant with current and forthcoming RoHS requirements, just how ready are you? How "bullet-proof" are your assembly processes? Do you know where the weak links in your documentation, procedures, materials and equipment are? Would you like to be absolutely sure or would you rather risk potential escapes of non-compliant products and the expense of litigation?
As an objective, knowledgeable and independent third-party, ITM can review your lead-free assembly processes and recommend specific direction for product compliance and process compliance improvement. With over 30 years of experience in PCB assembly and SMT processes, equipment, and materials, as well as extensive expertise in lead-free implementation, ITM's comprehensive process review will result in improved SMT lead-free assembly techniques and methodologies.
ITM's unique SMT Lead-Free Process Audit begins with us bringing our SMT and Lead-free expertise on-site to your facility. Unlike other audits, we don't just point out what you are doing wrong — we make positive and objective recommendations on how to do it right. We concentrate on improving your assembly process as well as troubleshooting specific problems you may be experiencing.
The entire review can generally be accomplished within 2 - 4 days (depending upon the number of lines in the facility) and with minimal disruption to factory personnel and routines. Our specific knowledge of, and experience with, most major manufacturers of production equipment and solder pastes gained through our ongoing consulting work in the field assures you of accurate and timely information and recommendations.
Prior to ITM's scheduled visit, specific information about your assembly process, personnel and facility will be queried including information regarding current process flow, equipment and materials being used, composition and characteristics of the product being used, current defect levels and specific trouble areas currently recognized. This preparation assures efficient and expeditious on-site work with minimal facility disruption.
Initial Meeting
The Lead-Free Process Audit begins with a meeting with appropriate engineering and production staff including Manufacturing, Process, Quality, Design, and management. Each participant presents their specific areas of responsibilities as well as process concerns and problems they may have.
Initial Process Examination
ITM's experienced personnel then proceed to make the initial examination of the assembly line(s). Procedures, equipment and materials are observed. This procedure provides additional insight for the examiner for the interview phase. Quality and operational documentation is also reviewed at this point.
Interviews
Participants involved in the initial meeting meet with the ITM staff individually to further discuss their areas of responsibilities. At this juncture, initial observations made by ITM are reviewed as well as problems in these areas being experienced are discussed in detail. Documentation and process control practices pertaining to the individual's area are also reviewed.
Assembly Processes, Materials and Equipment:
Materials - handling and validation
Components - handling and validation
Printing and Deposition
Component Placement
Reflow Soldering
Wave and Selective Soldering
Manual assembly and soldering operations
Rework and repair
Inspection - incoming, in-process and final
In-Circuit and Functional Test
Equipment set-up instructions
Equipment maintenance
5-S implementation
Quality Systems and Procedures
General Quality Systems
Quality Records
Material Procurement, Validation, Declaration Procedures
Skills, Training and Certification
Calibration Control
Internal Audits
Quality Records
Statistical Process Control
In-Process Controls
Non-Conforming Material Controls
Corrective Action
Specific areas of the assembly process are examined in detail. ITM may make measurements and analysis at the various processes. Compatibility of process parameters and materials will be scrutinized. Interviews with line personnel, as deemed appropriate, will also be conducted.
Process Audit and Gap Analysis Summation Meeting
Upon completion of the Process Examination, ITM will review its findings and compile its presentation for the Process Audit and Gap Analysis Summation Meeting.
Following the completion of the Process Examination, ITM will present its findings in a Summary Meeting with appropriate personnel. It is here that the Recommendations for Process Improvement will be submitted. These will include specific actions to resolve specific problems as well as issues and directions for improvement of quality and cycle time reduction.
Written Report
Within 1 - 2 weeks following the Process Review, ITM will submit a written report summarizing the findings and recommendations presented in the Process Review Summation Meeting. If desired, a follow-on meeting with Corporate Management to present ITM's findings can also be opted for.
In addition to the initial (proposed) Process Audit, the client can apply for the ITM Lead-free Process Certification. ITM shall revisit the client's facility at a future agreed upon date (within 8 months of the initial audit) for a follow-up audit. If all 1st Level Recommendations cited in the initial audit have been implemented and nothing else has degraded, ITM shall certify the client's SMT assembly process.
This certification states to present and prospective customers of the client that the processes, materials, equipment and personnel have been certified by ITM to be capable of producing quality PCB assemblies. ITM will be available to state and discuss this with said customers. Certification is valid for 2 years and renewal can be applied for with a follow-on Process Audit.
The ITM Consulting Difference:
ITM Consulting — We don't tell you want to hear, we tell you what you need to know
For more information, please contact: itm@itmconsulting.org
