Process Development and Implementation
ITM can assist you in setting up any assembly process which may be new to your facility, expanding your current process or developing a new capability including:
- Any Standard Surface Mount Assembly Process
- Lead-free Process
- No-clean Process [*note]
- Reflow of Through-hole
- Direct Chip Attach
- Ball Grid Array
[* note] No-Clean Implementation has been so popular that we list is as a separate Service.
ITM's experienced consultants can assist you in start up, process documentation, process control and Assembly Certification and will keep in touch throughout implementation and after.
Starting first with our pre-visit preparation, then an audit of your current assembly process and capabilities and finally process implementation (details below).
Prior to ITM's scheduled visit, specific information about your current assembly process, personnel and facility will be queried including information regarding process flow, equipment and materials used or proposed, composition and the characteristics of the surface mount product to be built (if available). This allows preparation that facilitates efficient and expeditious on-site work.
An on-site audit is the core of our New Process Implementation consultation. It consists of the following five elements:
The Process Review begins by meeting with appropriate engineering and production staff (manufacturing, process, quality, design, and management). Each participant should be prepared to present their specific area of responsibility as well as process concerns, problems they may have and any special needs with the new process implementation.
Initial Process Examination
ITM personnel then proceed to make the initial examination of the assembly line(s) and determine the effect the new process will have on current process capabilities. Procedures, equipment and materials are observed. This procedure provides additional insight for the interview phase. Current Quality Control documentation is also reviewed at this point.
Participants in the Initial Meeting will meet with the ITM staff individually to further discuss their areas of responsibilities. At this juncture, initial observations made by ITM are mentioned as well as problems noted in the initial meeting, observed on the floor, equipment changes/additions if any and/or the challenges with new process implementation are discussed in detail. Changes to the documentation and process control practices pertaining to the individual's area of responsibility will also be reviewed.
New Process Set up and Implementation
At this point, ITM Consultants will discuss and assist in the implementation of the new process including materials identification, process changes and control points, equipment control points and documentation updating. ITM consultants will be onsite during implementation and for a post implementation review.
Detailed Process Examination
The new assembly process will be examined in detail. At this point, ITM will make measurements and analysis at the various process centers including the printer, pick and place, reflow, inspection and repair systems. Compatibility of process parameters and materials will be scrutinized. Interviews with line personnel, as deemed appropriate, will also commence.
Upon completion of the New Process Set Up and Implementation, ITM will review its findings and compile a presentation for the Summation Meeting.
On the morning following the completion of the New Process Set Up and Implementation, ITM will review the process changes, control points, etc. It is here that recommendations for further process control will be submitted. These will include actions to resolve specific problems found during implementation as well as issues and directions for improvement.