Cutting, fillet, edge grinding, baking, inner pretreatment, coating, exposure, DES (development, etching, film removal), punching, AOI inspection, VRS repair, browning, lamination, pressing, drilling target, gong edge, drilling, copper plating, film pressing, printing, text, surface treatment, final inspection, packaging, and other processes are extremely numerous.
It sounds great, but the process is so long, and there are many problems to pay attention to.
1： The equipment is precious and needs to be taken good care of
If you ask the circuit board factory what is the most valuable, the equipment will never fall out of the top three.
In particular, those high-end and high-class foreign equipment are expensive, often tens of millions.
It is reasonable to say that such expensive things should be treasured.
However, in many circuit board factories, "noble" equipment is treated casually: just use it hard, not pay attention to maintenance and repair, it is really bad, just repair and repair.
It's just like a boy who took pains to marry a lovely girl and went home, and then didn't cherish it. He tried to call her every day, let her take care of all the chores and important things such as washing, mopping, buying vegetables, cooking, working and making money, and turned her into a yellow face.
People will get old and tired, so will equipment. No matter how good the performance of the machine is, it can't stand the ups and downs. Therefore, in those factories that do not cherish equipment, it often occurs that the equipment is shut down, and even the equipment with a value of several million has deteriorated seriously and has 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 the participation of all staff, so as to gradually achieve zero equipment failure.
2： It is important to save costs and quickly change production
At present, the era of small batch, multiple varieties and high production costs is ushered in. For the circuit board factory, the loss caused by changing production and stopping production line is very significant. Once the line is stopped, a large amount of silver will be lost.
Take the CNC molding machine as an example. Generally, the production change time can be as long as 50 to 90 minutes at a time, and one or two batch numbers need to be changed every day. The factory director can't bear to think about the efficiency loss caused by it.
In addition, there are inner layer exposure, text printing, anti-welding printing, dry film exposure, drilling and other processes. The production change time varies from ten minutes to tens of minutes.
Suggestion: implement rapid production change activities to gradually reduce the production change time of the above processes to within 10 minutes.
3： If the product pass rate is not raised, the profit will fall
The pass rate of the products of the famous enterprises in the circuit board industry will never be poor.
On the other hand, some small enterprises with mediocre performance may not perform well in the 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 product pass rate is poor. If the added value of the product is not high, the benefits of the factory will not be much better.
One of the important reasons is that the employees' awareness of product quality is weak. As shown in the above table, the manufacturing process of circuit boards is very long. If one or two employees in each process are absent-minded and do not take product quality seriously, the one-time pass 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, attention should also be paid to improving the skill proficiency of personnel and other relevant factors.
4： It is necessary to implement lean production according to the actual situation of the factory
In PCB factories, it is difficult to avoid such undesirable phenomena as leakage, leakage and corrosion of equipment. At the same time, because PCB factories mostly adopt the workshop split production mode, there are many transports between workshops and between processes, which adds a lot of unnecessary costs.
Suggestion: vigorously promote lean production, focusing on the improvement of the cleanliness of the equipment body and the improvement of the handling (logistics) efficiency.
5： Safety is the top priority. 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 minds 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 disaster.
Among them, the fire in the circuit board factory is the "devil" that we circuit board people most often hear and see.
"Fire is the natural enemy of PCB industry", "the industry with the highest frequency of fire", someone sighed. If we look back at the development history of the PCB industry for more than 30 years, we can say that the fire has followed closely, and many famous PCB factories in the world have been burned down.
Under this historical background, "fire protection is the backbone of the golden mountains and silver mountains" is becoming more and more important. Therefore, in the production process, the circuit board personnel must always pay attention to the safety of production, put safety in the first place, 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 chemical treatment, poor temperature control, and wire fire. It is recommended to use D=LEC or other methods to conduct safety risk analysis on production equipment, then take corresponding preventive measures, and track and verify the effect