Original Date: 05/16/1991
Revision Date: 01/18/2007
Information : On-Line Data Collection
Norden Systems has effectively networked PCs to collect visual inspection data from PCB assembly operations. This on-line data collection system has greatly reduced the required time to access defect data with a minimal initial investment. The system provides real-time defect data which can be sorted and manipulated several ways.
Under the pre-existing system, data collection consisted of visual inspection defect data in the form of handwritten reports from inspectors, followed by physically collecting, entering, and reporting defects per module - by program - once a month. The defect data reports were available 10 to 40 days after any given module was inspected. Products exhibiting defect trends would have oftentimes already exited the production area before the trends were detected.
Norden began using older, unwanted PCs and equipping them with a bar code reading capability to facilitate defect data input by product inspectors. Inspectors used bar code reader wands to enter part number, serial number, defect code and quantity, inspector number, and other similar data to what appeared on the handwritten defect data reporting forms. In-house software was developed to generate an inspection report which accompanies the assembly throughout the production process, and updates to the defect data base are provided immediately.
The computers are linked with Norden's Ethernet system, and the defect data is instantly available for review by supervisory personnel in a many formats including:
Daily and monthly executive summaries of soldering defects per assembly and defect rates by defect category Defect rates by program/product/process/inspector
In addition to the daily and monthly defect reporting activity, Norden uses the systems to:
Track historical and trend data Provide feedback on the effectiveness of corrective actions
Analyze the effectiveness of rework operations
Analyze the turnaround time for any given product.
Since the system is easy to use for inspection personnel and supervisory or management personnel its continued use is guaranteed. Defect data access time has been reduced from an average of 30 days to within minutes after an assembly inspection. The data collection system provides real-time access to defect data allowing Norden to effectively measure the outcomes of process controls and corrective actions as well as the benefits of shop floor training.
Norden has used this system since January 1991. A similar system has been implemented to track functional test results which enables Norden to track test failures in real time and follow up on trends and effectivness of corrective actions. In June 1999, the systems were updated to a Y2K compliant system.
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