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Profabs vue Production Control System Streamlines Processes and Enforces Quality Assurance

vue is the brainchild of Profab's 16 years of experience in manufacturing to the highest quality standards. It is our state of the art in-house built production control operating system which controls every aspect of the production cycle—from BOM conversion and verification, to goods receiving, to final inspection. vue was publicly announced in July 2010 and since then has undergone continuous upgrades—with plenty more features planned for future updates. Profab's quality assurance processes are unique and thus have created the foundation for our reputation and success.

Goods Receiving
The vue receiving system ensures that every part we receive is given a Profab unique identifier label on its packaging, containing a unique number and all relevant part information (Internal PN, Manufacturer, Manufacturer PN, Description, and PO). The unique number is used for the automated feeder setup verification, while the rest of the information is used for instant identification. Items are compared against their purchase order to ensure we receive the right part. Currently, an image of the reel or packaging is captured for a number of purposes. When receiving the same part in the future, it is verified against the previously received part. A second image is taken of the component for further traceability and verification. In the October update release, barcodes will be automatically identified on the scanned reel or package and all relevant part information will be identified and verified automatically as a verification measure.

Feeder/Bin Setup Verification
Feeder/bin setup verification utilizes vue’s automated feeder setup verification software—ensuring the right components are in the right location for the right assembly and in the right quantities

First Article Inspection
First article inspectors have vue monitors on their workstation. Since all boards are barcoded, inspectors have access to detailed silk information and simplified top and bottom layer gerbers to identify traces and possible shorts. Errors are reported by reference designator and are referenced on a number of views (top and bottom gerbers, silk screen info, image of sample board). Upon completion of the inspection, the inspector verbally communicates the errors with SMT operators and ensures all errors are corrected. The defects are recorded in vue for future reference and to be used for reference by in-process inspectors.

In Process Inspection
In-Process inspectors also have vue monitors on their workstations. All defects are reported within the vue stations and are instantly relayed to the previous processes, such as SMT, TH reflow oven, selective soldering, cable prep, etc. Operators instantly see on their monitors defects in order of rising occurence and by highest occurence which allows for real-time closed loop quality control. Any anomalies or emerging patterns are identified at their onset and preventative actions are immediately implemented. As well, we monitor the productivity of inspectors to ensure they are not working too slowly—or more importantly, too quickly

Final Inspection
All boards undergo final inspection in order to ensure all parts, cleaning, solder joints, and positioning are correct.

Quality Monitoring
All boards undergo final inspection in order to ensure all cleaning, solder joints, and positioning is correct.

Revision Control/ECN
Bills of Materials are maintained within vue to ensure everybody is using the most current revision. ECN's are enforced within vue by ensuring they are implemented site-wide and only with proper authorization.

BOM Cleansing/Verification
vue takes advantage of a number of databases in order to verify the integrity of bill of material lines and verify their AML's match. Any anomalies are confirmed with the customer to ensure the correct components are ordered and placed. These databases include parametric data for 150+ million parts and inventory information for over 1,000 suppliers of hard to find parts.