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Quality Assurance In Real Time: A Look Inside

Profab Electronics EMS employs a unique production control and quality assurance system which was developed from the ground up in collaboration by Profab's quality managers, production managers, and inspectors. It is called vue, and is the brainchild of Profab's 16 years of experience in manufacturing to the highest quality standards.

vue controls every aspect of the production cycle—from BOM verification, to goods receiving, to final inspection. It's focus is on empowering a true closed loop production cycle to ensure correct setup, minimal rework, zero-defect final product, and on-time delivery. vue allows for real-time reporting and analysis of defects—identifying patterns as they occur and correcting the source before more product is affected.

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 easy identification. Items are received against their purchase order to ensure we receive the right part. Currently, an image of the reel or packaging is captured for traceability and verification purposes. A second image is taken of the component for further traceability and verification. When receiving the same part in the future, it is visually verified against the previously received part. In the January 2011 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 second 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. This ensures minimal downtime for feeder changeovers, while ensuring the correct component is replaced.

Traceability
All PCBs are barcoded and can be traced back to the components used. vue has a very robust interface for identifying all products affected with a specific component, whether machine placed or hand placed during rework.

First Article Inspection
First article inspectors have vue monitors on their workstation which gives them access to golden board images, process engineering notes, detailed silk information and simplified top and bottom layer gerbers to identify traces and possible shorts. As defects are found, they are reported by reference designator and are instantly relayed to SMT operators. SMT operators are monitoring the progress of their first articles and are correcting issues as they are reported.

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 see on their monitors, in real-time, defects in order of rising occurence and by highest occurence which ensures any anomalies or emerging patterns are identified at their onset and corrective actions are immediately implemented with minimal lag-time. As well, we monitor the productivity of inspectors to ensure they are not working too slowly—or as important, too quickly

Final Inspection
At all stages of inspection, previously identified patterns and corrections are identified to make sure corrections were implemented properly. All boards undergo final inspection in order to ensure all parts, cleaning, solder joints, and positioning are correct.

Post-Production
Process engineers and quality managers evaluate defect reports after each production run in order to issue preventative and corrective actions. Generally, manudfacturability design flaws that were not identified prior to production are identified at this stage and are corrected. The focus is always on minimizing rework and allowing for efficient rework if necessary.