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Building an AOI

Views: 5658

Seems like every week there is a new thread where someone is... - Apr 25, 2007 by

This thread sucks. ... - Apr 27, 2007 by Chris  

Upper Management

#49282

Building an AOI | 25 April, 2007

Seems like every week there is a new thread where someone is asking which AOI to purchase.

I hope you realize that AOI equipment is not cheap. This company is in profit-assurance mode for the first 4 quarters of this year. As you know, when we are in profit-assurance mode, requests for extraneous expenditures must be denied.

I think you, in the Manufacturing Engineering group, are not fully challenging yourselves. I maintain that we should be able to build our own AOI internally. We have a machine shop. We have knowledge of robotics and vision systems. We have developers in our IT department who can write softwares. To demonstrate my faith in you, I have pledged $10,000 towards the development of this company's AOI system.

I will be out of the office traveling for the next two weeks. I'll be checking in on your progress when I return. Don't be afraid to rise to the challenge!

Upper Management.

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#49284

Building an AOI | 25 April, 2007

Hello Up Man,

In the days before AOI we had a thing called PEDRO's, which I believe means "sample" in some language. Anyway, it was just the 'golden board' in a plastic box so you could compare your run to it. Granted not as high tech or reliable as a real AOI system, but it's what we had.

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Upper Management

#49285

Building an AOI | 25 April, 2007

Dear Ms. Chunks,

Your valuable input has been noted. Unfortunately, your approach won't work in this case. Our customers would like for us to have AOI.

To be perfectly honest with you, if we could just rig up some camera-looking thing that moved around, that would probably be enough to impress them. We will also need some colored charts, with titles like "False Calls" and "First Pass Yield".

Upper Management.

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Upper Management

#49286

Building an AOI | 25 April, 2007

Dear Ms. Chunks,

Your valuable input has been noted. Unfortunately, your approach won't work in this case. Our customers would like for us to have AOI.

To be perfectly honest with you, if we could just rig up some camera-looking thing that moved around, that would probably be enough to impress them. We will also need some colored charts, with titles like "False Calls" and "First Pass Yield".

Upper Management.

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#49287

Building an AOI | 25 April, 2007

Yessir! I can duct tape my camera phone to the end of a broom and use that until we get some RTV (Redneck Tape Variant). Just be aware that the AOI will be down for PM, end of the day sweep ups, and incoming phone calls.

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ck_the_flip

#49289

Building an AOI | 25 April, 2007

Actually, I showed this to a customer recently http://farm.tucows.com/images/2006/01/uncle_rico_time_machine_2.jpg , and they were very impressed.

I told them we could use this apparatus to build through-hole circuit cards from 1982.

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#49290

Building an AOI | 25 April, 2007

I believe that leader of industry, Mattel, has a camera that can be obtained at a cost effective level. I believe it is called a BarBie model. And the camera movement can be based on systems from Lionel.

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SWAG

#49291

Building an AOI | 25 April, 2007

I'll sell you our fully functional 1997 OptiCheck for $9,999. It moves around and does all sorts of scanning-like impressive things with light.

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Cmiller

#49293

Building an AOI | 25 April, 2007

WOW, just no innovation here. Nobody thought to sick some suction cup thinggys to is so it can place parts too and a little dispenser so it can put down paste and yea, an old convection rework wand and wow, we can do SMT and AOI. GOD, what was I thinking putting all that $$$ into our process. I could have built a lightning head in my garage out of old garbage bags, candles and magnets out of some old toys!

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Machine Designer

#49386

Building an AOI | 27 April, 2007

In the infamous words of one of my good customers. "Vision systems suck, it's just that some suck less than others" and he would know having hand built AOI systems internally for over 10 years.

Do you have any idea how many people think one-off machine building is easy? It's not... do you know how many people think they can do what I do for less? Well they can't. I've seen it time and time again. We call them boat anchors and every macine builder and integrator no matter how talented their staff has a warehouse somewhere with 1 or 2 or more of them.

You can invest and lose hundreds of thousands of dollars with do-it-yourself projects and vision inspection is no exception. Vision is a matter of controlling... well damn well virtually everything. Lighting, motion, algorithms, cameras, conveyor, data flow, lighting and oh, did I mention lighting? And then at the end of the day whose going to support it and breast feed it when it's colicky and starts false calls and false failures by the gross and starts shutting down your production?

Good luck Upper Management!

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#49413

Building an AOI | 27 April, 2007

Why not add a laser pointer so we can also laser reflow the parts? And a hair dryer should handle the BGAs.

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#49416

Building an AOI | 27 April, 2007

This thread sucks.

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#50146

Building an AOI | 7 May, 2007

> This thread sucks.

I agree, this thread sucks!

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#50148

Building an AOI | 8 May, 2007

Hi It is very interest topic on building a AOI internal.(10000)

I am very aggree on Machine designer point of view. I had gone throught the state of develop a post reflow AOI which complete it begining of this year.

Just share part of it.

Few points you need to consider for building a AOI. 1)How fast on the programming and debugging during model change? 2)The fault rate of the system? 10%,5% 3% or low. 3)Effective of detect dry joint, fine short,IC lead dry joint, fine demaged chip,etc (Common defects Missing,tomebstone,Misalignment, polarity,overtune,etc shall can detect) 4)The inspection speed you need to consider as it will affect vibration of the system. 5)What type of image compare technology apply? Color image, gray level,etc We using color image compare technology. 6)Statistics Progress Control for the system. 7)How long the project taken? Etc.

We spend almost a year on the system

AOI consist of Mechnical/Electronic/Electrical system ,motion control system,lighting system, software system which integrat together. The most dificult parts are the motion control,lighting and software system which make how the system more effectives to use.

Feel free to ask. Regard Ken

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#50150

Building an AOI | 8 May, 2007

I heard an interesting statement from someone the other day. "AOI machines are a tool that are put on the other end of a bad process." "Why not fix the process?"

Interesting concept......eh ?

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#50152

Building an AOI | 8 May, 2007

Well, in manufacturings defense, I have to say we LIKE our AOI. We run preset-up jobs that are scanned in by the operators. The bar code on each reel is placed there from incoming. Incoming is a very, very busy place. From time to time we find these bar codes got switched and our AOI always catches it. You can call this a bad process but how else would you do it? I'm sure a QE with a tie would know how, but us common folk don't.

So I believe AOI does have a purpose beside taking up space and resources. It also makes a good sales pitch to new customers. I guess if you don't use it likea crutch, it can become useful. It just depends on the company and type of AOI machine.

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#50153

Building an AOI | 8 May, 2007

You guys must be QEs.

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#50162

Building an AOI | 9 May, 2007

AOI should not a be a filter at which you throw a mix of good and bad parts to hope it filters out all the bad parts. It shouldn't be seen as a "fix" to the problem of shipping bad parts to your customer.

It should be a tool to help you identify where your process is "bad" so you can work backwards and fix the process issues. It can also indicate when something in your prcess slips. Maybe it's a new operator, maybe it's that bad batch of brand-K paste that turned to a rock on the foil, maybe the component manufacturer started shipping you parts with AgPd terminations unannounced.

Whoever you quoted was a bit short-sighted, in my opinion. How do you find the holes in your process if you aren't looking for them? AOI is one good way to look for them. If I never went out on the floor to talk to the inspectors and operators or looked at the reports, I could safely assume our process was flawless.

Then again, I guess if our process was "fixed" we wouldn't need inspectors, or reports.

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#50163

Building an AOI | 10 May, 2007

I am not supporting that statement. I just thought it was interesting.

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