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Attaching a Cost to Solder Defects

C.K.

#5543

Attaching a Cost to Solder Defects | 13 March, 2001

Not to toot my own horn, but ever since I came on board at my company, wave solder defects have gone down by 35%.

This was due mainly to a new flux and a process control system that I implemented back in '99.

Now, the metric used was DPMO. How do I attach a $$-value to this? Any baselines or recommendations? Yes, I'm aware that there's an organization called CEERIS that's done this type of analysis before.

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#5571

Attaching a Cost to Solder Defects | 14 March, 2001

Most $$-value stuff is dependant on the cost structure of the company. Why not do a small cost study to measure the amount of time your improvements save? Folk in accounting should be able to "rough price" the $$ benefit of your efforts.

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Michael Parker

#5575

Attaching a Cost to Solder Defects | 14 March, 2001

The basic rule of thumb (info current as of 9/2000, from Ceeris and others) is the 10X multiplier for each major process step.

Catching a defect and correcting in SMT will cost $0.10 each. (think about $.04 placement cost, stop line time, operator having to do repair by hand, if before reflow, rework person after reflow will add a bit more cost) After hand load and wave/wash, multiply by 10X, therefore a defect now costs $1.00 ( to cover the added expense of materials, machinery, labor, etc.) After Test, 10X gets you to $10.00 per defect. After shipping, RMA's/Field Returns cost $100 per defect. These are all averages, samples audited in large, medium and small sized companies, mixed technology.

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