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Wrong Parts Loaded......again

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#72879

Wrong Parts Loaded......again | 13 October, 2014

Hello everyone. I'm looking for input on everyone's PVS (part verification system). At our facility we have a a straight forward, low tech verification system. Feeder files are exported from our equipment software to excel with columns containing Feeder Location>Designator>Part Number>Alternate. 2D labels are placed on all slots of the machine, operator scans slot, scans reel with unique material ID. Green light if it's good, red light if it's bad. Our software cannot lock out a machine if there is an incorrect scan. One operator does all the verification. Once in production our in house PVS goes into "Run Mode" where it allows verification for splice scans, but will not accept a material ID that has already been scanned into the PVS.

We still have operators scan slot, verify reel, load into wrong slot. It's a challenging task but is there anyone with some suggestions that can reduce this mistake? I'm told double verification will not work. First article is out of the question.

What's everyone else doing?

Thanks!

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#72890

Wrong Parts Loaded......again | 14 October, 2014

I've always used multiple verification, and it's worked rather well. But, it depends on the people that are doing the verification, and their commitment to accuracy. It also requires a little bit of extra time.

Given your system, are you still getting wrong parts loaded? From what I can read, there are only a couple of possibilities as to how it's happening. 1. Wrong parts on a reel from the manufacturer...this is a low probability, but, does still happen on occasion; 2. Operator ignoring the red light; 3. Wrong parts being provided from stock for splicing; 4. Operator splicing the wrong part.

The highest level of probability is that there is an issue with the operator loading the parts. This could be happening for a couple of reasons...trying to go too fast, not completely verifying the part number on the reel, not understanding how to correctly read/verify the part number, etc.

How to prevent this? Training, training, and more training. I also like to have the responsible party do the rework, if that's possible. It reinforces the importance of doing it correctly. Another method is to have independent verification (I usually only do this on the initial load, though, not on re-loads, or splices).

I'm not sure why first piece isn't an option. In our highest volume runs, we would do a first piece at least once per shift/run. We thought about doing first piece inspection with every part change, but, that became a little bit of overkill.

Another possibility is including AOI in-line. You could do it pre or post reflow, depending on the demand on the line...this would, at least, help to identify a wrong part loaded sooner in the process, and limit exposure to product built with the wrong part.

If your pick/place machine includes testing/part verification during assembly, I'd suggest using that as a way to capture defects earlier in the process.

However, capturing defects in process is not a true method of preventing the problem. It prevents long rework cycles, but, it doesn't fix the root.

cheers, ..rob

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#72894

Wrong Parts Loaded......again | 14 October, 2014

Rob, Thanks for your input. As you mentioned the cause of the issues is the operator verifying the correct feeder, scanning the correct reel, then loading it into the wrong feeder.

1.Wrong parts from supplier. Happens.. 2. Operator ignoring red light. They just keep scanning until the green light goes. 3. Wrong parts provided from stock room. Wrong labels do get placed from time to time. 4. Operator splicing wrong part. Most common.

It has all to do with operator awareness, but they are so reliant on our verification system that it is not a concern for them to verify what they're doing. I'm to the point of removing the system and going to the buddy system.

Just to clarify we do perform a first article verification at the beginning of each run. What happens after a splice? Typically the parts are similar caps and resistors in the same package and color. That's the issue..

Typically the wrong part is loaded directly to the left of right of the slot where the verification was performed. My idea was Scan Slot>Scan Reel> THEN Verification system requires scan of reels directly to the right and left previously performed verification. Maybe even a timer to allow splice.

It's difficult to achieve successful training when an operator is constantly told what they're doing wrong and never what they do right. It falls on deaf ears. From my few years in this field I learned you can set a process in place, but production will always do as they feel once you look away.

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#72898

Wrong Parts Loaded......again | 14 October, 2014

One Table...One feeder...One reel...no mistakes

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#72901

Wrong Parts Loaded......again | 15 October, 2014

Hi,

We have developed solution called Setup Center that helps you to verify online/offline verification.

Please read about a solution on our website: http://www.proventustech.com/#!-setup-center-for-samsung/cjeg

If you have any questions, you can contact me by email: alexeis@proventustech.com

Best Regards, Alexei

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#72903

Wrong Parts Loaded......again | 15 October, 2014

The best verification system combined with bad operator equals POOR RESULT. I think the real question is how to find a good operator and once you have him/her how to keep them? I am in process of losing one of my best operators(no challenge).

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#72910

Wrong Parts Loaded......again | 16 October, 2014

Evtimov, I agree. I'm leaning more towards the quality of worker rather than software, etc. Since this post this incident happened AGAIN! This time there was ZERO verification performed at start up.

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#72956

Wrong Parts Loaded......again | 23 October, 2014

One thing our operators do is compare the part marking at the end of the old reel to the part marking at the beginning of the new reel. We also send the operators sheets of paper that tell what component should be at what location and this sheet also includes the part marking that should be on the components. With that said, we have many components that do not have part marking on them. In that case we can just make sure that the components look the same.

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#73007

Wrong Parts Loaded......again | 4 November, 2014

What pick and place machine are you using? We use Mydata's with a software package for easy loading and traceabillity (Mylabel). We also have electrical verification checks on the first 3 picks of any feeder to ensure they are the correct parts.

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#73055

Wrong Parts Loaded......again | 13 November, 2014

Valor-Mentor has bardcode based verification solution with machine connection and control for most machines on market and options to connect to machines in various ways to lock system until verification process is done. Handles splicing and led bining to paired parts etc

They also have a production planning-grouping solution that reduces need for production to change as little amount of feeder changes reducing error further. Again is machine neutral and looks at part stock, work order sequencing, machine constraints and runs user selectable alogrithms to make feeder setups dynamic and least amount of changes ....

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#73056

Wrong Parts Loaded......again | 13 November, 2014

Valor-Mentor has bardcode based verification solution with machine connection and control for most machines on market and options to connect to machines in various ways to lock system until verification process is done. Handles splicing and led bining to paired parts etc

They also have a production planning-grouping solution that reduces need for production to change as little amount of feeder changes reducing error further. Again is machine neutral and looks at part stock, work order sequencing, machine constraints and runs user selectable alogrithms to make feeder setups dynamic and least amount of changes ....

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aj

#73057

Wrong Parts Loaded......again | 13 November, 2014

We use Buddy check system + part measure prior to all parts being loaded onto the machines...this is a manual approach but we haven't had a misload in years....

It has been mentioned above but the Operators have a huge role to play no matter what system is in place....

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#73058

Wrong Parts Loaded......again | 13 November, 2014

Hi,

As I heard, this system is a great tool but complex to implement and is not suitable for everyone, especially for small companies (and maybe some medium-sized companies). Small companies need a simple and locally without too much maintenance and skill, as well as a possibility to operate with existing manpower.

Best Regards, Alexei

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