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T&R Verification

#25909

T&R Verification | 2 October, 2003

Hi all,

I want to shoot a question out to you guys/gals. Do you require your operators to get tape and reel components verified by someone else before they put a new reel on the machine? We always do a first piece verification of the initial set-up, but we also have them get their reels verified every time one runs out. It seems like we waste a lot of time doing this.

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John Patricelli

#25913

T&R Verification | 2 October, 2003

Did not do the verification of replenishing reels at the last company I was with, and it bit us hard on a 300+ piece build, over 30 placements per board on 0603 size (if I remember right) were built right on 7 boards, then they ran out of reel 1, and put a new reel on, turned out reel had bad parts from manufacturer, and we had 290 some boards with 30 places each of rework to do.

After that fiasco, we did the verification, and ate the extra time it took to make sure it was right.

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RDR

#25918

T&R Verification | 2 October, 2003

We verify each reels P/N prior to placing into the machine for any reason. I have been bit even harder than John. We built 80 boards with 672 per 0402s when we discontinued the two operator process. We now even have them read the numbers backwards to prevent what I call glazing the P/N!

Russ

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James

#25919

T&R Verification | 2 October, 2003

Yes we verify every reel by some other operator. We hardly make mistakes now, due to the fact that they have to also write the initials of who verified it. There used to be many mistakes due to wrong reels, but now it is slim to none. It is better to take that extra time out then having to rework many parts. Hope this helps.

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gregp

#25920

T&R Verification | 2 October, 2003

It seems as though you got part of your answer, that is, better safe than sorry. Now you need to do it in such a way as not to waste time. Some pnp machines can alert you to a low quantity on the machine so another reel can be obtained and verified. With the use of additional smart feeders practically no time is lost on reel replenishment. I believe this was a good segway to what Ken Bliss will say next...Ken, take it away.

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#25925

T&R Verification | 2 October, 2003

we do a 2 person verification as well.. and record who changed and who verified.. Extra reels are setup before the run to minimize machine downtime..

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#25942

T&R Verification | 3 October, 2003

We fired an operator because he used to initial a whole sheet of reel change tracking sheet at the start of his shift "to save time!" Some people just don't get the picture. A whole reel of resistors (20,000) went through because he did not bother to verify and fill up the paperwork.

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Thomas Lee Radney

#25943

T&R Verification | 3 October, 2003

We have been through several stages of this journey. We had no verification initially, migrated to two person verification (with reel initialing) and finally to electronic verification. Each of these steps has given us a dramatic improvement in our PPM's.

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Dean

#25947

T&R Verification | 3 October, 2003

Buddy system at a minimum. In fact it does no good to verify your "stock" number. You need to verify the manufacturers numbers as-well. And even then, reels do get mis-labeled.

I seem to remember a story of a major CM supplier for a Big 3 car maker. A reel was changed without using a verification process. 5000 resistors were placed on PCM's and subsequently assembled into cars. It was eventually discovered after the cars were in lots ready for transport. The CM had their people in the lot dis-assembling the 5000 cars and inspecting (and repairing) the PCM's. Cheaper to inspect the reels... What is the price of lost customer confidence?

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