AI Quality Control

Quality Control

This section describes the machine Performance Certificate, a result of the Quality Acceptance Test (QAT), which is produced for all Axial products.
Every Axial machine is subjected to a Quality Acceptance Test (QAT) before being shipped to its customer. There are 4 phases to a QAT:

Phase I – Pre-Dry Cycle

The appropriate pattern program is loaded and the machine performs a short part run with all motions and mechanisms functioning to check setups and speed. All data is recorded on the machine’s event log.

Phase II – Dry Cycle

Can only occur after successful completion of the Pre-Dry Cycle. The machine is run with all motions and mechanisms functioning but without boards or inserting components for a pre-specified period of time. All data is recorded on the machine’s event log.

Phase III – Integrity Run (Final Run)

Can only occur after successful completion of the Dry Cycle. This is a simulated production run to check insertion performance and speed. Results are recorded on the machine’s event log.

Sequencer 6

2596C

VCD/Seq. 8

6241F

DH VCD 8

6292C/ 6298C

DH JW 8

6293C/    6299C

Radial 8 6380A/6388A

Phase I

 

 

 

 

 

Parts Run

2,400

2,100

2,400

2,400

500

Insertion PPM *

0

0

0

0

0

Intrinsic Availability **

100%

100%

100%

100%

100%

Phase II

 

 

 

 

 

Length of Run

2 hrs.

24 hrs.

12 hrs.

12 hrs.

12 hrs.

Intrinsic Availability

95%

95%

95%

95%

95%

Phase III

 

 

 

 

 

Minimum Parts Run

11,939

22,306

26,765

43,299

30,680

Allowable Insert Errors

0

1

0

0

4

Intrinsic Availability

95%

95%

95%

95%

95%

Acceptable PPM Levels

34 – 250

10 – 200

40 – 150

7 – 75

300

Confidence Level

95%

95%

95%

95%

95%

 

 

* (# of good insertions / total # of insertions)
** (# of hours the machine is ready to run / total # of hours machine planned to run)

Phase IV – Customer Acceptance (Optional)

Can only occur after successful completion of the Integrity Run. The customer visits the factory to watch verify the machine’s ability to meet performance requirements. The customer’s production run is simulated and all options are verified and explained. UIC can supply the PC boards, pattern programs and components or the customer may supply these items. (Must be supplied two weeks prior to the customer acceptance date.)

Phase V – Preproduction Acceptance (At customer site)

UIC Field Service personnel installs the machine and assures it is setup and running with the same degree of operational efficiency as at the factory.

Each machine ships to the customer accompanied by a Machine Performance Certificate, a result of the Quality Acceptance Test (QAT). This certificate sites the results of the QAT, characterizes our manufacturing process and states our commitment to quality and customer satisfaction. (See attached sample copy.)

Please take care when discussing this information with customers!! These QAT results, specifically PPM levels, are an indicator of the performance quality of the machines we ship, but actual performance in customer production environments will vary depending upon their setups and maintenance as stipulated in UIC manuals. Clearly, customers who follow our machine operation, setup and maintenance procedures should expect to average PPM levels as defined in the QAT for each machine.

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