| 1. Work Instructions | Enter 1 or 0. NA may be a valid response for shaded cells.^ | ||||||
| 1.1 | Are revision controlled Work Instructions displayed for the operator at each assembly station? (Score 0 if any unsigned/undated handwritten instructions or any handwritten instructions more than 48 hrs old) | ||||||
| 1.2 | Are component part numbers and their descriptions specified on Work Instructions? | ||||||
| 1.3 | Are component descriptions sufficiently detailed to ensure the correct component is being used? | ||||||
| 1.4 | Are the reference designators and the quantity per part number specified on Work Instructions? | ||||||
| 1.5 | Is component polarity or its non-existence consistently and unambiguously specified on Work Instructions? | ||||||
| 1.6 | Are the components on the Work Instructions listed by the most appropriate order of insertion? | ||||||
| 1.7 | Is the layout of lin bins/trays defined on Work Instructions for each assembly station? | ||||||
| 1.8 | Are all lin bins/trays located in the correct position as per Work Instructions for each assembly station? | ||||||
| 1.9 | Do Work instructions indicate if solder pallets/carriers or breakers must be used? | ||||||
| 1.10 | Do Work instructions indicate if a top hat, separators, plugs, Kapton tape, finger protection, etc. must be used? | ||||||
| 1.11 | Does the direction of build for the board align with the orientation of the board on the Work Instructions and Wave direction? | ||||||
| 1.12 | Do Work Instructions not only indicate what components need to be inserted but also the buddy check components? | ||||||
| 1.13 | Is the conveyor at entry to the wave, slower than the wave conveyor speed, and documented on Work Instructions? | ||||||
| 1.14 | Is there a documented process for the identification and control of non-completed boards resulting from breaks, shift changes, etc. | ||||||
| 1.15 | Is the PWB part number and Revision specified on the Work Instruction or line set-up instructions? | ||||||
| 1.16 | Does the PWB part number and Revision cross-reference to the PCBA part number and Revision? | ||||||
| 2. Station Breakout | 1, 2 | 3, 4 | 5, 6 | 7, 8 | 9, 10 | Actual | |
| 2.1 | Is there a document available which describes the guidelines for station breakout at Manual Assembly? | ||||||
| 2.2 | Has the number of assembly stations required been determined scientifically in order to maximize throughput within constraints? | ||||||
| 2.3 | Is there evidence that the line is evenly balanced with the defined number of stations and the defined station breakout? | ||||||
| 2.4 | Is there evidence to demonstrate that the assembly operators follow the defined station breakout on the Work instructions? | ||||||
| 2.5 | Is there evidence that sufficient time is allocated for component insertion at each station, as determined by the beat rate of the line? | ||||||
| 2.6 | Does following the breakout ensure that the insertion of subsequent components is not restrictive or increased in difficulty? | ||||||
| 2.7 | Does following the breakout ensure that ‘snap-in’ type components are inserted first or off-line? | ||||||
| 2.8 | Does following the breakout ensure that components that ‘look’ alike are assembled at different and non-adjacent stations where possible? | ||||||
| 2.9 | Does following the breakout ensure that components that ‘fit’ alike are assembled at different and non-adjacent stations, where possible? | ||||||
| 3. Line Set-Up and Verification | 1, 2 | 3, 4 | 5, 6 | 7, 8 | 9, 10 | Actual | |
| 3.1 | Are all Manual Assembly station set-ups verified according to Work Instructions and a log signed prior to start-up http://xanaxonlinebuy.com & re-start? | ||||||
| 3.2 | Are first-built boards verified against documentation for missing components, value, and for correct polarity pre Wave? | ||||||
| 3.3 | Are the components supplied to Manual Assembly appropriately prepped with correct lead length, forming and pitch, etc.? | ||||||
| 3.4 | Is it evident that lead snipping has been minimized through adequate component prep and/or pallet support design? | ||||||
| 3.5 | Are all totes or tray locations identified with printed part numbers, descriptions, circuit designators, station number, and/or layout information? | ||||||
| 3.6 | Are boards conveyed along the line automatically without the need to manually push the board forward or pull the board back? | ||||||
| 4. Tooling | 1, 2 | 3, 4 | 5, 6 | 7, 8 | 9, 10 | Actual | |
| 4.1 | Is tooling used to provide underside support on all sides, to minimize flexing, for the insertion of components that require a force or snap-in fit? | ||||||
| 4.2 | Is tooling used and is it adequate to prevent board flexing during all component insertion? | ||||||
| 4.3 | Is tooling used for snap-in components prone to bent pins, to verify the pin straightness prior to their insertion? | ||||||
| 4.4 | Is there a document available which describes the guidelines for pallet/carrier design? | ||||||
| 4.5 | Are footprint, co-planarity, depth below datum, ID, clamping mechanisms, chamfering, direction of flow, criteria addressed? | ||||||
| 4.6 | Are pallets/carriers identified by a name or tooling number which is traceable to the PCBA part number and revision? | ||||||
| 4.7 | Is pallet/carrier orientation to the line specified or indicated and correct? | ||||||
| 4.8 | Are pallets/carriers designed such a way that they support all non-snap-in components without the use of weights? | ||||||
| 4.9 | Are pallets/carriers appropriately milled out to avoid shadowing and insufficients? | ||||||
| 4.10 | Do selective wavesolder pallets/carriers use built in solder thieves to help reduce the occurrence of solder bridging? | ||||||
| 4.11 | Is there a documented requirement to clean pallets/carriers and to regularly inspect them for damage and is there evidence of this? | ||||||
| 4.12 | Are pallets/carriers in a good state of repair, clean, and satisfactorily stored to prevent damage? | ||||||
| 5. Manual Inspection | 1, 2 | 3, 4 | 5, 6 | 7, 8 | 9, 10 | Actual | |
| 5.1 | Are outputted boards 100% inspected pre wave (Top Side) for missing components, value and polarity? | ||||||
| 5.2 | Is there evidence to demonstrate that this quality inspection is conducted? | ||||||
| 5.3 | Is there a visual aid (hard copy or otherwise) which identifies the populated locations with polarity, and also the no-pop locations? | ||||||
| 5.4 | Is there a buddy check system used between stations to ensure the previous operation has been fully completed? | ||||||
| 5.5 | Is there evidence to demonstrate that a buddy check system is deployed between assembly stations? | ||||||
| 5.6 | Is the touch method used as part of the buddy system? | ||||||
| 5.7 | Are manually inserted components that are not tested by ICT specifically targeted for inspection in addition to the buddy check? | ||||||
| 5.8 | Is there evidence to demonstrate that at least an hourly defect feedback process to Manual Assembly is in operation and effective? | ||||||
| 5.9 | Is accountability for Manual Assembly defects traceable to a specific workstation and operator/supervisor? | ||||||
| 5.10 | Are snap-in connectors inspected for bent pins post-insertion? (Tooling or an alternate method with proven effectiveness must be used). | ||||||
| Maximum Score | 53 | 53 | 53 | 53 | 53 | 53 | |
| Score Obtained | 0 | 0 | 0 | 0 | 0 | 0 | |
| Score Percentage | 0% | ||||||
| Pass Percentage | 80% | 80% | 80% | 80% | 80% | 80% | |
| Outcome | Not Audited | Not Audited | Not Audited | Not Audited | Not Audited | Not Audited |
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