PCBA Quality Process Audit — Manual Assembly

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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