Camptech II Circuits - Manufacturing Process Control Plan

Machine
Process / Operation Reaction Plan & Corrective
Device Characteristics Methods
Action
Desciption
Sig. Tool
Product/Process Specification Evaluation/
No. Product Process Sampling Control Method
Tolerance Measurement Tech.

Sample Size Frequency

Inform supplier, determine if
Packaging condition, total quantity,
product can be used or needs to
documentation, follow Receiving
- Visual inspection Sign packing slip. be returned to supplier. QOP-
Material receiving Material ordered Process Visual inspection 5% All orders
- Verify against purchase order Receiving log. 83-01 Control of Nonconforming
No missing / shortage / extra quantity /
Product.
damages allowed.
Quarantine the part if necessary.
Inform supplier, determine if
- Purchase Order
product can be used or needs to
- Surface integrity - Micrometer
Sign packing slip. be returned to supplier. QOP-
Incoming Inspection 1 Copper clad laminate Visual inspection - Thickness - Electrometer 1 sample Each batch
Receiving log. 83-01 Control of Nonconforming
- Copper weight - Tape measure
Product.
- Panel size
Quarantine the part if necessary.
Inform supplier, determine if
- Purchase Order product can be used or needs to
- Surface integrity Sign packing slip. be returned to supplier. QOP-
2 Prepeg Visual inspection Visual inspection 1 sample Each batch
- Expiry date Receiving log. 83-01 Control of Nonconforming
- Product label information Product.
Quarantine the part if necessary.
Inform supplier, determine if
product can be used or needs to
- Purchase order
Sign packing slip. be returned to supplier. QOP-
3 Dry film Visual inspection - Expiry date Visual inspection 1 sample Every box
Receiving log. 83-01 Control of Nonconforming
- Product labels
Product.
Quarantine the part if necessary.
Inform supplier, determine if
product can be used or needs to
- Purchase Order
Sign packing slip. be returned to supplier. QOP-
4 Chemicals, solder bars Visual inspection - Expiry date Visual inspection Every container
Receiving log. 83-01 Control of Nonconforming
- Product labels
Product.
Quarantine the part if necessary.
Inform supplier, determine if
product can be used or needs to
- Purchase Order
Sign packing slip. be returned to supplier. QOP-
5 Solder mask and silk screen inks Visual inspection - Expiry date Visual inspection 1 sample Every pack
Receiving log. 83-01 Control of Nonconforming
- Appearance
Product.
Quarantine the part if necessary.
- Order review
- Order review - Check revision of supplied files Order processing
Order Processing 1 Order entry - Order entry Every order Inform customer
- Customer file verification - Confirmation with customer process
- Customer file verification
- Review of customer files,
Engineering/Planning - Check revision of supplied files Production work
1 Customer supplied information artwork, drawings, special - Production file versions Every order Inform sales dept.
Artwork - Confirmation with customer order
instructions
CAM report generation Pentalogix software Every order
- Engineering
Gerber file panelization Customer requirements Every order Redo. Receive updated files
- Customer file approval
Artwork generation:
- silkscreen
Engineering Customer requirements Every order Redo. Receive updated files
- solder mask
- copper layer
Drill data sheet Engineering Every order Redo. Receive updated files
Program generation Engineering Drill template Every order Redo. Receive updated files
Material Preparation &
1 Copper clad laminate thickness Measurement Production work order Micrometer 100% Production work order Recheck & reject
Release
Copper thickness Measurement Production work order Electrometer Production work order Recheck & reject
Material type, thickness, panel
Shearing/pre-cut Work instruction Production work order Production work order Recheck & reject
size

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 Camptech II Circuits - Manufacturing Process Control Plan
Machine
Process / Operation Reaction Plan & Corrective
Device Characteristics Methods
Action
Desciption
Sig. Tool
Product/Process Specification Evaluation/
No. Product Process Sampling Control Method
Tolerance Measurement Tech.

Sample Size Frequency

- Drilling data sheet
- Check for:
1) Misregistration - Drilling data sheet First off on Product
Drilling Excellon EX300 1 Machine set-up Prepare drills First off Each batch Machine adjustment
2) Extra, missing or miss located holes - Pin gauge work order
3) Measure drills
4) Incomplete drilled holes
Program selection Correct program selection
Tanks, heaters,
timer, racks and
Desmear & Etchback 1 Work instructions Check that holes are black Visual inspection 2-3 boards Each batch Visual inspection Repeat process
agitation motor,
rectifier

Chemcut
Deburring process Plugged holes are cleaned with
Deburring Deburring 1 Deburred panels Check for burrs and plugs Visual inspection 100% 100% Visual inspection
Worki instruction - WI-09 drills.
Machine

Tanks, heaters,
timers, racks,
Direct Metallization (DMS- - Visual inspection Sign off on Production Rejected board are run through
agitation motor 1 Work instruction Check for voids, residue 2-3 boards Each batch
E) - Copper flashed work order this process again.
and rails, mixer,
filter pump, oven
Oven dry
Copper flash
Pumice scrubbing
ISC 650 - Temperature: 110 ⁰C
Laminating
Laminator - Speed: 1.2-1.35 Panels are stripped of film,
Dry film 1 Laminated sheets Bubbling, film lifting Visual inspection 100% 100%
Dupont LC-2400 m/min cleaned and re-laminated.
Work Instruction
Laminator - Pressure: 40-60 PSI
Clean artwork, examine for
- Completeness of film package
nicks, cuts, opens, shorts, QC First off on
Exposing 1 Exposed copper - Film alignment Visual inspection 100% 100% Repeat process
excessive touch-up, Product work order
- Revision of films
misregistration, breakout
Various tanks,
Sign off on Production
Black Oxide heaters, racks 1 Work instructions Check for evenness of oxide Visual inspection 100% 100% Repeat process
work order
and HP 24 dryer
Multiline
Punch tooling holes
Punch Location Holes Technology 1 Check location and quantity Visual inspection Every panel Every panel Visual inspection
Work Instruction
Punch Press
Check for:
1) missing traces or pads
IS Procex
2) reduced spacing, trace widths Repeat process - pass through
Developing Aqueous Work instructions Visual inspection Every panel Every panel Visual inspection
3) shorts, nick, cuts, pinholes developer at a faster speed.
Developer
4) registration
5) dry film residue
Pumex SHD- Surface must be clean and free of
Pumice Scrubbing 1 Scrubbed panels Pumice scrubbing Visual inspection 100% 100% Visual inspection Re-clean
2000 oxidation
Tanks, heaters,
timers, racks, Work instructions
Direct Metallization (DMS- Sign off on Production Rejected board are run through
agitation motor 1 - Oven dry Check for voids, residue Visual inspection 100% 100%
E) work order this process again.
and rails, mixer, - Copper flash
filter pump, oven
Pumice scrubbing

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 Camptech II Circuits - Manufacturing Process Control Plan
Machine
Process / Operation Reaction Plan & Corrective
Device Characteristics Methods
Action
Desciption
Sig. Tool
Product/Process Specification Evaluation/
No. Product Process Sampling Control Method
Tolerance Measurement Tech.

Sample Size Frequency

Tanks, heaters,
Using pin gauges, a minimum of 3 holes
timers, racks,
checked for hole size before and after
agitation motor,
plating. - Visual inspection Sign off on Production
Copper & tin plating rails, rectifier and 1 Work instructions 2-3 boards Each batch Repeat process
Check for plating uniformity. No burnt - Caviderm work order
filter
copper or excessively high spots. No
voids in holes.
Tanks, trays,
racks, IS
Layers and boards must be free of dry Sign off on Production
Strip Resist developing 1 Work instructions -Visual inspection 100% 100% Repeat process
film resist work order
machine and
glass heater
First off
Repeat process - pass through
Etching Atotech 547XL 1 Work instructions Check for copper residue Visual inspection 100% 100% Sign off on Production
machine at a faster speed.
work order
Temp and time requirements specified Sign off on Production
Baking Various ovens 1 Work instruction - WI-20 100% 100%
in work instructions work order
Chemcut If board is not free of matte-tin,
Check board surface for matte-tin Sign off on Production
Stripe Matte Tin Developing 1 Work instructions Visual inspection 100% 100% pass through the machine again
residue and cleanliness work order
System at faster speed.
Pumice scrubbing Check board cleanliness Visual inspection 100% 100%
Pumex SHD-
2000, Pako
Solder mask Screening Auto-Printer, 1 Pumice scrubbing Check board cleanliness Visual inspection 2-3 boards Each batch First off verification
ATMA stencil
machine,
Check for:
Solder mask application. 1) Solder mask in holes
Apply photoimagible mask on 2) Correct registration
1 Visual inspection First off verification
board surface. 3) solder mask color
Work instruction - WI-18 4) Smooth surface and cleanliness
5) Fingerprints
Thermo-Matic Tack dry Strip the solder mask (if
1 Visual inspection First off verification
2.0 oven Work instruction - WI-18 applicable) and repeat process
Exposing
2 Visual inspection First off verification
Work instruction - WI-12
- Curing
- Correct oven temperature
3 Visual inspection First off verification
and baking time.
- Work instruction - WI-20
Hot Air Solder Leveling 1 Pumice scrubbing Check board cleanliness Visual inspection 100% 100%
Tape must not encroach onto the pads,
Apply tape. Sign off on Production
CEL Flux Coater 2 holes or any other circuit features that Visual inspection 100% 100%
Work instruction - WI-24 work order
requires a solder finish.
Flux coating.
Pass through the CEL Flux
3 Visual inspection 100% 100% First off verification
Coater, one panel at a time
Work instruction - WI-24

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 Camptech II Circuits - Manufacturing Process Control Plan
Machine
Process / Operation Reaction Plan & Corrective
Device Characteristics Methods
Action
Desciption
Sig. Tool
Product/Process Specification Evaluation/
No. Product Process Sampling Control Method
Tolerance Measurement Tech.

Sample Size Frequency

Check for:
1) Reduced spacing
2) Solder nodules
3) Plugged or reduced hole size
4) Excessive solder on surface mount
pads
5) Incomplete coverage of surface
copper
Lantronic HASL Panels are baked, fluxed and Re-
4 Solder levelling 6) Black holes Visual inspection 100% 100% First off verification
machine HASLed.
7) Dewetting
8) Granular solder
9) Delamination, measling or blistering
of base material
10) Blistering or discoloration of the
solder mask
11) Blow holes (check for low copper)
12) Solder on gold tips
IS Cleaning Sign off on Production
5 Cleaning Panels should not appear oily Visual inspection 100% 100%
Machine work order
Check for:
1) misregistration
ATMA stencil 2) colour of ink
Silk Screen Printing machine 1 Silk screen appearance Work instructions 3) idents on circuit pads Visual inspection 100% 100% First off verification
4) legible sharp image
5) skips or dry spots
6) correct date code and UL logo
Silk screen is removed by a
Bake No flaking or lifting of idents when tape
Colight UV 24 2 Silk screen appearance Tape test, Visual inspection 100% 100% First off verification solvent, panels are cleaned and
Work instruction - WI-18 is applied & then lifted
then re-screened.
Make sure that:
Accu Score AS-
- Load program - the correct program is loaded
Scoring 200 1 Set-up Visual inspection 1 panel Every order First off verification
- Tool pin/hole alignment - the panel orientation in the machine
is correct
- Location & depth of scoring
- dimensions & shape Re-program the machine, check
Caliper 2 Dimensions Work instruction - WI-36 Caliper, Visual Inspection 5% Every order First off verification
- no missing or extra scoring lines cutter/ bits

- Load program - Length and width of board

Routing Excellon Mark VI 1 Set-up - Tool pin/hole alignment - dimensions of cut-out Caliper, Visual Inspection 1 panel Every order First off verification
Work instruction - WI-36 - all required cut-outs have been made
- Length and width of board
Re-program the machine, check
Caliper 2 Dimensions Work instruction - WI-36 - dimensions of cut-out Caliper, Visual Inspection 5% Every order First off verification
cutter/ bits
- all required cut-outs have been made
Comprex Wash
Wash. Sign off on Production Re-clean. If necessary check
Final Cleaning Conveyorized 1 Appearance No soap residue and Routing debris Visual inspection 100% 100%
Work instruction - WI-28 work order machine & cleaning solution
Chamber
Sign off on Production Re-clean. If necessary check
Grieve Oven 2 Oven dry 200 F min. for 5-10 minutes
work order machine & cleaning solution
Leakage test voltage 150 - 200 volts Tester 100% 100%
TTI Bare Board Sign off on Production
Electrical testing 1 Isolation resistance test 5 Mohms Tester 100% 100% Notify supervisor
Testers work order
Continuity resistance test 10 ohms Tester 100% 100%
Check that board rev. matches,
1 A match of rev. # across all documents Visual inspection Rework or scrap
job card and drawing
Measure the PCB over the
Identify & locate failure, fix & re-
Micrometer 2 copper and compare it to the Micrometer
test.
job card and drawing

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 Camptech II Circuits - Manufacturing Process Control Plan
Machine
Process / Operation Reaction Plan & Corrective
Device Characteristics Methods
Action
Desciption
Sig. Tool
Product/Process Specification Evaluation/
No. Product Process Sampling Control Method
Tolerance Measurement Tech.

Sample Size Frequency

Check solder mask color &
3 Customer order Visual inspection
type
Check finish of copper under
4 Customer order Visual inspection
the solder mask
Check silk screen color, type
5 and both sides of the board, Customer order Visual inspection
pass tape test
6 Check panelization Matches customer order Visual inspection
Pin gauge 7 Check hole sizes Are within tolerances Pin gauge
Check all required in-process
8 inspection points on Have been performed & passed Visual inspection Sign off on Production
Final Inspection Appearance & surface production work order 100% 100% work order
Caliper 9 Check profile, slot and cut-outs Are within tolerances Caliper Repair if possible.
Granite table 10 Bow and twist of boards Are within tolerances Granite table
Check for special requirements
11 Customer order Visual inspection
by customer
Sufficient annular ring per IPC
12 Check angular ring Visual inspection
standards
No dirt, foreign matter, fingerprint,
burrs, nicks, flux residue, extraneous
copper, platting in non-plated through
holes, blurred silkscreen, etc.
Check for cosmetic
Date code, UL and manufacturer’s logo
appearance, surface
13 per customer’s master drawing or Visual inspection
imperfection, markings,
requirements.
solderability
Boards exhibit good wetting of solder
on the surface and in the solder coated
holes. No separation or other forms of
degradation of the conductive pattern.
Include following reports: Count Calculation 100% 100% Notify supervisor
- C of C Packing 100% 100%
- Production work order Sign off on Production Notify supervisor
Pack & Ship 1 - Test Report
Labelling - Ship per customer specifications Visual inspection 100% 100% work order Notify supervisor
- Final Audit Report
- Microsection Report Box 100% 100% Notify supervisor

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