SMT stage

Stop wrong material at loading

SMT problems concentrate in two places: material and changeover. Loading, splicing and substitution are three actions that must be checked reel by reel; changeover preparation time depends on whether the feeder placement table can be generated from the work order and whether material can be located quickly by bin.

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Process nodes

Eight nodes: which must block, which must record

A blocking point does not let the board continue; recording points leave an automatic trail that can be checked afterwards; decision points apply rules and bind the result to the SN. The order follows a typical SMT line and can be changed per line in the admin.

  • InterceptionNon-compliant work is stopped — no way around it
  • RecordedAuto-logged, queryable afterwards
  • VerdictRule-based verdicts bound to the SN
  1. 01 Interception

    Kitting

    Placement table generated from work order and model; racks light in feeder order; every reel scanned and checked

  2. 02 Recorded

    Solder paste and stencils

    Warm-up and open-time timers; stencil cleaning counts and tension tests recorded

  3. 03 Interception

    Loading

    Scan verifies feeder, part number and substitution; a mismatch locks the machine until resolved

  4. 04 Recorded

    Printing and placement

    Batch routing unlocks only after first-article approval; changeovers are not re-confirmed

  5. 05 Recorded

    Reflow

    Reflow profile bound to work order and program version; changes show before and after

  6. 06 Recorded

    Post-reflow inspection

    Defects entered by reference designator, linked to the feeder and reel

  7. 07 Verdict

    Depaneling and test

    Test results bound to the SN; failures enter the repair flow automatically

  8. 08 Verdict

    Handover to next stage

    Boards that missed a station or have an unfinished repair cannot flow into DIP

Shop-floor issues

Four typical changeover and wrong-material scenarios

These are not missing system features but the wrong way of recording: scanning skipped when it should happen, notes kept on paper when they belong in the system.

01

Changeover: finding material takes longer than setting up

On-site

High-mix, low-volume: a line may change over a dozen work orders a day. Material is found from the BOM, then dug out of racks — several reels of the same part may be stacked, and which one to use and how much is left is down to feel. Once collected, feeders are checked reel by reel; one wrong check means starting over.

System

The feeder placement table is generated from the work order and model, and the kitting list goes straight to the rack. The rack lights in feeder order and guides by FIFO with partial reels first. After picking, each reel is scanned and checked against feeder and part number; a mismatch is reported on the spot instead of surfacing at placement.

02

Wrong material: splicing and substitution are the gaps

On-site

Scanning once at loading is what most plants manage. But reel changes, splices and substitutions during production are often not checked at all. Substitutes are the worst: when the main part runs out, an operator splices a substitute; the system only accepts the main part number and alarms, so operators learn to work around it — and once checks are relaxed, genuinely wrong material passes too.

System

The feeder placement table maintains the mapping between main and substitute parts. Scanning validates three things at once: feeder, part number and whether substitution is allowed. Splice actions are checked the same way, requiring the remaining quantity on the old reel and the barcode of the new one; both records are kept.

03

Solder paste and stencils: the hidden source of defects

On-site

Insufficient warm-up, exceeded open time or repeated warm-up all affect print quality; over-used stencils or low tension cause insufficient or bridged solder. Both are usually kept on paper, and the numbers no longer match after a shift handover.

System

Solder paste is received by batch; issuing a scan starts the warm-up timer, opening starts a second timer, and the system refuses and locks out expired paste. Stencils are registered by number, each cleaning and tension test is recorded, and a warning appears as the count approaches the limit.

04

Traceability: boards and reels are many-to-many

On-site

One reel feeds many boards and one board uses many reels. To answer which reels a board used, recording what was loaded is not enough — the start and end time of each reel must be recorded and matched against routing timestamps. Without the time window, traceability stops at batch level.

System

Loading and splicing actions are timestamped; at routing, the board-to-reel link is built from feeder plus time window. Queries work in both directions: which boards a reel went into, and which reels a board used.

Modules involved

Modules used in this stage

Only the modules this stage requires are listed. Others are added or removed to match the line; master data is shared across systems.

Other process stages

Acceptance

What the system must answer after go-live

Acceptance is not a feature list — it asks whether the data can answer specific questions. If these four cannot be answered, the data is not really in the system.

  1. 01

    Pick any board and see its material

    Which reels, which batch, who loaded it, when — all four answered in one place

  2. 02

    Wrong material cannot get on

    Feeder or part number mismatch, or an unregistered substitute, raises an alarm at the machine and locks it; the board cannot continue until it is resolved

  3. 03

    Expired solder paste cannot enter the line

    Insufficient warm-up, exceeded open time or over-used stencils are refused by the system, not left to a supervisor's memory

  4. 04

    No first-article approval, no batch

    Batch routing is blocked until the first article is confirmed; if a reflow profile changed, the system shows who changed it and what it was before

Next step

Watch it at the model factory

Watch kitting, loading and splicing end to end at the model factory, including how wrong material is blocked and how substitute verification behaves in practice.

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Shenzhen Baichuan Zhike Technology Co., Ltd. · Since 2015 , serving electronics manufacturers across handsets, tablets, automotive electronics, FPC, WiFi modules, energy storage and more.

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