Download - Process Problem Inspection Sheets
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Sr No Date Product Nature of problem Qty Rework done
4/2/2013 Spot LED shift manually inserted.
4/2/2013 Flat Excess paste 18 Manually corrected
flat LED missing 2 Manually inserted.
9/2/2013 Spot Paste shift/short 1 Manually cleaned
10/2/2013 spot LED missing 5 Manually inserted.
Process name: Pick and place
Operator name:
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Suggestion
Pick and place
PCB sticking is done from below side and
Pick and place
Alignment problem at the start of process
LED surface is sticky so it does not seperated
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Sr No Date Product Nature of problem Qty Rework done
1 4/2/2013 Spot Tx shifting 8
Flat LED shifting
TX deviating
9/2/2013
10/2/2013
Process name: Reflow
Operator name:
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Suggestion
PCB pad size
PCB pad size
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Sr No Date Product Nature of problem Qty Rework done
1 4/2/2013 Spot
reverse mounted 12
with correct polarity
2 5/2/2013 FlatDiode D4/D5/D6touch up re-soldering
Tx soldering 89 Soldering done
Thumb Stoning
R3,R12 5 re-soldering
Diode D5 missing 1 New Diode mounted
3 6/2/2012 Spot
Tx EFD 10 dry
soldering 72 Re-soldering done
Cap 4.7 CE2/CE1
touch up 144 Re-soldering done
4 10/2/2013 All touch up 8 Re-soldering done
Cap 4.7 CE2/CE1
touch up 16 Re-soldering done
Lm1 Tx misplacment 4 Re-soldering done
5 12/2/2013 Spot
Cap 4.7 CE2/CE1
touch up
Lm1 Tx misplacment
15/2/2013 Spot Cap 4.7F missing 20 Re-soldering done
D3 shift 3
4.7 cap shift 4
R12/R15/R18
resistor shift 3
PROCESS PROBLEM INSPECTION SHEETProcess name: MI and
Operator name:
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Suggestion Corrective Actions taken Possible Solution
level.
operator. Instructions given instruction infront of the
Reflow process to be improved by providing
firm holding pallets. Diode length is short ascompared to padding.
Tx soldering is not done in reflow process
yet.
Conveyar speed to be decreased but need to
check cycle time and effect on LED
Pasteheight is not constant
Reflow process to be improved by providing
firm holding pallets
This should have been
screened after reflow
inspection itself. Tighten
inspection after reflow.
Need to do more pasting and reflow processfor Tx to be proper. Pad size is not matching
with Tx pins
Due to manual insertion at SMT level error
occures. Same size feeder not available.
PCB pad should be extra.
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Sr No Date Product Nature of problem Qty Rework done
1 4/2/2013 Spot R9(1.5K) Burn 31 R9 replaced.
2 5/2/2012
10/2/2013 Spot PCB off due to Tx dry 2 Re-soldering done
12/2/2013 Spot R9(1.5K) Burn in series 11 R9 replaced
13/2/2013 Spot Wattage is more than 4 Pending
15/2/2013 Spot Blinking failure 3 1.5 K replaced
Off due to Tx reverse 3 Tx correctly re-
Wattage is more due to 1 Cap 4.7 remounted
Process name: Spot testing
Operator name:
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Suggestion
Due to wire cut in testing jig, problem
Actual cause observed is dat, After IPA ok
Manual error at SMT level
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Sr No Date Product Nature of problem Qty Rework done
1 4/2/2013 Spot Flickering observed 236 Seperated for analysis and
2 11/2/2013 Spot Flickering observed 6 Seperated for analysis and
12/2/2013 Spot Flickering observed
15/2/2013 Spot Flickering observed 11 Seperated for analysis and
Process name: Spot dimming function checking
Operator name:
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Suggestion Remarks
As per suggested by Has this been
After PQ dimmers , diiming Flickering problem
Flickering observed
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Sr No Date Product Nature of problem Qty Rework done
1 8/2/2013 Spot T-connector missing 2 T-connector added
13/2/2013 . Inner box damaged/ 3 Box replaced
2 15/2/2013 Spot T-connector and inst shet 1 Re-inserted.
Process name: Final packing
Operator name:
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Suggestion Remarks
1) Exact packing as per
To be checked before
Exact packing as per picture
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Sr No Date Product Nature of problem Qty Rework done
1 12/2/2013 Spot Soldering was not done 1 Resoldering done
Process name: Final packing
Operator name:
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Suggestion Remarks
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Aq Q
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Sr No Date Product Nature of problem Rework done
Process name:
Operator name:
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Suggestion
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Sr No Date Product Nature of problem Rework done
Process name:
Operator name:
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Suggestion
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Sr No Date Product Nature of problem Rework done
Process name:
Operator name:
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Suggestion
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