Solve the dilemma of SMT first article inspection: make quality control more efficient and accurate

At the moment when electronic manufacturing is transforming to high density, multi-variety, and fast iteration, SMT (surface mount technology) is the core process of electronic assembly, and its quality control directly determines the market competitiveness of enterprises. As a key line of defense before mass production, first article testing assumes the core responsibility of investigating material mismatch, placement deviation, parameter abnormalities and other problems, and is a key link in reducing mass production quality risks and cost losses from the source. However, the traditional first article inspection mode has long been difficult to adapt to the needs of modern electronic manufacturing, and many pain points have become bottlenecks restricting enterprise production capacity improvement and quality upgrade. Shenzhen subit is deeply involved in the field of SMT testing, accurately insight into the pain points of the industry, and provides enterprises with efficient, accurate and intelligent first-article inspection solutions with intelligent first-article inspection equipment as the core.
The four core dilemmas of traditional first-article testing
In actual production scenarios, most electronic manufacturing enterprises are still trapped in the inefficiency and extensiveness of the traditional first-article inspection mode, and the specific pain points are reflected in the following four aspects:
1: The efficiency of manual testing is low, which seriously drags down the production cycle
Traditional first-article inspection completely relies on the experience and meticulousness of the operator, and requires two people to work together - one person holds a meter and pen to clamp the resistance, capacitance and other components, reads the values through the LCR bridge, and the other person manually compares and records against the printed BOM table and PCB drawings. In this mode, the inspection time per board is usually more than 30 minutes, and it can even take more than half a day to encounter complex circuit boards with more than 3,000 components. In today's normalized multi-variety and small-batch orders, frequent line change testing has made the first article inspection a bottleneck in production capacity, and the equipment waited for a long time, greatly reducing production efficiency.
2: The risk of human error is high, and the hidden dangers of quality are difficult to avoid
Electronic components are developing towards miniaturization, and micro packaging components such as 0201 and 01005 are becoming increasingly popular, and positioning deviations are very easy to occur during manual clamping, resulting in a high error rate. At the same time, in the process of manually reading values and manually judging results, problems such as missed tests, misjudgments, and recording errors are unavoidable. Once there is an omission in the first piece inspection, it will lead to the scrapping of the entire batch of PCB boards, bringing huge economic losses. In addition, the silk screen printing and polarity direction of ICs, triodes, and other components need to be observed with the help of a magnifying glass, which further increases the difficulty of judgment and the risk of error.
3: Data traceability is difficult, and the pressure of compliance audit is high
The traditional first article inspection adopts the paper recording method, which is not only cumbersome and easy to lose, but also has problems such as irregular records and no remarks on the measured values. When customers need to retrieve the first test report, enterprises often need to spend a lot of time searching and redoing, and even affect cooperation due to incomplete and non-standard reports. At the same time, paper records cannot be connected with the MES system, and the quality data is difficult to trace, which cannot provide effective support for production process optimization.
Fourth: High personnel training costs and poor team stability
Traditional first-article testing requires extremely high professionalism of operators, and a skilled inspector needs to go through more than 3 months of training to take up the post independently, with a long training cycle and high cost. What troubles enterprises even more is that the leave and resignation of core testing personnel will directly affect the production schedule, and the team instability caused by personnel turnover further aggravates the difficulty of production control.
Precise breakthrough: subit first article detector, reconstructing a new paradigm of first article detection
In response to the above industry pain points, Shenzhen SUIT takes "intelligence, efficiency and precision" as the core to create a new generation of SMT first article detector, which has been comprehensively upgraded from the four dimensions of detection efficiency, accuracy, data management and operation threshold, and built a solid quality defense line for enterprises before mass production.
Efficient detection: 30 times faster for single-person operation, suitable for flexible production
The first piece detector of subit adopts automatic flying probe testing technology, which accurately identifies the position of components through high-definition camera and visual positioning system, and the flying probe test head automatically completes the clamping test, and the detection speed can reach 1 second/component, which is more than 30 times the efficiency of manual inspection. For complex circuit boards with 3,000 components, it only takes more than 1 hour to complete the inspection, greatly reducing the inspection time. At the same time, the equipment supports offline programming, and programming and debugging can be carried out independently of production, effectively reducing the time of the equipment occupying the production line and perfectly adapting to the flexible production needs of multiple varieties and small batches. A single person can independently complete the whole process operation, which directly saves 1.5 people in labor costs compared with the traditional two-person collaboration model.
Precise control: eliminate human error and adapt to small packaging components
The equipment is equipped with a high-precision visual recognition system and intelligent parameter comparison algorithm, which can automatically extract the size of components, adjust the span of the stylus, and accurately adapt to ultra-miniature packaging components such as 01005, with a repeatability accuracy controlled within ±0.01mm. During the testing process, the equipment automatically reads the measured value and switches the instrument range without manual intervention, completely eliminating problems such as missed tests, misjudgments, and recording errors. For polarity-sensitive components such as ICs and transistors, the equipment can automatically take photos and retain them, and generate high-definition physical maps in the test report to ensure accurate polarity judgment.
Intelligent traceability: Data interconnection makes it easy to cope with factory audit compliance
The subit first article detector has a built-in intelligent data management system, which can automatically generate a standardized first article inspection report, which contains full-dimensional information such as measured value of components, standard value, error range, detection time, and operator, with pictures and texts, clear specifications. At the same time, the equipment supports seamless docking with the MES system, and the inspection data is uploaded to the enterprise management platform in real time, realizing the full traceability and in-depth analysis of quality data, and providing data support for process optimization. When customers audit the factory, they only need to retrieve the historical report with one click, and there is no need to spend time sorting and supplementing it, and it can easily meet compliance requirements.
Ease of use: Reduce training costs and get your team up to speed quickly
The equipment adopts a humanized operation design, the laser point guides the detection position, and the operator does not need to memorize complex drawings and parameters. New employees can get started after 2-3 days of training, and can become skilled workers within 1 week, completely solving the problems of difficult training of core personnel and poor team stability. The interface of the equipment is simple and intuitive, and the number of unmeasured, qualified and unqualified components is displayed in real time, effectively preventing missed testing and making the testing process more controllable.
Local deep cultivation: Shenzhen subit, better understand the needs of China's electronic manufacturing
As a local brand rooted in Shenzhen, SUBIT deeply understands the production pain points and development needs of Chinese electronics manufacturing enterprises. From equipment research and development, production to after-sales service, the whole process of localized response can provide enterprises with customized solutions to adapt to the testing needs of different industries (consumer electronics, automotive electronics, industrial electronics, etc.). The professional technical team responds 24 hours a day 7× to solve various problems in the use of equipment in a timely manner, so that enterprises can use it with more peace of mind.
Conclusion: Choose subit to make the first article inspection change from "bottleneck" to "advantage"
In today's increasingly fierce competition in electronic manufacturing, the efficiency and accuracy of first article inspection directly determine the quality competitiveness and cost control ability of enterprises. Shenzhen Subit's first detector uses intelligent technology to solve the traditional testing dilemma, which not only helps enterprises reduce labor costs and improve production efficiency, but also avoids quality risks from the source, providing core support for large-scale production and intelligent upgrading of enterprises.
Contact Shenzhen Subit now to get an exclusive first-article testing solution, make quality control more efficient and accurate, and help enterprises seize the opportunity in the fierce market competition!