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You’ve implemented a QMS and shop-floor system …….Now what? - Part 2

Jay Gorajia

Jay Gorajia

Posted Nov 16, 2010

In the previous blog post, we starting the review of how to manage costs by inter-operating between SMT Monitoring systems and Material Management systems.

Manufacturers deploy various manufacturing systems that provide necessary controls, enable data collection, support cost-saving initiatives, provide a means for compliance, and help decrease time to market. Yet most remain as islands of information, and provide the value intrinsic within their own confined systems.

In this post, we review how we can Manage Rework and Quality costs.

After implementing the Material Manager interoperability with the SMT Monitoring system, the material handling, inventory and changeover efficiency issues are handled.  But are those are not the only places where costs are hidden.  Another place where the burden is felt is quality returns and rework.  Rejected boards from In-Circuit Testers, Flying Probe Testers, Functional Test Units or even manual inspection stations, all need further troubleshooting and fixing.  More source of WIP.  As boards wait to be tested, they risk the possibility of hitting a customer due date for that order.  If an unexpected rework has been identified, and the volume increases, it puts stress on the whole eco-system.  Do we have enough replacement components to rework those boards?  Have we the certified man-power to perform that rework?  Will we hit the due date for that customer order?

QMS should have the ability to alert management as Acceptable Quality Levels (AQLs) are not met.  However, this needs to be done real-time.  It is too late if AQL breaches are found in post-mortem analysis.  Alerts should be setup as escalation of notifications for many of the following:

  • Number of repair loop met (e.g. 3 test and repair loops maximum per board)
  • Acceptable Quality Level (AQL)
  • First Pass yield %
  • Consecutive failure of the same type (defect)

If QMS and Material Manager are interoperating, then you can enable an added value of evaluating the inventory of the required components and pulling the required material to the rework stations as needed.  In addition, in post-mortem analysis, if the QMS identifies a high failure or defect count on a specific component location on an assembly, that can be tied into the material manager to find the specific vendor, vendor part number, and vendor lot for additional supply chain quality analysis.  A score card for your component vendors, for a change!

Using the QMS and Material Manager to identify quality problems during production is the most efficient way of managing costs, before the costs occur.

A full article can be referenced at:

Looking forward to your comments on optimization of Materials and/or ways to reduce manufacturing costs!

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About Jay Gorajia Follow on Twitter

Jay GorajiaJay Gorajia is Worldwide Consulting Manager, PCB DFM and Manufacturing Solutions, for the Consulting Division of Mentor Graphics. He works to improve efficiency and help define productivity solutions in design, manufacturing engineering and production for OEMs and PCB Assembly manufacturers. Mr. Gorajia holds a Bachelor’s degree (B.Sc.) in Electronic Engineering and a Masters in Business Administration (MBA) in Technology Management. He has published a number of articles and White Papers in industry leading technical magazines and industry conferences. Visit Electronics Assembly .… Exposed

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