|
1
|
- Certification For RoHS Lead Free Electronics Assembly Process Capability
Program
- John Kania, IPC
|
|
2
|
|
|
3
|
- Conceived and created by the industry for the benefit of the industry.
- Help industry prepare for lead-free requirements of the EU RoHS
Directive.
- EMS and OEM’s
|
|
4
|
- Confirm your internal RoHS lead free preparations.
- Validate your lead free process capabilities to your customers and
suppliers.
|
|
5
|
- “The IPC certification audit program has a simple goal: to audit an
electronics assembly facility…and determine if the facility has
processes and procedures in place to demonstrate that it is capable of
producing product to meet the lead free requirements of the RoHS
Directive”
|
|
6
|
|
|
7
|
- Initial program developed by two content experts.
- Over 40 years experience in electronics assembly industry.
- Leaders in RoHS lead free process implementation.
|
|
8
|
- AIM
- Apsco
- Celestica
- Cookson Electronics
- Fawn Industries
- Flextronics International
- GE Healthcare
- Hewlett-Packard
- Jabil Circuit
- Kester
- Plexus
- Raven Industries
- Solectron
- Vitronics Soltec
|
|
9
|
- Auditor and Beta site validation
- Solectron Charlotte
- Raven Industries
|
|
10
|
|
|
11
|
- General
- Training
- Surface Mount Assembly
- Wave Soldering
- Rework and Repair
- Assembly Materials
- Components
- Design and Engineering
- Test and Inspection
- Materials Assembly Database
- Materials Procurement
- Materials Warehouse
- Materials Field Return
- Quality
- Materials Declaration
|
|
12
|
|
|
13
|
- Are you tall enough for the lead free ride?
- Sample Checklist
- Self-audit checklist (30 business days)
- On-site audit (90 business days)
- Audit report (14 business days)
- Certification
- Appeal/re-audit
- Re-certification
|
|
14
|
|
|
15
|
- $7,000 IPC members
- $10,000 non-members
- $1,000 auditor expenses
|
|
16
|
- Now available globally.
- Audits currently underway:
- Axiom Manufacturing Services (U.K.)
- CTS Electronics Manufacturing Solutions, Inc.
- Riverside Electronics LTD.
|
|
17
|
|
|
18
|
|
|
19
|
- Value to the Industry:
- In a time of rapid change in response to external pressure the process
provides assemblers with a honest and technically sound method of
assessment of their readiness for the RoHS lead free requirements.
- The audit process provides expert and confidential feedback on technical
capability, training and documentation.
- Even for a company now building lead free assemblies the review exercise
provides a third party assessment based on accepted industry practices.
|
|
20
|
- Value to the Industry:
- 3rd party validation provides a “sanity check” with respect
to internal company efforts.
- The IPC auditor selection process insures that the audits will conducted
only by those with extensive assembly experience: judgments are made
only by those who have “been there and done that.”
- For small and medium manufacturers this is an opportunity to use general
industry knowledge and experience in crafting their own path to lead
free readiness.
- The audit process is not “hermetic”: knowledge exchange is part of the
process. You have the opportunity to learn from the exercise!
|
|
21
|
- Beta Site Audits:
- Two completed to date in the U.S.
- Feedback from U.S. audits (Auditor and audited) been incorporated into
audit forms and process to improve quality.
- Comments received back from audited companies indicate that the exercise
provides process improvement benefits that go beyond certification.
|
|
22
|
- Beta Site Feedback:
- “We were very satisfied with the technical knowledge and approach of the
auditor and felt it lead to a good interchange of ideas and discussion.”
- “The program allowed [us] to benchmark our RoHS lead free readiness
against . . . technical experts. This will be a stepping stone to
improve our own RoHS lead free process audit questionnaire and
readiness.”
- “It highlighted to the team the importance of “due diligence” of some
critical areas and future questions that may be asked of our customers.”
|
|
23
|
- Summary:
- This program provides an industry developed, fair, third party
assessment of a companies lead free process capability.
- The audit process itself provides feedback to the audited organization
on process improvement.
- Certification through the IPC audit program provides a high level of
confidence to a companies customers that their supplier has the
capability to meet the lead free requirements of the RoHS Directive.
- This is not just a certification exercise; it is a learning and improvement
process!
|
|
24
|
|
|
25
|
- Founded 1997,
- Leading provider of training and certification for the electronic
industry.
- Deliver training in PC Board Technology, Fiber Optic Technology, Cable
and Wire Harness, Wire Harness Assembly.
- For each technology, we offer basic training for those with little
experience as well as advance training.
- Provide Consulting services to entire Electronic Industry.
|
|
26
|
- Learn the audit procedures and prepare to conduct the audit
- Understand the objectives of the IPC audit
- Review all questions in questionnaire
- Get copy of Lead-Free roadmap from customer
- Define whether or not audit is for
- EMS
- OEM
- Supplier/Distributor
- Verify flexibility of roadmap
|
|
27
|
- Verify personnel assignments are defined and in place.
- Try to define lead time from design to product release
- Define whether or not this program has been funded by upper management
|
|
28
|
- Identify company or facility operational business:
- EMS House
- High volume, low mix
- Low volume, high mix
- OEM
- Supplier
- This information impacts the assessment of various process commitments
|
|
29
|
- Emphasize:
- Conversion to lead free is not as simple as many people perceive
- Controls of materials is more important than physical assembly process
- Verify material control processes
- Check for repeatability of this process
- Verify personnel have been trained
|
|
30
|
- Verify the following items with facility personnel
- Cost of program and has it been budgeted
- Inconvenience of implementing for various customers
- Does the roadmap reflect this difficulty
|
|
31
|
- Define who is responsible for Material Declaration Sheets.
- How are they collecting the MDS information?
- Get the plan for the distribution of MDS information.
|
|
32
|
- Auditor should:
- Be cognizant various assembly processes
- Eliminate personal bias of any manufacturing processes styles and
techniques
- After reviewing questionnaire, summarize some questions to help review
the total facility and eliminate ambiguities within the answers provided
by the questionnaire.
|
|
33
|
- Lead free program
- Define whether there is a part number program in place and is part
storage segregated or are the materials mixed within storage area?
- If yes, how are the part segregated within the manufacturing operation?
- How are the parts segregated when issued to manufacturing?
- How do the assembly operators know what is lead free and what is not?
- Define who does the training and how were they trained?
|
|
34
|
- Keep communications open with customer
- Propose an agenda for the visit
- Define paperwork to be provided for review based upon the questionnaire
submitted
- Define sections of manufacturing which will be reviewed and audited.
|
|
35
|
- Finalize agenda for meeting and follow it.
- After meeting, collect and collate information to provide customer with
results and conclusions of audit.
- Define whether or not there is more work to be done to successfully pass
the audit.
- Provide conclusion and result report at closing meeting and to IPC for
follow on action with customer.
|
|
36
|
- Jenny Porter – Site RoHS Lead
- May 2006
|
|
37
|
- Founded in 1977
- Headquartered in Milpitas, Calif.
- Sales of $10.4 billion in fiscal 2005
- Serving customers in communications, networking, computing and storage,
consumer products, automotive, medical and industrial markets
- Traded on the NYSE, under the symbol SLR
- Two-time winner of the Malcolm Baldrige Award
|
|
38
|
|
|
39
|
|
|
40
|
|
|
41
|
|
|
42
|
|
|
43
|
|
|
44
|
|
|
45
|
|
|
46
|
|
|
47
|
|
|
48
|
|
|
49
|
|
Notes
