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Model-Based Flexible PCBA Rework Cell Design
Published in Cornelius Leondes, The Design of Manufacturing Systems, 2019
Although the number of rework systems available in the market has grown considerably over the last few years, the rework process itself has not been fully automated. The reasons for the limited automation in rework include: The necessity for flexibility to accommodate a wide variety of components and board designs and rather complex process requirements for their reworkThe relatively high cost of vision and associated equipment required for automated reworkRework is still viewed by most companies as an admission of failure in the design and manufacturing processes, even though defect rates can be as high as 35%.
Interconnection technology
Published in Stephen Sangwine, Electronic Components and Technology, 2018
Minor faults can occur in PCB manufacturing and assembly that require some manual attention to the board. The process of correcting production faults is called rework. If a board needs attention to correct a fault that has occurred in service, the work is called repair. Similar manual techniques are applicable in either case, although the types of fault encountered may be different. Rework may involve removal of excess solder from a board, removal and replacement of an incorrect component, or addition of a component omitted during manufacture. Repair may involve reconnection of a broken wire or PCB track, replacement of failed components, and restoration of a mechanically damaged or burnt area of PCB. Some types of repair and rework on PCBs are delicate jobs for skilled craftsmen, but some limited skill at component replacement is needed by most electronics engineers doing development work on hardware.
A deteriorating inventory model for determining optimal replenishment run time with failure rework and shortage
Published in International Journal of Systems Science: Operations & Logistics, 2021
In real life production environment, the fabrication of defective items is to be anticipated due to process deterioration, setup mistakes, tools mistakes or other controllable and/or uncontrollable issues (Hinckley, 1997). These defective items can be scheduled to rework. Rework items is one of the important issues in reverse logistics where second-hand products are reworked to diminish waste and environment evils and also overall production/inventory costs can be reduced significantly. For instance, the paper industry, the semiconductor industry, the glass industry, the metal processing industry and the plastic industry employ rework as an acceptable process in order to achieve the required levels of quality and quantity. The economic production quantity (EPQ) model problem for single item under the assumptions of imperfect production and perfect rework have been broadly carried out in the past decades (for instance, Widyadana & Wee, 2012; Singh, Jain, & Parrek, 2014; Shah & Shah, 2014; Li, Chan, Chung, & Tai, 2015; Kundu & Chakrabarti, 2015; Jawla & Singh, 2016; Khanna, Kishore, & Jaggi, 2017; Chiu, Li, Chiu, & Chiu, 2018). However, in real life manufacturing process, quality of reworked items is not always perfect. Owing to deterioration of process, imperfect technology, human error, unpredictable issues or numerous other factors, generation of defective items during rework process is inevitable. In this paper, system of imperfect production and imperfect rework is carried out to supply 100% high-quality products to markets.