MSA FOR AOI AUTOMATED INSPECTION

Customer : Measurement system analysis AOI for Sentata ( MSA –AOI)

Issues : Internal Flex Cable Handling fixtures and process mapping
Models de HD: Sensata B27-812746-001 & 002
Project Title
AOI – MSA ( FLEX Cable Criteria Acceptation) , 25% Max acceptance per IPC-A-610 Rev F

Project Scope
To Standardize the acceptation Criteria thru AOI on HD PCBA Where the Flex Cable its Used ASSY P/N
(Sensata B27-812746-001 & 002)

Green Belt Project

As team for consulting : Filemon Sagrero/Juan M/

Deployment Champion
GB Ing Hector Garcia

Process Owner
Process Owner: Rosalva Camacho

Finance Representative
Sigmatron International

Mentor
Moises D/ Filemon Sagrero/Juan M/
Problem Statement
Customer has been reported misalignment flex cable versus solder pad
over the HD PCBA customer Sensata B27-812746-001 & 002, and due this
problem the flex cable & PCBA have non contact and lack of welding reflow
process.
Project Objective
 Design a Measurement system (MSA) and define the acceptance criteria
thru AOI process between Operator and production shifts
 To create a more effective inspection Go-no-Go by means of the use of AOI
( Automated Optical Inspection) over this defect by means of the
standardization of criteria according the 25% Max acceptance per IPC-A-
610 Rev F
 To Document the MSA Validation & to warrantee both production shift
criteria
 Up-Date Work instruction with the validated criteria
Business Benefits
• Business/CTQ action to answer 2 SCAR from customer (
• Reworks cost $ 11.21 each PCBA
 Qty PCBA’s 2018
30500
30000
29500
29000
Projected Sales for 2018: 28500
28000
Moth July Moth Aug Moth Sep Moth Oct Moth Nov Moth Dic
2018 2018 2018 2018 2018 2018

USD COST PER YEAR

30000

25000

20000

15000

10000

5000

0
7/1/2018 8/1/2018 9/1/2018 10/1/2018 11/1/2018 12/1/2018

B27-812745-002-REVA B27-812745-002-REVB B27-812746-002-REVA B27-812746-002-REVB B27-812745-001-REVA

B27-812745-001-REVB B27-812746-001-REVA B27-812746-001-REVB Grand Total Per year USD
 251489 Top 2 , Misalignment switch
DEFECT PARETO ROOT CAUSE

4
4

2
1 1 1
1

0
SW2,SW4 XTAL U1 J1
1819,1810 1745 1810 1819
Lifted Switch Defective Mising Solder Wrong Assy Fixture to hold switches , this condition of fixture is
Component causing misalignments when component is mounted
by hand

EFFECTIVENESS (INTERNAL INDICATOR) IMPROVEMENT ACTION

CURRENT:

TBD after improvements

AFTER: to implement fixture 8/20/18

Containment : Manufacturing Guide number GL-PD 479

Rev 03, with QC alert for switch misalignment inspection.