Optimal Electronics Corporation

Optel™ - Lead Free and RoHS Compliance

Traceability as a Presription to RoHS Compliance
Supplying a Declaration of Compliance to a particular RoHS standard is only the beginning. The real challenge is ensuring compliance over time through all assembly processes and being able to prove this in the event of an audit. This requires a comprehensive system that controls all material in the entire chain of custody and provides an “as built” record of each product. Thus, it must begin with material receiving and encompass SMT (Surface Mount Technology) machines, PTH (Pin Through Hole) machines, manual stations, rework stations, and box build stations, leaving no gaps. It must also manage the operational challenges caused by the different process used in lead free electronic assembly. For example, lead free solder pastes do not remain tacky as long as tin-lead pastes, and the higher reflow temperatures used in lead-free processes mean many components need to be treated as moisture sensitive components for reliability.

Optel supports all of this. Screen printers are controlled to ensure the proper paste and stencil are used. Non-compliant parts cannot be kitted or otherwise enter the assembly process. Panels or boards are serialized and the system automates component level traceability logging – down to the reference designator – for all components and assembly steps, even in a multi-vendor, multi-technology environment. Takt time is automatically captured, preventing boards whose tackiness has exceeded spec to enter pick & place machines. Moisture sensitive materials are tracked and controlled to ensure they don’t exceed out of bag time. Temperature, humidity, oven profiles, and other process variables can even be monitored and logged to provide process traceability.

Works with MRP systems and reports back accurate on-hand inventory counts to the system
Material receiving and comparison between purchased versus received materials per purchase order
Eliminates non-compliant parts via closed-loop part verification
Real-time tracking of material location and quantity, including reels on feeders and machines
Screen printer control to ensure the proper paste and stencil are used
Reporting on every transaction a material ID (license plate) went through
Takt time automatically captured, preventing boards whose tackiness has exceeded spec to enter pick & place machines
Tracks and controls “out of bag” time for moisture sensitive components
Traceability is supported per reference designator for SMT, PTH, manually placed, and reworked components, in addition to system assembly (aka box build).
Automatic component cycle counting eliminates manual component counting
Supports manual and automated (carousel) material storage systems
Detailed setup verification history
Temperature, humidity and oven profiles can be monitored and logged to provide process traceability
Integrates with Lean Manufacturing for complete manufacturing control

OPTEL CAPABILITIES

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Our high mix PCB manufacturing environment benefits from Optel's powerful dynamic scheduling algorithms, coupled with its machine optimization and program generation capabilities. Integrating Optel into our broader MES architecture helps us better balance multiple assembly lines, automatically program a variety of machines, and schedule setups instead of work orders. Schedule control and visibility is an important aspect of our strategy for cost-effective electronic assembly in North America, and Optel compliments the capabilities of our own plant-wide information applications, the FactoryTalk Production and Performance Suite.

Mike Reynolds
Director, Operations
Rockwell Automation