In the production of multilayer PCBs, each board is assigned unique internal codes, which must be clearly distinguished throughout the manufacturing process. Different production process cards are used to manage and track progress. One critical aspect of this process is the transfer and handover of auxiliary products, typically handled via batch cards (also referred to as Lot Cards), a practice often referred to as “excess.”
Given the large volume of online products and the complexity of the various models, the production system must support fast, simple, and error-resistant operations for tasks such as inventory counting, scrapping, and repairs. These tasks need to be executed efficiently and without disrupting the production flow.
However, most general-purpose ERP systems fall short when it comes to handling specific requirements like individual coding for different layers, tracking excess numbers, managing scrap material, and replenishing both inner and outer layers separately. As a result, a more specialized solution is required to properly manage these complex operations.
In general, the level of detail in a production operation plan directly correlates with the richness and value of the information it provides. However, this also makes the calculation of production more complex. A more detailed plan offers a clearer roadmap but demands more precise forecasting and resource management. On the other hand, a rougher plan, while simpler, offers less insight and has lower value in terms of production accuracy and efficiency.
In the PCB (Printed Circuit Board) industry, the production process is often intricate, especially for complex multilayer boards. Engineering data preparation and Manufacturing Instructions (MI) for such products can take a significant amount of time. Despite this, customer delivery timelines are typically tight, placing additional pressure on production teams to meet deadlines.
The key competitive advantages in the PCB industry lie in several critical areas: engineering research and development, production management, material control, and outsourcing processing. Among these, effective Work in Process (WIP) control is particularly vital in on-site production management. When WIP is not properly managed, it leads to a range of issues such as inventory mismanagement, material losses, production stagnation, inaccurate WIP tracking, delayed material replenishment, increased line changes, and unclear delivery schedules. These problems can severely impact overall production efficiency and product quality.
PCB products are highly diverse, typically classified by the number of layers. These include single-sided, double-sided, four-layer, eight-layer, and even ten-layer boards. The specific processing materials, process flows, parameters, testing methods, and quality standards for these products are communicated to the production and outsourcing units through detailed production instructions (MI). These instructions ensure that every stage of production follows the necessary protocols, maintaining consistency and quality.
For simpler PCB products, such as those with four or fewer layers, the production process is relatively straightforward. A single process card can typically guide the production from start to finish, without the need for adjustments or the creation of new process cards during the manufacturing cycle. In contrast, for more complex products, such as those with blind and buried vias or boards with more than six layers, the production process becomes more intricate. These products involve different circuit diagrams, process flows, and parameters for the inner and outer layers, as well as specialized molds and other auxiliary equipment. As a result, multiple production instructions and process cards are created to manage the unique manufacturing needs of each layer, ensuring the process is tightly controlled and the production output is accurately tracked.
Overall, the PCB industry has entered a phase of steady and sustained growth. As the demand for increasingly complex PCB products rises, the industry’s focus on refining production processes, improving WIP control, and ensuring timely deliveries will continue to be critical factors for success.
Given the large volume of online products and the complexity of the various models, the production system must support fast, simple, and error-resistant operations for tasks such as inventory counting, scrapping, and repairs. These tasks need to be executed efficiently and without disrupting the production flow.
However, most general-purpose ERP systems fall short when it comes to handling specific requirements like individual coding for different layers, tracking excess numbers, managing scrap material, and replenishing both inner and outer layers separately. As a result, a more specialized solution is required to properly manage these complex operations.
In general, the level of detail in a production operation plan directly correlates with the richness and value of the information it provides. However, this also makes the calculation of production more complex. A more detailed plan offers a clearer roadmap but demands more precise forecasting and resource management. On the other hand, a rougher plan, while simpler, offers less insight and has lower value in terms of production accuracy and efficiency.
In the PCB (Printed Circuit Board) industry, the production process is often intricate, especially for complex multilayer boards. Engineering data preparation and Manufacturing Instructions (MI) for such products can take a significant amount of time. Despite this, customer delivery timelines are typically tight, placing additional pressure on production teams to meet deadlines.
The key competitive advantages in the PCB industry lie in several critical areas: engineering research and development, production management, material control, and outsourcing processing. Among these, effective Work in Process (WIP) control is particularly vital in on-site production management. When WIP is not properly managed, it leads to a range of issues such as inventory mismanagement, material losses, production stagnation, inaccurate WIP tracking, delayed material replenishment, increased line changes, and unclear delivery schedules. These problems can severely impact overall production efficiency and product quality.
PCB products are highly diverse, typically classified by the number of layers. These include single-sided, double-sided, four-layer, eight-layer, and even ten-layer boards. The specific processing materials, process flows, parameters, testing methods, and quality standards for these products are communicated to the production and outsourcing units through detailed production instructions (MI). These instructions ensure that every stage of production follows the necessary protocols, maintaining consistency and quality.
For simpler PCB products, such as those with four or fewer layers, the production process is relatively straightforward. A single process card can typically guide the production from start to finish, without the need for adjustments or the creation of new process cards during the manufacturing cycle. In contrast, for more complex products, such as those with blind and buried vias or boards with more than six layers, the production process becomes more intricate. These products involve different circuit diagrams, process flows, and parameters for the inner and outer layers, as well as specialized molds and other auxiliary equipment. As a result, multiple production instructions and process cards are created to manage the unique manufacturing needs of each layer, ensuring the process is tightly controlled and the production output is accurately tracked.
Overall, the PCB industry has entered a phase of steady and sustained growth. As the demand for increasingly complex PCB products rises, the industry’s focus on refining production processes, improving WIP control, and ensuring timely deliveries will continue to be critical factors for success.
