Electroless nickel / gold production management experience learning

Electroless nickel / gold production management is currently responsible for one of the wet treatment production lines. The line is a manual production line, no traffic lifting, thanks to manual mention, discharge nickel / gold plate production. In addition, in recent years, as surface coating increases the amount of OSP, chemical nickel / gold, and chemical silver, plating nickel / gold production board is less, and conceivable that the management difficulty is relatively large. Therefore, in the actual production process, due to the management is not in place, negligence details, we have also paid a lot of price. However, in spite of this, we have also made many improvements, "eating a cut and making the best use of our talents." With the gradual improvement of production management, the nickel / gold plating production line has been steadily becoming more and more stable. As a result, many orders have been won by the enterprises. This article on the nickel plating / gold production management introduced some superficial personal experience.

1 nickel plating / gold production line overview

The line was purchased in 1994, Hebei Baoding plating tank production line, after several transformation, it is now 4 nickel cylinder, a gold cylinder, the largest production of functional cylinder board width 750mm × 540mm. according to. The standard size of 356mm × 406mm standard board accounting, the production capacity of 1,747 square meters / month.

Due to the lack of market orders, usually only 3 nickel cylinder open to use. Therefore, the actual monthly capacity is 1310m. Staffing is actually less than 2 people, wet production and production foreman take into account the operation. The line managers, technicians, only a few individuals with more than 2 years of experience in production of nickel plating / gold production experience of college graduates, operators of lower educational level, most of the province or nei***oring rural areas into the city junior high school students, Vocational students, most of whom have not been systematically galvanized theory training, the lack of basic knowledge of nickel plating / gold production. As mentioned earlier, due to the lack of market orders, nickel-plated / gold wire is often half-parked half-open state, maintenance is even more difficult. The monthly operating time, the average operating rate of only 17% to 49%. In addition, many kinds of products, small quantities, imperfect process management, equipment maintenance is not in place, self-test is not strict, rework rate is high, a pass rate (through rate) is very low.

In 2005, with the increase of PCB orders of Shanghai high-definition television market in Shanghai and the gradual opening up of the U.S. market, the task of electroplating nickel / gold production rose sharply for a short time, and the production of nickel / gold electroplating lines was difficult to complete even after 24 hours of operation. Customer orders at this time it is just put forward the design changes, two larger quantities of the car plate from the original whole plate of nickel / gold, replaced by local plugs and lap (bonding) parts of the nickel / gold and then hot air Flat processing, the original process obviously can not meet the customer's quality requirements. Customer complaints and return events have occurred.

High quality and high requirements of PCB production and low quality of the workforce is not compatible. Almost all of the online workers are migrant workers in their early twenties, floating in the heart and having a poor sense of responsibility. Personnel factors severely restricted the production, its product rejection rate as high as 30%.

2 Electroless nickel / gold production is a multidisciplinary integrated technology that requires qualified operators

Electroless nickel / gold production involves multidisciplinary, multifaceted knowledge.

It involves electrochemical-nickel plating / gold itself is an electrochemical process, nickel / gold metal ions in the cathode to metal reduction Electrodeposition in the nickel / gold plating is extremely important, it is related to whether the Printed on the board to get meticulous, close and with a good combination of the base metal copper metal Ni / Au coating. In general, quality defects in nickel coatings account for 70% to 80% of defects in nickel / gold plated products. Only by familiarizing the nature of the electroless nickel / gold production line, eliminating the factors that affect the quality of the coating and maintaining and managing it properly and effectively can the quality of the nickel / gold plating be ensured.

It involves the surface treatment - the quality of nickel coating defects mainly depends on the surface treatment before nickel plating is fully in place. PCB surface degreasing degreasing than the surface roughening micro-etching, acid leaching activation is good, is to ensure that the bond of nickel-copper key.

It involves the mechanical engineering one by one rack is good or bad, the layout of the cylinder groove, as well as the turbine scroll swinging and cheering and other conditions are by no means underestimated, and sometimes a simple filter leak is enough Lead to pinhole nickel coating even peel scrap.

It involves material science - AR grade must be used in the purity of sulfuric acid and nickel sulfate is more demanding, if the impurity component is high, there will be quality defects nickel plating.

In addition, it relates to safety and environmental protection. Gold-plated virulent raw materials used to gold potassium cyanide is the state strict safety control of toxic chemicals, waste water and waste is strictly controlled emissions. Operation and management must not be careless and careless.

For the characteristics of nickel / gold production line, because the production operation is manual rather than automatic line, which requires the operator to be able to monitor process parameters at any time, and can quickly analyze and determine the cause of the problem, troubleshooting hidden trouble. At the same time, for safety reasons, the operator must be highly responsible and responsible. Therefore, nickel / gold plating production line not only requires management and operations staff have a certain amount of comprehensive knowledge, but also must be of good quality.

3 Electroless Nickel / Gold Process Quality Management Measures to be taken

Currently, the hot topics of manufacturing technology are CIMS and FMS, as well as Japan's Lean Production and GE's 66. So, what kind of path should our gold / nickel plating take?

In general, advanced nickel plating / gold production line equipment, most of them automatically controlled by PLC programming, the operator only need to tune out the internal procedures, as long as the timely loading and unloading boards, traffic and liquid auto-addition system can automatically complete the production and Basic maintenance. This manufacturing technique can be referred to as a pseudo-flexible manufacturing system (PFMS).

To achieve CIMS or FMS requires more investment, automated monitoring of process parameters also requires substantial investment. At present, our main contradiction is not full automation, but a "human" factor (no accountability). Therefore, we establish a "production line responsibility system", mainly to learn Japan's L. P. , Learn from the main features of lean production:

(1) external users to "God", internally to "people" as the center;

(2) In the organizational structure to "streamline" as a means;

(3) The use of "Team Work" and "parallel design" in working methods;

(4) Adopt "JI T" mode on the way of delivery.

One of the most crucial is to give full play to the role of people, take a good and fast way. Here's a brief introduction of some of our practices.

3.1 first implement the "line responsibility system"

The technical staff will be assigned to nickel / gold plating production line, and the production supervisor, foreman, operator wet process line group. Line group work is:

(1) Carry out the correct electroplating nickel / gold production process, monitor and adjust the process parameters. The focus is to monitor the pre-treatment of micro-etching volume, the nickel cylinder pH and the first board of the combination and the thickness of nickel / gold and routine maintenance, to ensure the stable production of nickel / gold plating.

(2) Give full play to the maximum production capacity of the equipment and reduce the auxiliary production time, especially the detection time of the first plate. Assessment of equipment utilization of the production line.

(3) Strict implementation of standard cost, saving water and electricity. Daily production according to the planned area of picking, and the implementation of the examination and approval system, material consumption directly linked to the monthly performance of supervisors, daily record of water consumption and production area to maximize water conservation.

(4) responsible for the quality of products, and the quality management department to carry out three tests in collaboration: the first inspection, sampling, final inspection. Once found quality problems, the whole analysis to discuss solutions, and to develop corrective and preventive measures, while informed QA audit tracking implementation of the rectification. Efforts to improve the product pass rate (pass-through rate), to ensure product reliability.

(5) to carry out. TPM full equipment maintenance and "6S" (finishing, reorganization, cleaning, cleaning, literacy) activities on their own nickel-plated / gold line equipment for timely and effective maintenance, to ensure normal operation. The establishment of daily check-point equipment, recording equipment, process parameters, the problem is not covered, bold exposure, timely rectification and follow-up effect.

(6) A detailed record of the additional production and processing area of syrup, assessment of the production efficiency and process discipline of each team.

(7) Conduct detailed regulation and registration on the requisition and allocation of highly toxic gold cyanide potassium and strictly implement safety management.

(8) Responsible for the technical learning of the entire process line staff and help each other to improve together.

3.2 The core of comprehensive responsibility is to give play to the enthusiasm of people

In addition to the above, we must also improve the quality of our employees in an effort to achieve the following:

(1) give full play to the enthusiasm of employees, so that employees know personal interests are closely related with the interests of the factory. When the indicators such as output, quality and consumption have been fully over-fulfilled, the individual's income will also increase accordingly. To "people" as the basis, implement positive incentives, implement incentives greater than the fine.

(2) To cultivate the professional dedication of employees and to educate employees who love electroless nickel / gold wire to develop themselves into a serious, skilled and responsible electroless nickel and gold wire operator.

(3) To improve staff's knowledge of nickel / gold production operation and maintenance and teach the following courses:

① electroplating nickel / gold theory, about "Electroplating Technology";

② advanced manufacturing technology: sending foreman and backbone learning lean manufacturing curriculum in Japan;

③ Electroless nickel / gold plate inspection standards: GB and IPC PCB inspection norms and common nickel / gold plate defects and causes, and solutions;

④ Electroplating nickel / gold wire structure of the principle and maintenance methods;

⑤ EHS knowledge and MS. DS protection knowledge.

With a system of accountability and staff familiar with and dedication to business, can we truly achieve the harmonious production and development centered on "people".

Customer-oriented parents, "zero defect" as the ultimate goal to "streamline" means the ultimate goal is to get the maximum economic benefits for the enterprise. In addition to the above measures, we also:

(1) Reduce all personnel that can be reduced, encourage and cultivate multi-skilled workers, and promote one multi-skill, technology, equipment and operation tasks to be absorbed by one person as much as possible. Now basically fixed 4 operations.

(2) to save expensive gold salt, the customer does not require thickness, we try to follow the relevant agreement default IPC-II standard production, not blind plating, while the monthly statistics of the consumption of gold salt, the gold-plated area of large consumption of gold salt In particular, the high cost of the board promptly bring marketing manager to pay attention.

(3) increase income and reduce expenditure, waste pickling liquid used to clean the anode copper rod and cathode Fiba.

(4) assisting the busbar product department to carry out surface treatment of copper busbars.

(5) Proposals, appraisals and assessments of rationalization proposals should be organized and implemented to provide suggestions for the development of the factory. Everyone should be aware of the cost and contribute more to saving energy and reducing consumption.

It is worth mentioning that in the past, there was no clear hourly reward for nickel / gold production, and workers' enthusiasm had risen significantly since they promised to honor and check-in their working hours. Therefore, as managers, we have full confidence and determination and believe that we only need to "talk in confidence and do what is necessary," especially in terms of interests and benefits. We often say that enterprises must shoulder their social responsibilities. However, caring for employees, raising employees' income and providing a stage for growth will inevitably increase the enthusiasm of staff and workers. As a result, our changes will not be difficult to implement.

4 to achieve the effect of responsibility system

After the implementation of the process line responsibility system, the staff is uplifted and accomplished:

(1) a substantial increase in production, has always failed, and now often eat enough.

(2) The pass-through rate has been greatly increased, doubling up to a maximum, and the yield and quality have significantly increased.

(3) basic consumption of materials at the end, costing well documented, consumption of gold salt began to decline.

(4) orders increased year by year, and establish a fixed multi-layer nickel / gold plated customer base, substantial increase in economic efficiency of the factory.

5 Conclusion

In electroless nickel / gold production, the first element of the theme is still "human." Japan's experience in manufacturing technology has inspired us: Only by giving full play to the role of "people", striving to improve the quality of "people", strengthening and optimizing management, and making full use of equipment will create wealth and value for businesses and society!