SOP-42Q-MES0024 Traceability Setup

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PTS PTS Production Setup Version MES15 Portal 1.0 Work Instruction

 

This Work Instruction is 42Q's corporate standard. This document is under revision control. The latest revision is located on Intranet. Once printed it is an uncontrolled copy. All alterations to this work instruction require approval. Contact the IT Global Education and Training Department to submit suggested alterations and or updates.

This edition applies to MES15 Portal 1.0 Application and all subsequent releases and modifications until otherwise indicated in new revisions.

SFDC Production Control

As its name implies, the Shop Floor Data Collection (SFDC) system is responsible for the collection of data from the shop floor. The collected information is then stored in the Manufacturing Execution System (MES). Specifically, the real-time information collected by SFDC is utilized by Reporting and MES Web to create quality control reports. The SFDC system uses manual and automated barcode scanning to monitor and collect data for a product line or plant. Thus SFDC plays an important role in maintaining unit histories and directing product movement on the manufacturing floor.

The system provides Access Control between the modules of the application, including the functionalities of each screen. The current version has an SFDC Configuration page which provides access to all sub modules pages and its functionalities (view, add, edit, delete, print and generate output file).

General Notes

• This Work Instruction is a basic general training guide and is not meant to teach the process flow for individual plant or department functionality. Individual 42Q sites may have minor or specific process changes that will be documented at the site level.

Assumptions

• Availability of SMT material placement program (e.g. Fuji SMT job program) or Hand load material placement (e.g. Material items and associated reference designator under Hand load operation).
• Serial number printed on board prior SMT and/or Hand load operation process.
• Each SMT machine has been assigned a unique name for identification purpose. (i.e. Workstation name)

Prerequisites

1. Understand PTS terms definition from Glossary SOP-5-I-MES0044-C_RA_PTS GLOSSARY

2. Pick List has been obtained from plant engineering and uploaded into PTS, for EZ-Pick List – Refer to SOP-5-I-MES0049

Overview

This overview explains the process for production setup in PTSWEB base on the following two different production setup scenarios:

Scenario 1

Production Setup for a new (or previous built) product item on a new shop floor production line, suggested following the steps below in PTS:

1. Convert and upload SMT Picklist into PTS.	Refer SOP-5-I-MES0049, Define EZ Pick List.
2. Create a New Production Line.	Refer to 2.1 Create a New Production Line.
3. Create all required Workstation(S).	Refer to 2.5.1 Create a New Workstation.
4. Add the Workstations into the Production Line by sequence.	Refer 2.6.1 Add a Workstation into a Production Line.
5. Define Workstation Process Sequence in a Production Line.	Refer to 2.7 Workstation Sequence.
6. Define Workstation Parameters for each added Workstation(s).	Refer 2.8 Workstation Setup.
7. Define Picklist for each above added Workstation(s).	Refer 2.9 Define Picklist.
8. Define Auto-Scan Mapping. (Optional)	Refer 2.10 Location Mapping.
9. Set Production Online.	Refer 2.11 Set Production On/Off-Line.

Scenario 2

Production Setup for a previous built production item on where previous built shop floor production line, suggested to follow the steps below in PTS:

1. Convert and upload SMT Picklist into PTS.	Refer SOP-5-I-PTS0014, Define EZ Pick List.
2. Define Picklist for each Workstation which corresponding to the associated Production Line.	Refer 2.9 Define Picklist.
3. Set Production Online.	Refer 2.11 Set Production On/Off-Line.

NOTE:

This work instruction is a general training guide and is not intended to provide a shop floor production process flow for all individual plants or departments.

NOTE:

Please avoid setting up a new assembly on any existing created production line in PTS. It is recommended to have a PTS production line naming setup for one specific assembly exclusively.

Production Setup

1. To access the Production Setup page, navigate to Shop Floor Control >

Production Control.

Figure 1: Production Set-Up (PTS)

 

 

Create a New Production Line

Figure 2: Create New Line

RTENOTITLE

 

1. Select Create Production Line.

2. Enter the new Production Line Name. (See following section for naming format suggestions).

3. Select Create to confirm addition.

Note the following naming conventions for the Production Line.

By Shop Floor Location

Format: Area Location +

Production Zone - Production Part Number - Production Process - Production Side

Area Location: F (Floor), G (Ground)

Production Zone: Floor level or zone area in production either in alpha or number format.

Production Part Number: as named.

Production Process: S (SMT), H (Hand Load)

Production Side: T (Top), B (Bottom)

Example: F2-ABC12345-S-T

Production Line for produc ABC12345 top side SMT production at 2^ndfloor.

By Production Process

Format: Production Process +

Production Zone – Production Part Number – Production Side

Production Process: S (SMT), H (Hand Load)

Production Zone: Floor level or zone area in production either in alpha or number format.

Production Part Number: as named.

Production Side: T (Top), B (Bottom)

Example: S2-ABC12345-T

Production Line for produc ABC12345 top side at SMT Line/Zone 2.

Search a Production Line

Figure 3: Search Production Line

RTENOTITLE

 

1. Enter the production line name or key words in the Search Line Name field.

2. Select the line name from the list.

3. The related production line will be listed in Production Line Available text box.

NOTE: Input the first 1 or 4 key words for the line name, then the line name will display.

 

Rename Production Line

Figure 4: Rename Production Line

RTENOTITLE

 

1. Select the production line from the Production Line list.

2. Open the pop-up menu by Right-Clicking, and then select Rename Production Line.

3. Enter the New Name in "New Production Line".

4. Select Change to rename the production line.

 

Figure 5: Rename Production Line Form

 

NOTE: Production line name can be changed only when the production line is in off-line mode.

 

Hide/Recover Production Line

Figure 6: Hide/Recover Production Line

 

1. Select Hide/Recover Production line.

 

Figure 7: Hide a Production Line

 

2. Select a production line (The line is in offline and visible status) then select Hide Production Line.

3. Select OK to hide the production line or Cancel to exit.

 

Figure 8: Recover a Production Line

 

4. Select a production line (The line is in offline and hidden status) then select Recover Production Line.

5. Select OK to recover the production line or Cancel to exit.

NOTE: The online production line not allowed to be hidden. Please set the production line to "off-line" before hiding it.

Workstation

Create a New Workstation

1. Select Create Workstation from the functional option menu. (See following section for naming format suggestions).

2. Workstation Name: Enter the workstation name.

3. Select the Equipment. (This is optional)

4. Select Create to create the new workstation.

 

Figure 9: Workstation Name and Equipment

 

NOTE: The equipment should be added first in Production >

SMT Machine part Traceability >

Machine Registry module.
Suggested naming format for Workstation

By Shop Floor Location

Format: Area Location +

Production Zone - Placement Machine

Example: F2-CP6B

Explanation: Fuji CP6B placement machine located at 2^nd Floor.

By Production Process

Format: Production Process +

Line/Zone - Placement Machine

Example: S2-CP6A

Explanation: Fuji CP6A placement machine located at SMT Line 2.

By Placement machine model with associated serial number

Format: Placement machine model – Placement machine serial number

Example: CP6-SN12345

Explanation: Fuji CP6 placement machine with its own unique machine serial number SN12345.

Hide WorkStation

Figure 10: Hide Workstation

 

1. Select Hide WorkStation.

2. Select a WorkStation (The Workstation should be at visible status)

3. Select Send to hide the WorkStation or Cancel to exit.

Recover WorkStation

Figure 11: Recover Work Station

 

1. Select Recover WorkStation.

2. Select a WorkStation (The Workstation is at hidden status).

3. Select Send to recover the WorkStation or Cancel to exit.

 

Add WorkStation

This module allows the user to add or remove workstation(s) from production line.

Adding Workstation into a Production Line

Figure 12: Add Workstation into a Production Line

 

1. Select the production line from the production Line list.

2. Open the pop-up menu by right-clicking on the line name then select Add Workstation menu. Select the workstation name from Workstation name pull down list to add to the specific production line.

3. Select Add to add the workstation.

 

Figure 13: Add Workstation- Set Button

 

NOTE: The selected production line must be off-line for workstation addition or removal.

NOTE: The Workstation Name will auto-completed after entering the first 4 characters.

Removing Workstation from a Production Line

Figure 14: Remove Workstation

 

 

1. Select the production line from the production Line list menu.

2. Select the workstation name from Workstation pull down list which is under "In Use."

3. Open the pop-up menu by right-clicking on the workstation then select Remove Workstation menu.

4. Select OK to remove the Workstation from this production line or select Cancel to exit.

 

WorkStation Maintenance

 

Figure 15: Workstation Maintenance

 

 

1. Select the production line from the production line list.

2. Select the workstation from the workstation(s) list.

3. Open the pop-up menu by right-clicking then select Workstation Maintenance option.

4. Renaming: Fill in a new workstation name in the New Workstation field and then select Change to rename the selected workstation name.

5. Equipment: Select the Equipment, then select Change to reset the Workstation type.

 

Figure 16: Workstation Maintenance- Detail

 

NOTE: The workstation can be renamed only when the production line is in "off-line" mode.

(See Set Production Off-Line)

 

Workstation Sequence

The purpose of this module is to redefine the proper workstation sequence for the production line if the previous setup is incorrect.

Following is the example to redefine the workstation sequence:

 

Figure 17: Workstation Sequence in a Production Line- Before

 

1. Select the production line from the production Line list.

2. Select the workstation from the workstation(s) list.

3. Select Workstation Sequence to shift up the Workstation process sequence.

 

Figure 18: Workstation Sequence in a Production Line- After

 

 

 

NOTE: The workstation process sequence goes from down to up and is allowed under the Workstation Sequence option. Please move each workstation to the correct workstation process sequence if required.

 

Workstation Setup

This module allows the user to setup the scanning behavior and scanning rules for each defined Workstation under the associated Production Line.

 

Figure 19: Workstation Set-Up Parameters

 

1. Select the production line from the production Line list.

2. Select the workstation to be set up, then right-click to open the pop-up menu.

3. Select Workstation Setup.

Workstation Setup Parameters

1. Barcode Regulation: (Recommended)

Fill in "Barcode Regulation" based on the serial number mask which is applied on each PCB serial number barcode label. If blank, no serial number will be validated for all PCB serial scanning.

2. Scanning Behavior: (Compulsory)

• Scan by Later Workstation: All workstation material placements can be recorded with the next Workstation(s).
• Must Scan At this Workstation: All workstation material placements are required to be recorded at this Workstation before reach and/or scan at next Workstation(s).
• Scan for Previous Workstation: All this workstation material placements will be recorded with the previous Workstation placements.

3. Scan Board/Panel: (Compulsory)

Select the Scan Board/Panel for both 1^st Side and 2^nd Side

• Board: Each individual PCB board number.
• Panel: Each PCB panel number.
• Serial: Each PCB serial number.

4. Scan Extra S/N: (Compulsory)

Define if extra serial need to be scanned. If it is required to scan the PCB boards additional barcodes such as, the package label, select Yes. Default is No.

5. S/N Regulation: (Required if Scan Extra S/N is Yes)

Define the serial number barcode regulation.

6. Completed MSD: (Required if MSD control is needed)

Default is No.

Note: MSD control is only applied to the workstation(s) prior reflowing process.

7. Scan Side: (Required if Scan board/Panel is "Yes")

Define which production side(s) need to be scanned.

• 1st Side: First PCB production side or One PCB production side.

I.e. Such as PCB ’

s TOP side production only which do only have material placements on one PCB side.

• 2nd Side: Second PCB production side.

I.e. Such as TOP side can be called 2^nd Side as it is the second production side after BOTTOM side placement finished.

• 1^st& 2^nd Side: Top and Bottom side.

I.e. Both production sides required to be scanned at the same Workstation.

8. Scan Material: (Compulsory)

 

• Select Material Barcode (For plant which used PTS format material label that included a unique printed PTS material barcode).
• Select SSCI P/N (For plant which might used standard plant approved / developed material label that included printed SSCI Part Number barcode).
• Select Manufacturer P/N (For plant which might used manufacturer provided label that included printed manufacturer Part Number barcode)

9. Process: (Compulsory)

Select the type of process for this workstation:

a. SMT: For SMT Machine workstation.

b. Hand Load: For Manual process workstation.

c. AI: For Auto Insertion workstation.

NOTE: Different setup option defines different material loading process. Refer to the Load Material work instruction for more detail.

10. Device ID: (Optional)

Enter any integer from 0 to 999 according to the SFDC setup. If the generic attribute is set for higher device numbers using the base 34 system, the device ID may go from 0 to ZZZ.

11. Select Change to set up this workstation.

12. Select History to check the log for the change of setup parameters.

Define Pick List

This module allows the user to assign the early prepared/loaded SMT placement program into a Workstation under the specific Production Line.

Figure 20: Select Picklist for Workstation

 

1. Select the production line from the production Line list.

2. Select the workstation, then right-click to open the pop-up menu.

3. Select Define Picklist.

4. Enter the keywords for Picklist name.

5. Select Search to search Picklist name.

6. Select the Picklist name to view material placements with reference designator listing.

 

Figure 21: Show Picklist Option

 

7. Select " +

" to assign the selected picklist into the Workstation.

NOTE: For additional Picklist information, see the SMT Part Traceability work instruction.

Location mapping

This sub-module is designed to map PTS workstation with SFDC location, so that SFDC will forward serial number information to pre-mapped PTS workstation upon board scanning, which helps to avoid duplicate board scanning and improve production efficiency.

To map a PTS workstation with a SFDC location, please select the workstation of a production line, and right-click to open the pop-up menu then click on Location Mapping.

Figure 22: Location Mapping Interface

1. To update an existing mapping, double click on existing mapping; edit the information, then select Update.

2. To delete existing mapping, select Delete.

3. To configure a new mapping, select Add and a new line will be created.

• MES User ID (Mandatory): SFDC user ID at MES. Select from the drop-down list.
• Location Name (Mandatory): Fill in SFDC location name that to be mapped with selected PTS workstation.
• Device ID (Optional): Fill in SFDC Device ID.
• Select Update to complete the mapping or Cancel to exit.

 

Set Production On/Off-Line

Set Production On-Line

• Once the user has the production line and workstation ready, the production line must be set to" On-Line" mode to start work order production. The user cannot load material or scan board if the production line is off.

 

Figure 23: Work Order Selection When Set Production On-Line

 

1. Select the production line to be set on line from the production Line list.

2. Open the pop-up menu by right-clicking, and then select Set Production online.

3. Enter a released Work Order number, if known, or Select the work order from the list by selecting Show.

4. Select the Work Order (you can view the BOM detail by selecting the " +

" at the left).

5. Select the " +

" at the right to select the Work order.

6. Select Check in the BOM/PL column to verify the BOM against the defined picklist and vice versa, below two sessions, if there are unmatched items.

 

Figure 24: Select Work Order

 

Figure 25: Show BOM/PL Validation

 

• Items that do not exist in BOM

To compare and validate all material placements in SMT placement program (i.e. PickList) that does not exist in ERP BOM.

• Items that do not exist in PickList

To compare and validate all material placements in ERP BOM that does not exist in SMT placement program (i.e. PickList).

7. Fill the required Work Order with associated production ECN.

8. Select On-line to set the production line online after confirming the Work Order and ECN selection.

NOTE:

If the work order BOM components do not match the defined picklist , the user will need to follow confirmation and update accordingly.

• Confirm that the Work Order you enter/select is associated with the latest ECN.
• Confirm the Picklist defined is correct.

 

Set Production Off-Line

Once the work order is completed on the production line, the production line needs to be set to Off-Line mode.

1. Select the production line to be set on line from the production Line list.

2. Open the pop-up menu by right-clicking then select Set Production offline.

3. Choose Set Production On/Off Line functional module.

4. Select Off Line to set the line offline.

 

Figure 26: Setup Production Offline

 

Load All

This module allows the user to load all materials to the workstation under the following conditions.

1. Set the production line offline (do not unload materials).

2. Change setting for the workstation if needed.

3. Set the production line to online again.

4. The user can use the "Load All" function to load all materials to the workstation.

NOTE: The user can only load all when not using the unload function.

NOTE: If some materials are invalid/expired, those materials will fail to load if using the "load all" function. All other valid materials will load successfully.

 

Figure 27: Load All

 

1. Set the production line to to online from the Production Line list.

2. Open the workstation lists by selecting the " +

" at the left.

3. Open the pop-up menu by right-clicking on the workstation, and then select Load All.

4. The information will display if the Load All function succeeds.

5. The user can check the loaded material at the page "Load Material Report."

Further Information

This completes PTS Production Setup information. For further information on a specific functional area refer to Intranet.

SOP-5-I-PTS0010_C_R3_Production Load Material

SOP-5-I-PTS0011-C_R3_PST_PRD_Production_Scan_Board

SOP-5-I-PTS-0012-C_R3_PST_PRD_Production_Rework_Record

SOP-5-I-PTS0014_Define_EZ_Pick_List

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Document Revision History

Date	Author	Title	Version	Change Reference
01/08/13	Helena Wang	Technical Writer	1.0	Initial SO Work Instruction
17/02/14	Ashley Martin	Technical Writer	1.0	Review and Format
28/02/14	Elaine Fonaro	Technical Writer	1.0	Format for WIKI
04/03/2016	Elaine Fonaro	Technical Writer	v 1.10	Updated Oracle Occurrences to ERP