SOP-42Q-MES0048 Production Part Traceability
This edition applies to MES15 Portal 1.0 Application and all subsequent releases and modifications until otherwise indicated in new revisions.'
Contents
- 1 Production
- 2 Production Part Traceability
- 3 Appendix A: Load Material Error and Resolution List
- 4 Appendix B: Scan Board of Error Message and Suggested Solutions
- 5 Further Information
- 6 Document Revision History
Production
This edition applies to MES 15 Portal1.0 and all subsequent releases and modifications until otherwise indicated in new revisions.
The Parts Traceability System (PTS) is one of the applications within the MES suite of tools. It was developed to meet the demands of customers to provide component level traceability as well as to provide some required quality controls. This system plays a very important role in automating the production lines and raising productivity as well as enforcing rigorous product quality control. It has been implemented to many Sanmina plants across the globe. This application and the features it provides continue to evolve, as the changing technologies used for the SMT process equipment tools become more detailed and rich in functionality. There is and will continue to be a requirement to support the older technology tools. We strive to provide the flexibility to support each of the line types and provide the different and many levels of traceability required for the business.
Production Part Traceability
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 Sanmina sites may have minor or specific process changes that will be documented at the site level.
- On line help is available in PTS.
- This work instruction is applicable to all PTS MES15 only.
Assumptions
- All production materials (included feeders if applicable) would be unloaded from workstation after production end.
Prerequisites
1. Complete the PTS Getting Started – Basic Navigation Work Instruction, SOP-5-I-PTS0001.
2. PTS Production Line environment setup is completed and under on-line state. See SOP-5-I-PTS0009.
3. Material Reels are labeled in PTS format correctly. See SOP-5-I-PTS0002.
4. All the feeders are labeled and been setup correctly in PTS. See SOP-5-I-PTS0015-1.
Overview
This overview explains the material verification logic flow in PTS before the materials are being loaded into workstation.
| Tasks | Purposes | References |
| 1. a. Defined picklist (listing of materials placement) in PTSWEB > EZPicklist or convert placement programs (as depends on the machine type). b. Assigned each defined picklist to the associated workstation under the required production line in PTSWEB > Production Setup. |
To provide what materials will be used and what placement environment will be setup for verification and future traceability purposes. |
a. SOP-5-I-PTS0014 Define EZ Pick List b. SOP-5-I-PTS0009 Production Setup |
| 2. Assigned the correct Work Order and ECN (Engineering Change Notification) when set the required production line in PTSWEB > Production Setup. |
To identify a BOM to be used for SSCI and AML materials verification in PTS material loading. |
SOP-5-I-PTS0009 Production Setup |
An error message will display during material loading on either PTSWEB > Load Material or NetDC data collector for any failure such as AML material verification failed, feeder type and corresponding records cannot be identified, and material quantity low level status alert etc. Please see Appendix A for the complete errors listing and suggested solutions.
Confirm High Value QTY (PTS)
When production line is set offline, system would unload high value material automatically. This location is used to input remaining quantity for high value material.
NOTE: if the production line includes high value material the system will prompt user "Please confirm remain qty of high value material!"
After the high value material unloads, the user should request to confirm the reel remaining qty in this function. Material reel will change to on hold status until quantity conformation is set.
Prerequisites
To prevent the operator from entering the wrong quantity, please go to PTS "System Settings" page and set High-Value Tolerance > (%) and High-Value Tolerance < (%) parameter first in order to keep the remaining qty correct. It will prompt the correct range when the qty operator entered is out of tolerance range.
1. To access the Confirm High Value QTY (PTS) page, navigate to Production > Production Part Traceability > Confirm High Value QTY (PTS).
Figure 1: Confirm High Value QTY (PTS)
1. All unconfirmed high value materials will show in the list.
2. Search the specified high value material by searching Workstation Name, Barcode or Part Number.
3. Double click the line, and then enter the high value material quantity into the Confirm Qty column.
4. Select Update to confirm the QTY.
5. Once successfully updated, the high value material information will disappear from the list.
6. Select Cancel to exit.
NOTE:
- The item Confirm Qty will be bordered in red.
- Update is disabled if the confirm Qty is invalid.
- The unconfirmed high value material cannot be used in load material.
- If unconfirmed high value material is used, the message "Please confirm the high value Qty" will display .
Break Panel
Once the production line is set to scan the panel at the end of the appointed line, the operator needs to use this function to break the panel. Panel number refers to the Picklist board number. The break panel operator needs to scan panel barcode and the all boards barcode. Board barcode needs to match with regulation in workstation setup and board qty refers to Picklist.
1. To access the Break Panel (PTS) page, navigate to Production > Production Part Traceability > Break Panel (PTS).
Figure 2: Break Panel
1.
- Scan the panel barcode which had been scanned in Scan Board Barcode module.
- Once the panel barcode is correct, the Data for Work Oder, Workstation, Break Qty will display.
Figure 3: Break Panel Data
- Scan each individual board barcode associated to the panel.
- Select Submit.
- Select Reset to re-scan the Panel barcode.
Rework Record (PTS)
1. To access the Rework Record (PTS) page, navigate to Production > Production Part Traceability > Rework Record (PTS).
Figure 4: Rework Record (PTS)
1. Scan or input the product board barcode to be reworked.
2. Enter the PCB reference designator to be repaired, then the old component and old code will display.
3. Scan or enter the new material barcode for updating the material placement record.
4. Enter the Remark information.
Figure 5: Rework Record- Submit
5. Select submit.
6. The system will display the result on the board rework screen.
NOTE: PTS will update the material with its new assigned material barcode.
Replace Board Barcode
The purpose of this module is to replace the scanned board barcode under various circumstances such as barcode label replacement for warranty board and damage barcode label.
1. To access the Replace Board Barcode page, navigate to Production > Production Part Traceability > Replace Board Barcode.
Figure 6: Replace Board Barcode
Figure 7: Replace Barcode- Submit
1. Scan or enter the original barcode.
2. Scan or enter the new barcode.
3. Select Send.
4. The result will display in the list on the Replace Barcode main screen.
Board Scanning Status
Board scanning status will show the latest scanned board on the production line.
1. To access the Board Scanning Data page, navigate to Production > Production Part Traceability > Board Scanning Status.
Figure 8: Board Scanning Status
1. Enter the first 4 characters of the line name.
2. The production line name will display.
3. Select the production line.
4. The scanned barcode information will display in the Board Scanning Status list.
Touch
This module is the entrance for Load material, Load SMT Tools, Material Queue, Scan Barcode, Prepare Material, Unload Material, and Load Prepare Material.
1. To access the Touch page, navigate to Production > Production Part Traceability > Touch.
Figure 9: Touch
Load Material
1. To access the Load Material portlet, select the Load Material function from the Production > Production Part Traceability > Touch menu.
Figure 10: Load Material
Workstation: Input or scan the Workstation, the detailed items for load material will display.
NOTE:
- For SMT workstation, the fields will contain Material barcode, feeder barcode, and station;
- For AI workstation ,the fields will contain Material barcode, station;
- For HL workstation, the fields will contain Material barcode.
Figure 11: Load Material to a SMT Workstation- PTS Web
- Material Barcode: Scan (or Input manually) material reel PTS barcode.
- New Feeder Barcode: Scan New Feeder Barcode. (Apply to the feeder which will be loaded to the defined SMT machine slot).
- Old Feeder Barcode: Scan Old Feeder Barcode. (Compulsory in replenishment base on following cases: 1. to update what other feeder has been used before replenishment. 2. To advice same feeder will be used after replenishment...)
- Station Location: Scan the station barcode. (I.e. SMT machine slot, as formatted in SMT placement program.)
- Request Material: This field will show if set Yes at the Work Station Setup.
- Select Send.
- "Material has been loaded" will display after material loads successfully.
- The detailed information can be seen at the "Load Material Report" page.
Note 1: Feeder can be unloaded Individual and Checkout "Unload All" blue button to unload all feeders barcode (feeder name) at the function Unload material. See section 7 for details.
Note 2: The MSD Floor Life is applicable if the material has been classified MSD level and MSD controlled option is activated in PTS. MSD Floor Life is indicated in green (the remaining time on production before the material is sensitive to moisture and/or red (the time recorded on such material is been sensitive to moisture). See SOP-5-I-PTS0021 for details.
Note 3: The workstation floor life (the Green bar indicator as shown in Figure 4) is resulted when all loaded materials are not sensitive and/or this MSD controlled option is not activated. It is measured using the least material MSD Shop Floor Life of the loaded material as guidance.
Note 4: If user defined thickness and orientation do not match with SMT defined, the information will be prompted with red font at the top side of the screen.
Note5: If SMT program file has defined material thickness and orientation but without defining in Manufacturer Information, system is not to appear prompt information at top side when loading material.
Load SMT Tools
This function is used to load jig for next scanning board.
Prerequisites
- Set Jig Control=Yes under System Setting(PTS) page;
- Jig barcode has been created;
- Mapping has already been created for this barcode.
1. To access the Load SMT portlet, select the Load SMT Tools function from the Production > Production Part Traceability > Touch menu
Figure 12: Load SMT Tools- PTS Web
- Input or scan Workstation Available.
- Input corresponding jig barcode in Jig Barcode textbox.
- Select Enter.
- System will auto verify whether the jig barcode can be loaded to the selected workstation based on defined mapping. If the jig barcode is correct, it will then be loaded successfully. An error message will show up at the top side if system fails to load jig.
- If the JIG has been loaded to the workstation, then the user can enter the workstation and JIG barcode again to unload the Jig from this workstation. See figure 13.
Figure 13: Unload SMT Tools- PTS Web
The JIG barcode will be unloaded after selecting the Unload Icon (blue arrow).
Prepare Material
To prepare material in advance while production line either in offline mode or online mode.
1. To access the Prepare Material portlet, select the Prepare Material function from the Production > Production Part Traceability > Touch menu
Figure 14: Prepare Material- PTS Web
1. Workstation: Scan (or Input manually) Workstation.
2. Work Order: Scan (or Input manually) Work Order.
3. BOM P/N, ECN Number: If workstation and work order are correct, BOM P/N and ECN number will show automatically.
4. Barcode: Scan or input manually material barcode.
5. Feeder: Scan or input manually new feeder barcode.
6. Station Location: Scan or input the station barcode. (I.e. SMT machine slot, as formatted in SMT placement program.)
7. Select Enter.
8. If prepared successfully, the user can search the information in the "Prepare Material Report" page.
Load Prepare Material
Load prepared material singly.
1. To access the Load Prepare Material portlet, select the Load Prepare Material function from the Production > Production Part Traceability > Touch menu
Figure 15: Load Prepare Material- PTS Web
1. Workstation: Scan (or Input manually) Workstation.
2. New Feeder: Scan New Feeder Barcode. (Apply to the feeder which will be loaded to the defined SMT machine slot).
| 3. | Input Station Location number. |
| 4. | If request material is needed, select the checkbox. |
| 5. | Select Enter. |
| 6. | The successful prompt information will display at the top of the page. The user could also go to the "Load Material Report" web page to check if the load material was successful by entering the same information as prepare material. If load prepare material was successful, the information (before prepared material) will disappear from the "Prepare Material Report." |
NOTE1: Prepare material before load prepare material or user can load material directly.
Unload Material
Unload Feeder/Material from Workstation.
1. To access the Unload Material portlet, select the Unload Material function from the Production > Production Part Traceability > Touch menu
Figure 16: Unload Feeder with Material
2. Make sure the Unload All is not checked.
3. Scan or enter the Workstation.
4. Scan or enter the Barcode.
5. Check the High Value box to input the Confirm QTY if needed.
6. Select Enter to unload material.
Figure 17: Unload All Material from Workstation
1. With the Unload All checked.
2. Scan or input the Workstation.
3. Select Enter to unload all materials.
NOTE: Check the Unload All button to unload all materials. (USED WITH CAUTION)
Material Queue
This functional is used to batch joint materials.
Prerequisites
- Set Allow material queue =Yes under "System Settings (PTS)" page;
1. To access the Material Queue portlet, select the Material Queue function from the Production > Production Part Traceability > Touch menu
Figure 18: Material Queue- Add to Queue
1. Workstation: Scan or input the Workstation.
2. Station: input the Station. The loaded material will show automatically.
3. Confirm Qty: Input the confirm Qty.
4. New material Barcode: Input or scan the New material Barcode,
5. Select Save.
6. If the save is successful, the material queue will like the following. See figure 19.
7. Select Cancel to exit.
8. Select Return to return to the previous page.
Figure 19: Material Queue- Queue List
9. Select Unload to delete the material list if needed.
NOTE1: The first material must be loaded and cannot be unloaded from the Material Queue list.
NOTE2: Material queue max reels and Material queue max Boards cannot be larger than that values set at the system settings page if Allow Material Queue is YES.
Scan Barcode
After the production line has been activated the materials loaded in PTS, go to the Scan Barcode module .
1. To access the Scan Barcode portlet, select the Scan Barcode function from the Production > Production Part Traceability > Touch menu.
- General Board/Panel/Serial barcode scanning
Figure 20: Scan Board Barcode
1. Input the Workstation name, and then select Enter. The BOM, Picklist, and Work Order information will display. The field Board Barcode will show and can be edited.
2. Scan the PCB board/panel/serial barcode (as per Workstation Setup defined in Production Setup module; Please refer SOP-5-I-PTS0009 Workstation Setup)
Figure 21: Scanning Prompt on Successful Board Barcode
3. After input barcode is verified (including the barcode format and if any previous scanning has been processed), a successful prompt will display at the top of the screen.
Extra Board Barcode Scanning
Figure 22: Scan Board Barcode- Scan Extra S/N
1. Scan Extra (Extra serial number (i.e. Package label)) is required to scan if Scan Extra S/N has been defined on the current workstation setup.
2. Select Send.
Replenish Material
It is compulsory to update all replenish materials and feeders in all PTS online production environment. As described in Load Material, new replenish material will be replaced after input either/both new material barcode and feeder barcode. See following sample scenarios for illustration.
| Scenario 1: (Process) SMT (Material) New material package with unique PTS material barcode. (Feeder) Same feeder will be used for refilling purpose. |
|
| Material Barcode | Scan new PTS material barcode from new material package. |
| New Feeder Barcode | Scan the existing loaded feeder barcode. |
| Old Feeder Barcode | Scan the existing feeder barcode. |
| Old Remain Qty | Click AUTO to retrieve from PTS material record. |
| Station Location | Scan SMT slot position barcode. |
| Scenario 2: (Process) SMT (Material) New material package with unique PTS material barcode. (Feeder) Different feeder will be used for refilling purpose. |
|
| Material Barcode | Scan new PTS material barcode from new material package. |
| New Feeder Barcode | Scan new feeder barcode. (i.e. Feeder will use after replenishment).. |
| Old Feeder Barcode | Scan last used feeder barcode (i.e. Feeder which used before replenishment). |
| Old Remain Qty | Click AUTO to retrieve from PTS material record. |
| Station Location | Scan SMT slot position barcode. |
| Scenario 3: (Process) Auto insertion (Material) New material package with unique PTS material barcode. (Feeder) New feeder barcode. |
|
| Material Barcode | Scan new PTS material barcode from new material package. |
| Station Location | Scan station barcode. |
| Scenario 4: (Process) Hand Load (Material) New material package with unique PTS material barcode. |
|
| Material Barcode | Scan new PTS material barcode from new material package. |
Appendix A: Load Material Error and Resolution List
| Error prompt | Comments (R: Reason S: Solution) |
| Feeder does not match! | R: Feeder type mismatches what defined in feeder picklist. S: To check the feeder type this defined in Feeder Maintenance. (Ref: SOP-5-I-PTS0015-1 Feeder Maintenance) or S: To check the feeder type associated to this material in SMT placement program. |
| Feeder is now in use! Material is now in use! |
R: Feeder or Material is still in used or loaded at affected online or offline workstation. S: Unload the affected feeder by first find out which production line and what workstation has such feeder loaded then unload the feeder through proper unloading process as described in section 6. |
| Station does not exist! | R: Invalid or Mismatch material loading location as what defined in feeder picklist. S: To check the station (or slot) location this defined in feeder picklist. |
| Feeder does not exist! Old feeder does not exist! |
R: Feeder barcode record is not found in PTS. S: To insert the feeder barcode and assigned the feeder type in Feeder Maintenance. (Ref: SOP-5-I-PTS0015-1 Feeder Maintenance) |
| Station or Designator does not match! | R: Defined picklist (material p/n and reference designator based on station setup) is different than BOM (material p/n and reference designator). S: To check and compare the consistency of feeder picklist and production BOM. |
| Old feeder does not match! | R: Feeder barcode record is not defined or found in PTS. S: To check if such old feeder barcode is been used at the same station. Or S: To check if such old feeder barcode record is been defined in PTSWEB > Feeder Maintenance. |
| Material barcode not found! | R: As prompted. S: To check if the affected material barcode is existed in PTSWEB > Material Report. Consult with material labeling team for re-label if necessary. |
| No old feeder in workstation! | R: As prompted. S: Not required to scan any feeder in "Old Feeder Barcode". |
| The new feeder needs to be reworked! | R: Affected feeder is required to feeder maintenance. S: See SOP-5-I-PTS0015-I Feeder Maintenance. |
| Material isn’t in AML! | R: Such material is not in BOM’s Approved Material List. S: Enable AVL after obtained approval from Quality team. See SOP-5-PTS0006-C Incoming Enable AVL. |
| Old feeder must be released! | R: As prompted. S: Re-input the old feeder in "Old Feeder Barcode". |
| No BOM item | R: Incorrect BOM loaded when set PTS production online. S: To check if the work order has been assigned to the correct BOM p/n. |
| No material in picklist! | R: As prompted. S: Re-define the picklist by first set the affected production offline. |
| Material has been run out | R: Attempted new input material is been recorded zero quantity in PTS. S: Cycle-count the material and update the material in PTSWEB > Reprint Material Label. |
| Material has been expired | R: Attempted new input material is been expired. S: Baking process and history required in PTSWEB > Unfinished MSD Handling. |
| Material not found in BOM | R: Attempted new input material (its SSCI P/N) is not found in BOM. S: S: To check if the work order has been assigned to the correct BOM p/n. |
Appendix B: Scan Board of Error Message and Suggested Solutions
| 2. Error prompt | 3. Comments (R: Reason S: Solution) |
| 4. Incorrect BOM! | 5. R: Loaded materials which listed from SMT picklist and/or its reference designator are not defined in the selected ECN BOM. 6. S: Verify the materials are all correctly defined in both SMT picklist program with associated designator and ECN BOM under PTSWEB > Show BOM. 7. (Ref: SOP-5-I-PTS0024-1 Inquiry & Reporting) |
| 8. Check component loaded. | 9. R: Component which has been attempted to load is already expired. 10. S: Load the alternative material package which comes with a valid production shelf life and condition. 11. (Ref: SOP-5-I-PTS0010_C Production Load Material) |
| 12. Only <# of loaded materials / Total # of materials should load> Material Loaded! | 13. R: Incomplete number of material(s) loaded to the scanning workstation. 14. S: Load the reported missing materials to the affected scanning workstation. 15. (Ref: SOP-5-I-PTS0010_C Production Load Material) |
| 16. This board floor life has expired. | 17. R: The PCB is been expired and not applicable on shop floor production. 18. S: Oven baking required to set the temperature and humidity conditions back to specifications. 19. (Ref: SOP-5-I-PTS0021 MSD_Control) |
| 20. Check is panel? | 21. R: Incorrect scanning behavior setup on workstation.. 22. S: To check the Panel option is selected under Workstation Setup > Scan Board/Panel. 23. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 24. Incorrect Panel Barcode Format | 25. R: Incorrect barcode regulation setup on workstation.. 26. S: To check the Barcode Regulation is been correctly setup under Workstation Setup > Scan Board/Panel. 27. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 28. Incorrect Barcode Format | 29. R: Incorrect barcode regulation setup on workstation.. 30. S: To check the Barcode Regulation is been correctly setup under Workstation Setup > Scan Board/Panel. 31. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 32. Incorrect Panel Extra S/N Format | 33. R: Incorrect barcode regulation setup on workstation.. 34. S: To check the S/N Regulation is been correctly setup under Workstation Setup > Scan Board/Panel. 35. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 36. Incorrect Extra S/N Format | 37. R: Incorrect barcode regulation setup on workstation.. 38. S: To check the S/N Regulation is been correctly setup under Workstation Setup > Scan Board/Panel. 39. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 40. Panel Not Yet Released | 41. R: Affected panel is not been scanned through all workstations before Break Panel process. 42. S: To check the panel is been went through all workstations scanning prior breaking panel. |
| 43. Duplicated Serial Barcode | 44. R: As prompted. 45. S: To investigate, re-issue and reprint a unique serial barcode for scanning. 46. |
| 47. Duplicated Barcode | 48. R: As prompted. 49. S: To investigate, re-issue and reprint a unique board barcode for scanning. |
| 50. Barcode Length can’t exceed 48! | 51. R: As prompted. 52. S: Re-define the barcode length to less than 48 alphanumeric size in Workstation Setup > Barcode Regulation. 53. (Ref: SOP-5-I-PTS0009-C_R3_C Production Setup) |
| 54. Previous workstation not scanned! | 55. R: Affected unit is not scanned at previous workstation. 56. S: Scan the affected unit at the missing scanning workstation. |
| 57. This MSD material has expired! | 58. R: Loaded material(s) is expired and is not allowed to use in production. 59. S: Unloaded the affected materials for further material investigation and load a valid such as baked or sealed material. 60. (Ref: SOP-5-I-PTS0021_MSD_Control) |
| 61. Can’t Generate continous serial barcode | 62. R: Continuous serial(s) is been generated and been scanned. 63. S: Verify the scanning always start from the smallest serial on the panel. 64. |
Further Information
This completes Production Load Material information. For further information on a specific functional area refer to SanminaNet.
Document Revision History
| Date | Author | Title | Version | Change Reference |
| 08/01/13 | Helena Wang | Technical Writer | 1.0 | Initial SO Work Instruction |
| 02/17/14 | Ashley Martin | Technical Writer | 1.0 | Review and Format |
| 02/28/14 | Elaine Fonaro | Technical Writer | 1.0 | Format for WIKI |
