Analysis of Alternative Rework Strategies for Printed Wiring Assembly Manufacturing Systems
Klegka, John S.
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This paper presents a model for predicting the cost of test, diagnosis, and rework activities in the manufacture of printed wiring assemblies (PWA's). Rework is defined as all actions taken to correct or improve the basic assembly process. These actions may include those of inspectors and solder touchup technicians who do not add value to the PWA, but whose actions are required in order to produce acceptable yields from the manufacturing process. Two alternative rework strategies for contemporary PWA manufacturing systems are presented: terminal rework and distributed rework. Rework may occur after all assembly operations have been accomplished (terminal rework) or it may be distributed throughout the assembly process. This paper allalyzes the economic basis for deciding between the two rework strategies. The paper assumes that the only reason for utilizing distributed rework is to reduce the cost of producing acceptable PWA's, otherwise the cost of the distributed rework effort cannot be justified. The paper presents a model of each rework strategy. The effect of each strategy upon first pass yield (FPY) of the manufacturing process is discussed. The effect on FPY is then used to evaluate the economic benefit of each rework strategy as an aid in deciding which strategy to use. The increase in FPY needed to justify distributed rework is calculated.
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