Missing Steps

Eight drilling machines are in place, two NC routers, one automated punch, one Cobra laser [out of two], one plasma [out of three] and we are printing and etching. Our new AOI machine is just amazing, false calls are down 90% [way to go Camtek] the new Emma bare board tester is busy and the lamination layup area is nearing completion. We really need to get the layup area  finished because the input needs to increase dramatically “yesterday”. The rebuilding process certainly provides challenges to the “patience impaired”. What is missing is the plating process. All the equipment is here and is being installed thanks to IPS and Chemcut keeping schedule. The bookbind hand line is wet and will be operational near term. The horizontal electroless is in the installation phase and will be operational along with the acid copper cells as quickly as we can plumb and run. Mil-p-50884 qualification methodology will be used internally. Our” daypack” is available on each machine to demonstrate suitability for operation. Assembly is very busy and the HASS machine is in constant use. Cooperation from Raytheon, Textron, Telephonics, GE and L3 has been crucial to our recovery. Technical support and advice where requested has speeded the process. Lessons have been learned and we will share them at a later date. Thanks to our personnel who are returning at a 100% rate as they are asked to return. Follow some of the pictures to get an idea of our progress or come on in when it strikes you.

Moving Ahead

Since last we spoke the plant has really come a long way. Building improvements are nearing completion. Give an engineer an opening and he will enter. The M&P group headed by Jay Sergo [left] and our Production Manager Joe Wilson have dramatically improved our layout. Until the new building is complete we will occupy about 49,000 square feet. Who thought it was an opportunity for Lean application, Manufacturing and M&P that’s who. The machinery and equipment arriving daily, is occupying prepared sites with all their needs met. Air, exhaust, electric is available upon delivery in the proper sequence. Our new 689 drills are large board format, which will be complimentary to our 50 inch press. Electrical flying probe is large board format and has had been immensely helpful on a couple of programs where the ability to fixture a 45 inch panel has reduced pogo pin testing. Four laminating press’s have been calibrated and are back in operation. The new plating room is ready to accept the automated electroless line, the book bind line and the pulse system. Variability has been the key design criteria, we expect greatly improved copper distribution due to our new anode mask system. Out put of the plating room is expected to more than double. Last but not least, the assembly operation has been moving ahead with very little interruption, new equipment has been added and testing and proof of all operations has been completed. We are calling our operators back to work, the return rate has been 100%. Our people and our key customers have been extremely loyal and helpful once again thank you for your support.

Gitten er done

Shipments have been on a steady incline. The focus of our Materials and Process group along with our Quality department has been on maintaining our high level of acceptance. Our customers demand and will receive at least as high an acceptance level as before the fire. FCI intends to support this requirement by using our standard specifications to direct activities. IPC-610 and J Std-001 are our principle guides to quality assurance in our assembly area. Eli Kim just returned from being recertified as an IPC and J-Std trainer examiner. Materials & Process engineering are responsible for all processes within FCI’s process map. Quality Control under Paul McDowell is responsible for auditing and certifying these processes. FCI is using a typical strategy of gathering key process indicators to expose process anomalies. Typically these indicators are not cause for rejection, but may be cause for rework and could become defectives in the case of an escape. An example of a process indicator being tracked is the number of shorts or solder spurs detected after wave solder. We have base line information and we are comparing today’s yield to yields before the fire. Our equipment has been cleaned, repaired or updated as required and calibrated in all cases. A variance in occurrences could indicate a change in process due to a change in equipment geometry when compared to baseline data. Positive trends are welcome [we are seeing those indicators] and will allow for reduced observations down stream. Paul and Eli are making increased observations using our multi axis X-Ray machine. If the hole fill is not correct we will know and be able to apply an immediate corrective action. Let’s talk people, specifically our people that had some time off due to the fire and who may be using a new piece of equipment or may have moved from one physical position to another. Eli will re train and recertify each operator on an accelerated schedule. Paul has training records for each operator. It is our intention to improve the qualification of each operator during the training and certification process. The goal is “ No Doubt” or mission assurance, which ever way you want to look at it, it is right every time.

Fire Update

Fire is one of the most feared natural occurrences known to mankind. FCI wishes to thank all the fire companies that responded along with our local officials. We had at least 8 fire companies respond and we wish to recognize them individually our gratitude to Warminster Fire Department, Warrington Township Fire Company #1, Horsham Fire Company, Enterprise Fire Company of Hatboro, Ivyland Volunteer Fire Company, Newtown Fire Association, Warwick Township Fire Company and Southampton Fire Company #1. Their dedication and skill mitigated what could have been absolutely devastating to our company. Due to the emergency response our losses were minimized. Our facility, which is 55,000 square feet, is arranged in a cellular fashion. Machinery, which in some companies would be arranged by departments, is arranged to serve a process. An example would be drills are not all in one spot; they are in or near the image area, test area, plating area where they serve the needs of the specific process map.  That lean concept allowed us to be shipping product 3 days after the event.  We at FCI are confident that our operations will be fully running as quickly as possible. When we measure what is most valuable to our company it is our people, our customers and our suppliers. FCI’s typical term of employment surpassing 15 years on the average is testament to how we value our people and our confidence has been reinforced. Customers like Raytheon, Textron and Telephonics make us smile. And talk about suppliers, Belfor our site clean up company is just excellent along with our prize suppliers Attotech and Chemcut where we are just amazed. We will keep every one updated directly or at this site. We are open for business and will be expanding our base of product offerings in the near future. Till then thanks for working with us.