The factory production equipment continued to come on-line at a continuous rate over the last quarter, finalizing in early December with the installation of our XRT™ System 7000. This latest and greatest offering from XRT automates the registration of highlayer count panels utilizing two x-ray cameras to view multiple targets within a multilayer PCB panel, analyze data, corrects and drills registration holes for a fully automatic production process. When the panel is 24X30 and is 30 or more layers, even the “discriminating laminator” and driller appreciates this help.
Other production equipment incrementally added to FCI production capacity includes 2 Plasma machines for a total or 3, Cobra Lasers went from 1 to 2, Camtek AOI capacity doubled, as have the Emma Flying probe electrical testers, which not only increased board size capability to 26 x 32, but also allow Kelvin testing < 1 ohm capability. Out on our fully functional plating line is a new dedicated Tin Tank IPS (Integrated Process System) which replaces the Tin Lead Tank and dramatically reducing the heavy metals in our waste, supporting FCI’s position to be environmentally conscious.
The final piece of equipment is our new ink jet printer, the ideal answer to legend printing, and accurately logging number generation for serialized assemblies. With very minimal operator intervention, and high reliability, this addition is the ideal frosting on the manufacturing cake.
Personnel staffing levels and readiness are complete, re-qualifying all operators to IPC-610D, J-Std and other process specs such as electroplating, specimen preparation or lamination and layup. The wall outside the assembly area is adorned with recent training certifications earned by personnel.
Lean manufacturing methods are embraced across the production facility, as observed at the entrance of the plating room, carts with materials and travelers stand ready for the next processing step.
A busy area at FCI continues to be the HASS center. FCI, a name synonymous with high quality and high reliability products, validates products under temperature and vibration testing to make sure both the designs and manufactured products exceed demanding real world criteria.
Automated SMT Line and Hand Assembly Areas are fully staffed to support FCI’s assembly and “Up-level” integration strategy. This area operates with increased understanding of FOD control methods in addition to adherence to IPC-A- 620, IPC610, and J-Std-001.
Layup is another area following sound FOD control methods. Having been re-constructed with ergonomic contaminate free tables and ceiling the HEPA filtered environment maintains the proper level of FOD control starting with Plasma cleaning materials entering the room.
QC Lab runs daily audits on each chemistry throughout the factory before each production day. When finished products are ready for QC checks they provide a complete service, from making mounts and performing microscope inspecting of each coupon’s cross section to running surface level tests for intra and post assembly operations.
The pace continues to increase, now having completed all but one customer requalification all capability is in place and capacity has returned to levels before our event last summer. With the Final pieces now all in place the future is looking bright as 2009 ends, and with a promising 2010 ahead it will surely be an excellent year for FCI, and its valued customer base.
We have finished this latest segment of our 46 year history. As always, we extend our sincere Thanks to our select Defense and Aerospace customers who have worked with us through our recovery, and continue to place their business with us.
The invitation to give us a call, come in, and see our factory 1st hand is always open. Lets make some product together.
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