Des cas industriels récents ont montré que certains fabricants ont connu des défaillances fonctionnelles sur des lots entiers de PCBA en raison d'un buzzer manquant. (Référence SPK) during the SMT process. As a leading one-stop PCBA solutions provider, Fully Hong has conducted an in-depth investigation into such failures and implemented robust mistake-proofing systems that eliminate these issues at the source.
1. Root Cause: Why Was the Buzzer Not Mounted?
The Fully Hong engineering team reverse-engineered the failure and traced it to a series of breakdowns across three critical stages: design, production, and quality control.
✅ Key Findings:
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Design Deficiency:
The PCB pad supported both SMT and DIP processes, but the preferred assembly method wasn’t clearly specified. -
Production Misinterpretation:
The English BOM description differed from the Chinese production interface, causing SMT operators to incorrectly assume the component was to be surface-mounted. -
Quality Control Oversight:
IPQC failed to verify the assembly route. The DIP workstation assumed the buzzer had already been mounted via SMT.
2. Fully Hong’s Preventive Mistake-Proofing Mechanisms
At Fully Hong, we’ve developed a multi-layered quality assurance framework that ensures zero component omission—especially for hybrid-process parts such as buzzers.
Triple-Layer Mistake-Proofing System
1. Smart Design Review System
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Automatically detects components that support both SMT and DIP
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Enforces mandatory designation of preferred process (Par exemple, “DIP ONLY”)
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Gerber files include auto-generated process-layer warning markers
2. Production Execution Safeguards
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Multilingual BOM auto-conversion system (supports 12 languages)
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MES system validates process routing in real-time
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SMT machines automatically ignore non-SMT component positions
3. Full-Process Quality Gating
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First Article Inspection follows “Triple Verification” (Nager / Drawing / Physical Sample)
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AOI program trained to detect hybrid-process components
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Handover checkpoints require dual-signature confirmation between stations
3. Why Choose Fully Hong?
We have systematized our manufacturing processes to ensure consistent, high-reliability results for all your PCBA projects:
✅ 100% identification accuracy for hybrid-process components
✅ <0.01% missing component rate — among the industry’s best
✅ 72-hour rapid response mechanism for issue resolution
📢 Experience Our Quality System for Yourself
➡️ Book a factory tour
➡️ Request our “High-Reliability PCBA Manufacturing White Paper”
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