Elimination of the P3 of Solder Joint and Assembly Inspection,

Throughout our industry we will find an exsorbent amount of hardware backlog that is caught up in a cycle that cannot be used without a great amount of rework. This hardware is generally referred to as work-in-process WIP, however it should be referred to as procrastination hardware, due to the fact that it is rejected in many cases due to the lack of decision making. I call this the P3 syndrome Perfection Procrastination and Paralysis. The problem that has arisen is that everyone wants high reliable hardware, but their assembly line is working to a lesser requirement without strong process control or with a lack of control. The inspections are inspection to the high side of the high reliability specification and find it easier to reject hardware than to make a decision on acceptability. This results in unnecessary rework and touch up and finally the loss of hardware. There are some points required to correct this dilemma and that is with a well planned in process assembly and inspection program, one that controls the manufacturing process from beginning to end and then the use of one specification throughout the entire process. The final point is the calibration of inspectors and assemblers so they are decision makers and not procrastinators. Author