Statistical process control integration systems and methods for monitoring manufacturing processes

• US 6,445,969 B1
• Filed: 01/09/1998
• Issued: 09/03/2002
• Est. Priority Date: 01/27/1997
• Status: Expired due to Fees

• Current Assignee: Circuit Image Systems, Inc.
• Original Assignee: Circuit Image Systems, Inc.
• Inventors: Leon, John, Kenney, Jim
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US09/005,259
• Time in Patent Office: 1,698 Days
• Field of Search: 700/28, 700/29, 700/30, 700/31, 700/32, 700/50-51, 700/52, 700/95, 700/96, 700/108-110, 700/117, 700/121, 702/82, 702/83, 702/84, 702/179-181, 295/641.1, 297/39, 295/661, 295/647, 29/33.M
• US Class Current: 700/108
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/5143 and means to machine product
• CPC Class Codes: Y10T 29/5148 including severing means
• CPC Class Codes: Y10T 29/515 to trim electric component
• CPC Class Codes: Y10T 29/5193 Electrical connector or terminal
• CPC Class Codes: Y10T 29/53174 Means to fasten electrical component to wiring board, base, or substrate

Abstract

A method and system for monitoring process parameters associated with a manufacturing or testing process. The system includes: at least one machine which is used in the manufacturing or testing process; at least one sensing device, coupled to the at least one machine, for measuring a process parameter associated with the at least one machine; and a controller, coupled to the at least one sensing device, for receiving and storing measured data from the at least one sensing device. The method includes the acts of: measuring a value of a process parameter associated with a machine used in the manufacturing or testing process; converting the measured value of the process parameter into a digital data signal having a specified data format; transmitting the digital data signal to a controller; and storing the digital data signal in a database.

Claims

1. A statistical process control integration system for monitoring and storing certifiable manufacturing process parameters associated with the manufacture of printed circuit board (PCB) manufacturing processes in use at multiple, geographically separate manufacturing sites comprising:

a preclean/scrubbing system at each of said manufacturing sites through which a copper panel is transported;

a proximity sensor for detecting a copper panel passing through said preclean/scrubbing system and generating a trigger signal;

a laminator at each of said manufacturing sites which laminates a sheet of resist onto a surface of said copper panel;

a photoprinter at each of said manufacturing sites which exposes select portions of said resist to light, thereby polymerizing the exposed portions of the resist, wherein the photoprinter includes a vacuum chamber;

a developing machine at each of said manufacturing sites for removing select portions of said resist from a copper panel, wherein the developing machine includes a developing chamber and a pressurized nozzle located inside the developing chamber for spraying a developing solution onto the resist;

an etching machine at each of said manufacturing sites for removing select portions of said copper panel, wherein the etching machine includes an etching chamber and a pressurized nozzle located within the etching chamber for spraying an etchant solution on the copper panel;

a stripping machine at each of said manufacturing sites for stripping resist from said copper panel, wherein the stripping machine includes a stripping chamber and a pressurized nozzle located within the stripping chamber for spraying a stripping solution onto the resist and the copper panel;

at least one sensing device coupled to each laminator, photoprinters, developing machine, etching machine and stripping machine, each such device measuring a controllable process parameter associated with the PCB manufacturing process at the manufacturing site in which said sensing device is located;

signal converters at each manufacturing site coupled to each of the sensing devices at each site to convert the output of each sensor to digital signal having a specified data format;

a digital communications network coupled to each of said signal converters;

a monitor located at a site geographically remote from at least one of said manufacturing sites and coupled to said digital communications network, said monitor, upon receipt and identification of said trigger signal, initiating a data gathering protocol for said manufacturing site, said monitor storing preset process parameters and comparing said preset values with the digital signal received from said signal converters and automatically calculating when a measured process parameter is not within a specified tolerance and providing a readout alerting an out-of-tolerance parameter; and

a recorder coupled to said monitor for storing certifiable manufacturing parameters received from each of said manufacturing sites including sites geographically remote from said monitor.

2. A statistical process control integration system for monitoring and storing certifiable manufacturing process parameters associated with the manufacture of printed circuit board (PCB) manufacturing processes in use at multiple, geographically separate manufacturing sites comprising:

a laminator at each of said manufacturing sites which laminates a sheet of resist onto a surface of a copper panel;

a photoprinter at each of said manufacturing sites which exposes select portions of said resist to light, thereby polymerizing the exposed portions of the resist, wherein the photoprinter includes a vacuum chamber;

a developing machine at each of said manufacturing sites for removing select portions so said resist from a copper panel, wherein the developing machine includes a developing chamber and a pressurized nozzle located inside the developing chamber for spraying a developing solution onto the resist;

an etching machine at each of said manufacturing sites for removing select portions of said copper panel, wherein the etching machine includes an etching chamber and a pressurized nozzle located within the etching chamber for spraying an etchant solution on the copper panel;

a stripping machine at each of said manufacturing sites for stripping resist from said copper panel, wherein the stripping machine includes a stripping chamber and a pressurized nozzle located within the stripping chamber for spraying a stripping solution onto the resist and the copper panel;

at least one sensing device coupled to each laminator, photoprinter, developing machine, etching machine and stripping machine, each such device measuring a controllable process parameter associated with the PCB manufacturing process at the manufacturing site in which said sensing device is located;

signal converters at each manufacturing site coupled to each of the sensing devices at each site to convert the output of each sensor to a digital signal having a specified data format;

a digital communications network coupled to each of said signal converters;

a monitor located at a site geographically remote from at least one of said manufacturing sites, said monitor storing preset process parameters and comparing said preset values with the digital signal received from said signal converters and automatically calculating when a measured process parameter is not within a specified tolerance and providing a readout alerting an out-of-tolerance parameter, and

a recorder compiled to said monitor for storing certifiable manufacturing parameters received from each of said manufacturing sites including sites geographically remote from said monitor.

3. A statistical process control integration system for monitoring and storing certifiable manufacturing process parameters associated with the manufacture of printed circuit board (PCB) manufacturing processes in use at multiple, geographically separate manufacturing sites comprising:

a laminator at each of said manufacturing sites which laminates a sheet of resist onto a surface of a copper panel;

at least one laminator sensor coupled to each laminator, for measuring a lamination process parameter and converting a measured value of the lamination process parameter into a first signal;

a photoprinter at each of said manufacturing sites which exposes select portions of said resist to light, thereby polymerizing the exposed portions of the resist, wherein the photoprinter includes a vacuum chamber;

at least one photoprinter sensor coupled to each photoprinter, for measuring a photoprinting process parameter and converting a measured value of the photoprinting process parameter into a second signal; and

a developing machine at each of said manufacturing sites for removing select portions so said resist from a copper panel, wherein the developing machine includes a developing chamber and a pressurized nozzle located inside the developing chamber for spraying a developing solution onto the resist;

at least one developer sensor coupled to each developing machine, for measuring a developer process parameter and converting a measured value of the developer process parameter into a third signal; and

an etching machine at each of said manufacturing sites for removing select portions of said copper panel, wherein the etching machine includes an etching chamber and a pressurized nozzle located within the etching chamber for spraying an etchant solution on the copper panel;

at least one etching sensor coupled to each etching machine, for measuring an etching process parameter and converting a measured value of the etching process parameter into a fourth signal; and

a stripping machine at each of said manufacturing sites for stripping resist from said copper panel, wherein the stripping machine includes a stripping chamber and a pressurized nozzle located within the stripping chamber for spraying a stripping solution onto the resist and the copper panel;

at least one stripping sensor coupled to each stripping machine, for measuring a stripping process parameter and converting a measured value of the stripping process parameter into a fifth signal; and

signal converters at each manufacturing site respectively coupled to each of the sensing devices at each site to respectively convert said first, second, third, fourth and fifth signals into first, second, third, fourth and fifth digital signals having a specified data format;

a digital communications network coupled to each of said signal converters;

a monitor located at a site geographically remote from at least one of said manufacturing sites, said monitor storing preset process parameters and respectively comparing said preset values with said first, second, third, fourth and fifth digital signals received from said signal converters and automatically calculating when a measured process parameter is not within a specified tolerance and providing a readout alerting an out-of-tolerance parameter; and

a recorder compiled to said monitor for storing certifiable manufacturing parameters received from each of said manufacturing sites including sites geographically remote from said monitor.