Main board production process?

SMT->； DIP->； W/S ->T/U-> test-> Age->; OQC-& gt； Packaging->; customer

The above is the layout of ASUS motherboard production line, which is explained below!

1) SMT

The English abbreviation of surface mount technology is also the key of motherboard manufacturing technology. In fact, in a word, the motherboard is designed, and the remaining production is the process of welding the required parts to the PCB. SMT is a welding technology, and ASUS's SMT technology is still in the forefront in the industry, otherwise many SMT ggmm will be taken away by others ... Of course, the stability and quality of SMT largely depend on the equipment. The first-line brand equipment used by ASUS, printer-DEK, high-speed machine-Fuji, GSM- universal GSM 2 Reflow-Heler (I don't know if it is written correctly), and later ASUS bought Siemens equipment 13 line, which was more expensive. It is about 1.5-2 times of the original line. It is said that the monitor in charge of importing Siemens equipment publicly declared himself a multimillionaire when he returned to the stage to entertain guests. Haha, it can be seen how much those devices know! ! But originally, he was going to leave his job. Later, ASUS wouldn't let him go, so he just dawdled in Taiwan Province Province and only reported to the company every day. Now it seems that he has come to Suzhou again! ! ! I ran away and came back. I wonder how many second-tier manufacturers can afford these devices. It is estimated that Panasonic, Philips and so on are used. Therefore, the equipment guarantees the quality of ASUS to a great extent.

Of course, in addition to equipment and materials used, SMT mainly depends on the quality of solder paste. At present, the well-known solder suppliers in the world are Alpha and Kester, both of which are ours, but they are very expensive, and solder paste is a great cost. Therefore, ASUS basically does not use these two kinds, unless OEM customers specify, such as Hewlett-Packard to specify Kester. These are all related interests, that is, ASUS buys a lot of things from Taiwan-funded enterprises. If it wasn't bought in the mainland, I won't say much here. Most of ASUS's solder paste is made by Taiwan-funded enterprises, which is called Sheng Mao Solder, and most of the solder paste and tin bars (later used by W/S) are made by it. Even if the customer asks for something else at first, ASUS will replace it for you for various reasons when your order is big and you can't get away. At that time, customers had no choice but to change, so they were all Shen Mao's. I did this once, replacing the FLUX kester95 1 designated by HP with alpha s500, which saved the company millions every year, but gave me a salary increase of 300 yuan at a time. ! ! ! ! Pour! ! ! ! ! However, according to my conscience, Alfa ls500 is indeed better than Kester 95 1, but because it offended the people certified by Alfa's Hewlett-Packard Laboratory in the United States, it killed those who didn't use Alfa, and then there was no way out, so it was changed. It seems that HP people are no longer in charge of this project.

Finally, the process flow of SMT is briefly described: printer-printing solder paste on PCB, high-speed machine-printing small parts such as small chip capacitors and resistors on PCB, printing large parts such as GSM- large IC and South-North Bridge chip on PCB, reflow-heating to melt solder paste, cooling, and so on.

2) Dipping

That is, artificial plug-ins, IC, SMD capacitors, resistors, chips, etc. They are all made of SMT and vertical capacitors, and some I/O interfaces are manually inserted into the PCB surface and then soldered with W/S (wave soldering)!

So there is nothing to talk about here. The first is the human factor. The operator was not happy today, so he did not make any noise when plugged in, and it was not detected later. Then the unlucky one is the user, but the chance is very small.

The key is the material problem, which is decided at the time of design, while the design of RD depends on who it is for, how to request it, price, cost and so on.

Of course, there may be problems in the production process, because many materials have substitutes, and sometimes this is the problem. Can they be replaced? The quality of the two companies cannot be the same. Hehe, let's see who has strong public relations ability! ! ! Purchasing, material control, quality control, production, every department should do it well, and then use yours! ! ! !

3) W/S (wave soldering)

This is the second technological process in the motherboard production process, and the quality of welding is mainly determined by the quality of equipment and the quality of flux and solder used.

Asustek's wave soldering machines are all SOLTEC, world-class equipment, produced in the Netherlands. At present, only one device in the United States can match it. Asus once evaluated that kind of equipment, but my classmate denied it (my classmate was in charge of that evaluation). There seem to be three or four such devices in BenQ, Suzhou. In the Yangtze River Delta region, apart from ASUS, SOLTEC should have no more than 20 wave soldering machines, while ASUS has 72.

As mentioned earlier, the quality of wave soldering depends on flux. Generally, large OEM customers will specify flux (of course, they will also specify many consumables related to products such as solder paste and tin bars), but as mentioned above, they will eventually be replaced by ASUS. He has the ability to convince customers that I can do better and cheaper with this, so I won't mention it, but I think customers must know it, or they will get sick! ! ! Are you really still customer-centric?

Most of the flux used in ASU is Alpha LS5000A. This flux was specially developed by Alpha for air separation. You may be able to buy something with the same formula in the market, but it is impossible to make this model because it is specially designed for ASU. To be honest, this flux is really classic! ! Stable performance, good cleanliness and strong weldability! ! !

So whether Dell, Hewlett-Packard, Intel, Sony, IBM (server board) or its own brand ASUS, most ASUS use this brand, but ASUS launched a Kester, because the company launched the "Golden Goose Plan" in 2004 (that is, each department has cost-saving indicators, which is mandatory).

The low-cost flux also makes the brothers behind complain bitterly, as if I made it myself, 8? 1, and later introduced a domestic low-cost flux, hehe. Don't be surprised, ASROCK was born with fate. What about the price of more than 300 yuan? So everyone bought ASROCK's or endure it! ! After all, it is so many meters! !

In the factory, ASROCK is synonymous with bad goods, and almost no one takes it seriously, as long as it passes the test and produces about 5000 /pcs/line a day, regardless of the appearance acceptance, so it's funny to see the comments from some magazines and websites! ! But our consumers don't know! ! !

Tell me about the process. In W/S, firstly, the PCB with parts inserted passes through the spraying system of the equipment, and then the flux is evenly sprayed on the PCB. After being heated and activated in the heating zone, molten tin (indicating that the so-called tin bars and solder paste are both 63/37 Sn/Pb, and now RoSH in the European Union has begun to lead-free) will climb into the holes of the parts and rise to the PCB along the pins of the parts. ! !

As for the quality and purity of solder, it meets the requirements. After a long period of use, some other metals in the solder will also exceed the standard, such as copper and silver. Therefore, it is necessary to test the solder regularly (monthly) and replace the full bath tin once a year (the practice of ASUS). I don't know how to do anything else.

4) T/U

The so-called T/U is trimming, and the solder joints on the back of the motherboard welded by wave soldering mainly have defects such as short circuit, virtual welding and insufficient tin consumption. These ASUS have an appearance acceptance standard, which should still represent the old higher requirements of the industry. Unfortunately, this standard has been lowered again and again! ! !

In T/U section, it is mainly to manually check whether the solder joint is OK with a magnifying glass, or repair it with a soldering iron, or cut off the short circuit. The easiest thing to happen here is to pull off the pad, or to break the hole after maintenance, which should be scrapped. However, some people will fill the hole privately, fill the hole with copper wire, then tin it and insert the parts for welding. The appearance can't be seen at all, and the test can't be measured. It is most likely that there will be problems in the hands of users, so it is estimated that it will be used. ! !

There is also a harmful board, which is the tin overflow board. As you can see from the words, the tin in wave soldering overflows to the parts of the board, which is often caused by high line speed and high tin wave. After the overflow of tin, it should be scrapped, but when it comes to the number of scrapped departments, we will try to fix it, that is, remove the tin from the surface of the parts. This kind of plate is easy to distinguish. In order to remove tin, flux must be used, and there must be residue in flux. No matter what detergent you use, it will leave traces, especially after a long time! Cleaning in time, after a long time, as long as you look at the light, you can see that the surface of this part is different from other parts, or the reflection is basically flux. After the tin overflow plate is repaired, it will definitely leave a large area of flux traces! ! !

5) Testing

There are three tests: ASUS, ICT, fun and manu.

1) ICT is the circuit test, whether there is an open circuit or a short circuit. At this time, peripherals (such as CPU, DIMM (memory) and other fixtures) are not added to avoid burning the fixtures when going to fun in the future.

2) Function

The main function test is to add CPU, DIMM and other peripheral devices, and start the test. All the problems will be found here, and the basic fun will be OK.

3) MANU

It is actually measured, and all peripheral devices have been connected, tested and checked for compatibility. , so just to be safer. Sometimes it's too late, something will happen to Manu. This kind of board is not a big problem, and there will be problems occasionally. And some boards don't open MANU station at all, so it's just a scale, not a full test. Only a few OEM customers such as Dell and Intel require 100% full test, and the test data is transmitted to customers online, so it is impossible to be lazy! ! !

6) Age and gender; Finished product inspection

Age and age. OQC belongs to QA department and specializes in sampling inspection. The detection method is the same as MANU's, and the proportion will generally be small. However, as long as there is a little defect, it will be criticized and rejected, and all works will be retested! ! Where the age is aging test, and the boot test is repeated! !

7) packaging

Then there are packages, instructions, CDs, manuals, telegrams, etc. Put them all in boxes, pack them and ship them out! ! !

Ok, the process is over! ! Behind it is the comparison of various brands of motherboards made by ASUS! !

Second, the brand contrast is strong! !

Asustek OEM (ODM after 2003) has motherboards from Dell, Intel, Hewlett-Packard, Sony and IBM, as well as its own ASUS and ASUS. In fact, ASUS is also an OEM, but it should be of low grade and low requirements. Don't do OEM, because OEM represents the high standards, high requirements and high quality of the factory! ! !

Explain that IBM OEM is the motherboard of the server, so I won't say it here! !

The following is a detailed description of the pros and cons of each brand motherboard in the order of quality I personally think.

1) Dell

As we all know, Dell has an assembly plant in Xiamen, and the motherboards made by ASUS are sent there. There is a reason why Dell ranks Dell first. You may not think highly of Dell's products at ordinary times, but international manufacturers are international manufacturers, and their process requirements and technical level are first-class in the industry. He has first-class experts in various processes, and the list audited by Dell has become a model in the industry (by the way, relevant practitioners need to leave email addresses, which is Dell's top secret information). Many processes and technologies developed by ASUS were born under the requirements of Dell audit. Most of Dell's orders were given to Foxconn, and ASUS didn't get many orders, because the online qualification rate of ASUS's boards could not meet their requirements, and there was once a risk of cutting orders! ! ! I also spent some time on the Dell team. After all, Dell is the longest OEM customer of ASUS, and it is rich in resources in all aspects. After all, Dell is the most demanding and the factory is still very tired. Of course, the quality is also the most guaranteed. But I have never used Dell's desktop, and I don't know how to use it! ! Besides, DIYer can't buy Dell's motherboard, but you should be able to buy tooling goods from the factory in Suzhou (don't ask how they came out,? 8? 1, by the way, the value of boards lost by ASUS like this should not be less than 10 million a year. The craziest time was to find that the whole shipment was gone and finally appeared in the Middle East market. Are there many people? I heard that someone in Zhongguancun, Beijing was stationed in Suzhou to receive goods at that time. Now there is no such good thing. In 2004, the company launched a special anti-theft plan.

2) Intel

Intel's second place was completely moved by Dell's popularity, because in manufacturing technology, Intel doesn't have its own things, but no matter which one, it has to give him face, because it needs his chips, so his things are based on Dell. However, just taking other people's things, without experts, the content is still lacking. It is easy to be fooled. So although there are intel people stationed in ASUS (Dell has no resident technicians, only one customer representative, but the annual review is a headache for ASUS), our engineers don't really care about him because he doesn't understand! ! !

Anyway, after all, it is a big factory, and Intel is the last thing ASUS dares to offend. Personally, I think intel takes ASUS's production line as the experimental base for its own chips, and the latest chipsets are all produced there first, and the quantity is not large, not exceeding 1000/ sheet, so you'd better buy those mature chipsets for intel's motherboard, and the latest ones are test boards. However, the mature motherboard should still be very stable, and the yield even exceeds that of Dell. The most important thing is that the daily output is low, probably not more than 65,438+0,000/line. Every day Dell is about 1, 200- 1, 500 units/line. Therefore, ASUS does lose money when it does Intel, but it also has to pay, but it will be flat if people give some benefits on the chip.

3) Sony

First of all, Sony's motherboard is also used in Sony's brand machine. It is estimated that you have little chance to buy it in the market, but its quality requirements are also very high. The reason why it ranks third is that it is not common. As we all know, Sony's quality requirements are really high. However, Sony's recent frequent quality problems are surprising. I always think that the high quality requirements that Sony has been asking for are only for its suppliers. When there is a problem or it fails to meet its requirements, Sony asks for compensation, and he also accepts the products. After accepting it, I think he will never throw it away or sell it to consumers, so I think this is the root of Sony's frequent quality problems! !

Even so, in order to get Sony's notebook OEM order, ASUS still had to OEM the motherboard for Sony, even at a loss, and sent people to Japan to do heavy work many times! ! ! But overall, in the factory, Sony's board requirements are still relatively high! ! The output is about 900- 1200 PCs/ line, because Sony's board design is better, and a large number of SMT components are used, resulting in low output of SMT section, and it is useless to accelerate later! !

4) HP

To tell the truth, HP ranks here because it is an OEM brand, otherwise I will rank behind ASUS's own brand! ! ! Because of its quality requirements, the requirements from HP are really not so good. I have worked in the HP team for more than a year, and I feel that HP is not like an international brand, not as professional as Dell, and HP customers are not professional enough. So basically, the audit is to browse the production line, eat and drink, and basically don't know much about the process. However, all the cards of HP are used on their own desktops, so people seldom use them, and HP's gold medal service will be replaced if it is broken! ! Don't worry, there's another thing in the factory. As long as it is an OEM brand, everyone's quality awareness will be higher. After all, customer complaints will be more difficult to handle! ! So I ranked it fourth! ! The output is 1500- 1700 PCs/ row.

5) ASUS

To be honest, I don't think ASUS's boards are worse than HP's, because HP's boards are all made by ASUS ODM, so most of them are of the same design, that is, the same board made for HP and ASUS itself, but with different names, such as PTGD series, HP's PTGD 1-R, and ASUS's own P4GD-**** *. ! !

Asus has its own brand. To tell the truth, it used to be synonymous with high quality. Until now, many fans still think that ASUS's board will be higher than other brands, but it is not! ! ! As mentioned above, apart from quality assurance, ASUS equipment has a deep accumulation in technology and is at the forefront of the industry, but I believe that the current ASUS is not the ASUS of the past, and the culprit is the output! ! ! After 2002, after ASUS began to attack the city and plunder the land, it began to cut prices and grab orders. As a result, the factory has to produce 24 hours a day for 30 days, even working overtime during the Spring Festival! ! And the daily output is also increased to the limit again and again! ! Hurry up, there's only chaos down there! ! Because they are all assembly lines, put them in the past as early as possible. The terrible thing is that grassroots management cadres are also involved in fraud. When they get off work, the boards that have no time to test will happen, and they are all packed! ! Can this board guarantee to go out?

Besides, the treatment of ASUS employees is really cheap. To be honest, front-line operators don't have the right attitude. How to guarantee the quality? I will attach the resignation message of ASUS employees later, so that everyone can have a look and really understand the real situation of ASUS.

6) ASROCK

ASROCK should have appeared in the market in 2003-2004. I don't remember clearly. Asus reopened a brand that occupied the low-end market, and it was still branded in the factory, but after all, it was a low-end brand, and no one took it seriously! ! I don't want to waste time talking about its quality! ! ASROCK adopts large line production in the factory, about 5000 PCs/ line, others are JIT lines, that is, SMT and back-end production are connected, while large line is SMT production first, semi-finished products are put into storage, and after a certain amount is accumulated, the back-end production begins. The reason is that the latter part of the big line is fast, and if JIT and SMT are used, it will not be able to get on, so there will be quality problems in warehousing and midway transportation. This is still a small problem, the key is the latter part. ! The board was put down before it was too late to look. What qualities are there?

So I saw some comments about ASROCK's board at that time, which was simply funny! ! I don't know how much it costs to the people who do the evaluation! ! ! Don't say more, it's really not worth saying! ! Don't buy the motherboard of ASUS unless you have no money to buy rice. Of course, there is no money to buy rice, and it seems that there is no need for a computer! ! ! Ha ha! !