My Personal Project

• Owner: Azman Bin Abdullah

• PCB out counter & buzzer triggering from Re-flow (Heller 1812 MK111) machine
• Alarm Triggering when completed PCB washing (Miele G 7823) and Low liquid detergent detected
• Laser printing machine “COHERENT” improvement.
• Spare Part Database (MS Access) stand alone for REL Lab department
• Fixture sub project (part time).

Introduction

Project 1 Overview�PCB out counter & buzzer triggering from Re-flow (Heller 1812 MK111) machine�

Objective

• This project is to reduce scrap of pcb drop during reflow process.
• Accurate Counting: Implement a reliable counting mechanism that detects each PCB as it exits the reflow oven.
• Buzzer Notification: Integrate a buzzer system that triggers an audible alert after a specified number of PCBs have exited.
• Real-Time Monitoring: Provide real-time data on the number of PCBs exiting the oven, allowing for immediate adjustments if necessary.
• Data Logging: Maintain a log of PCB counts for production tracking and quality control purposes.
• User Interface: Develop an intuitive interface for operators to set the count thresholds and monitor real-time data.

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Development

• Research = Understand how reflow soldering impacts the out counter and buzzer on the PCB. Are you investigating reliability, performance, or triggering issues? and Focus on the relationship between the reflow soldering process and its effect on the out counter and buzzer circuitry.
• Design= Design circuitry using Arduino and related part needed in this project (etc: sensor, buzzer, LCD & Arduino Uno). Creating Arduino IDE code. Sketch the layout of the project.
• Planning = Create prototype base on design and layout. Planning timeline step by step from design, coding,assemble and testing,
• Implementation: Perform functionality test using prototype and Check for any issues caused by this prototype.
• Results and Evaluation: Conduct a final round of testing on production units to ensure consistency and reliability. Gather feedback from users to identify any remaining issues or areas for improvement.

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Goal

• Reflow ovens are used in the electronics manufacturing process to solder components onto PCBs. Monitoring the number of PCBs processed is crucial for maintaining production schedules and ensuring quality control. Automating the counting and alert system reduces the risk of human error and increases efficiency.
• Increased Accuracy: Automated counting reduces the risk of human error and ensures precise tracking of PCBs.
• Improved Monitoring: Real-time data and logs provide valuable insights into the production process, aiding in quality control and efficiency improvements.
• By implementing this PCB out counter and buzzer triggering system, the production line becomes more efficient, accurate, and easier to manage, ultimately leading to higher quality and consistency in the manufacturing process.

Project 1 Overview�PCB out counter & buzzer triggering from Re-flow (Heller 1812 MK111) machine�

Project 2 Overview�Alarm Triggering when completed PCB washing (Miele G 7823) and Low liquid detergent detected�

Objective

• This project is to alert operators when washing machine completed wash and trigger technician when washing liquid in low level.
• To ensure the PCB washing process has been completed correctly and to identify any deviations from expected parameters, thereby maintaining quality and reliability in the finished PCBs.
• Ensure that the washed PCBs meet all quality and cleanliness standards.
• Notify operators of successful completion.
• Train operators and maintenance staff on the alarm system’s use and response procedures.
• To ensure continuous monitoring and effective usage of liquid detergent during the PCB washing process, thereby maintaining wash quality and preventing process interruptions caused by low detergent levels.

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Development

• Research = Understand the Washing Process: Identify all stages of the PCB washing process, including pre-wash, wash, rinse, drying including liquid detergent level in tank support.
• Design= Design circuitry using Arduino and related part needed in this project (etc: floating level sensor, small speaker, alarm module, dark/light sensor, LCD & Arduino Uno). Creating Arduino IDE code. Sketch the layout of the project.
• Planning = Create prototype base on design and layout. Planning time line step by step from design, coding,assemble and testing,
• Implementation: Perform functionality test using prototype and Check for any issues caused by this prototype.
• Results and Evaluation: Conduct a final round of testing on production units to ensure consistency and reliability. Gather feedback from users to identify any remaining issues or areas for improvement.

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Goal

• Ensure all contaminants, including flux residues, dust, solder balls, and other impurities from the PCB surface are removed.
• Increased Accuracy: Automated triggering operator and technician to attend the machine.
• Achieve a high level of cleanliness to meet industry standards and prevent performance issues.
• Prevent the washing machine wash with low detergent or without detergent.

Project 2 Overview�Alarm Triggering when completed PCB washing (Miele G 7823) and Low liquid detergent detected

Project 3 Overview�Laser printing machine “COHERENT” improvement.��

Objective

• This project to prevent laser machine Intermittenly stop marking and error prompt when Moveable table out from the fix location (Magnetic stopper lock).
• This existing magnetic stopper/ lock not strong enough to lock the table.
• When marking incomplete, causing PCB reject (incomplete mark printed on PCB).
• Reduce repeated process/ re-marking on pcb.

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Development

• Research = Understand the laser marking process: Identify all stages of the laser marking process.
• Design= Buy metal bar, magnetic stopper and fabricate stopper holder base on existing stopper with same dimension.
• Planning = Create prototype base on design and layout.
• Implementation: Perform functionality test using prototype and Check for any issues caused by this prototype.
• Results and Evaluation: Conduct a final round of testing on production units to ensure consistency and reliability. Gather feedback from users to identify any remaining issues or areas for improvement.

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Goal

• Ensure all process smooth with remaining error or problem
• Increased Accuracy: Reduce or eliminate error during laser marking process.
• Prevent the laser machine error during marking and creating scrap PCB.

Project 3 Overview�Laser printing machine improvement.�

Intermittenly stop marking and error prompt when Moveable table out from the fix location (Magnetic stopper lock).

Magnetic stopper Intermittent release lock during laser mark.

Project Idea

Fabricate magnetic block Same dimension as same as xisting block

- Buy the Metal bar and Magnetic stopper and fabricate stopper holder from vendor.

- Fit part and item to machine

- Verify the function of part and item installed

- Run the diagnostic of stopper function

- Analyze the magnetic lock capabilities of movement table lock.

- Discuss about problem facing, feedback and improvements of the project.

- Running the actual process and keep monitoring.

Fit into machine

Creating simple board for power supply 24vdc splitter

Project 4 Overview�Spare Part Database (MS Access) stand alone for REL Lab department��

Objective

• This project to manage spare parts inventory, track usage, balance, set minimum qty and handle supplier/vendor information.
• Preventing stockouts helps in maintaining smooth operations, avoiding downtime or delays in production or repair activities.
• When inventory levels fall at the minimum quantity, need to ordered in a timely manner.
• Store all relevant data about spare parts, suppliers, and transactions in one place, making it easier to access and manage.
• Organize data in a structured way, making it easier to retrieve specific information when needed.
• Track costs associated with purchasing and maintaining spare parts, helping to manage budgets effectively.

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Development

• Research = Study about Parts, Inventory, Supplier, Transaction, which location use, Part location
• Design= Part Table, Designated table, Supplier table, Inventory Table, Transaction table and define relationship. Add Inventory, Transaction, supplier part query. Creating related form.
• Planning = Develop a database to manage spare parts inventory, suppliers, and transactions. Requirements gathering. Testing database design.
• Implementation: Set Up database, Design and Create tables, Create forms, Create queries, Create report.
• Results and Evaluation: Conduct a final round of testing on functionality. Gather feedback from users to identify any problem occur.

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Goal

• Ensure accurate tracking of spare parts in stock, including quantities on hand and locations.
• Helps in maintaining optimal inventory levels, reducing both excess inventory and stockouts.
• Ensures that spare parts are available when needed, minimizing downtime and operational delays.
• Track all transactions involving spare parts, including purchases, usage, and adjustments.
• Ensure that each transaction is recorded with relevant details such as date, quantity, and type.
• Provides valuable insights into inventory and supplier performance, supporting better decision-making.
• Secure access and backup procedures safeguard data from unauthorized access and potential loss.
• Achieve efficient implementation and maintenance.
• Update database regularly by team and improve from time to time.

Project 4 Overview�Spare Part Database (MS Access) stand alone for REL Lab department�

Category

Machine, Item description, Part No, Area, Cabinet, Row, In, Out, Min, Min Hit, Date update,

Update By, Notes, Vendor, PO, Unit Price MYR, Supplier, Manufacturer, Reorder Level,

Target Stock, Picture Attachment, Where use.

Project 5 Overview�Fixture sub project (part time).���

Objective

• Understand and Define Customer Requirements.
• Ensure Quality and Compliance.
• Plan and Manage project task.
• Coordinate Delivery and Installation.

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Development

• Carefully analyze the customer's drawing to understand the specific requirements. Pay attention to dimensions, materials, tolerances, and any special notes.
• If there are any unclear aspects in the drawing, contact the customer for clarification.
• Review the customer drawing thoroughly to understand the design intent, dimensions, tolerances, and materials specified.
• Test the prototype to ensure it meets all functional requirements and customer specifications.
• Conduct quality checks at various stages of produce to ensure accuracy and adherence to the design specifications.

Goal

• Customer satisfaction
• Precision and quality
• On-time delivery
• Compliance with specifications
• Ensure that the fixture is manufactured exactly according to the customer's specifications.
• Maintaining high standards of quality, efficiency, and customer satisfaction.

Project 5 Overview�Fixture sub project (part time).�

Conclusion

• Using personal projects is a powerful way to apply knowledge, develop skills, and achieve personal goals. By reflecting on the successes and lessons learned from these projects, I can continue to grow, improve, and tackle new challenges with confidence. The experience I gain from private sector not only enhances my potential but also contributes to my overall development and success in various areas of life.

End

Thank

you