The term “survey” as applied to the manufacturing process implies an audit, and when a standard is the topic of the audit, the audit takes the form of a compliance audit. The compliance audit in this instance is the comparison of the requirements of IPC-J-STD-001, The Requirements for Soldered Electrical and Electronic Assemblies to the manufacturing process that is in place. In order to accomplish this task, audit procedures are used to compare the manufacturing process to the requirements of the standard.

Step One: The auditor and the auditee meet to discuss and plan the audit, establishing the dates of the audit, the needs of the auditor as to location, meeting rooms, equipment, supplies, formulating an audit team list and designating escorts. This meeting serves as the introduction of the two parties that are to be involved in the audit process.

Step Two: Establish the scope of the audit or define the goals, expectations, and limits. It is at this time that the auditee defines the specific details of the specification as they relate to the process to be audited. Is the goal of the audit to determine how (and if) the manufacturing process relates to the general requirements of the specification, to a specific product class, or to compare the process to a more advanced classification, (e.g., Class 2 processes to Class 3 requirements)?

Step Three: Determine methods of assessment or, in reality, establish the path the audit will take. This would include a review of the quality plan, the organizational structure of the company, and how the manufacturing processes are constructed and executed. Examples: Is the company certified to an ISO specification? Is the company management structured as “line and staff” or “line”? How are the manufacturing processes developed, executed, and controlled? What is the layout of the manufacturing facility? Is there a general flowcharting of the manufacturing process, and are there separate flowcharts for individual products?

Step Four: Develop audit checklists which will be used during the execution of the audit to mirror the requirements of the specification to the procedures and processes employed. The audit checklist for IPC-J-STD-001 would include all of the elements or sections of the general requirements, the specific requirements as to the product being manufactured, and the method of their manufacture. In addition, there would be supporting requirements, such as inspection, quality assurance, and Statistical Process Control (if mandated).

Step Five: Execute the audit. Use the documentation supplied to verify compliance to the requirements, physically track parts and materials through the manufacturing process, reviewing records and tracking progress of the product through the use of the flow charts. If adequate processes, flow charts and controls are in place and in use, the auditor will be able to determine the status of the product by casual observation of any process or applied procedure at any point in the process.

Step Six: Review the audit findings and observations with the auditee’s representative in outline form, relating general observations and reviewing specific areas of concern.

Step Seven: Generate and present a formal and detailed Audit Report based on the audit findings and observations. These topics will be specific to the requirements of the specification and may contain probable cause and suggested corrective action, again within the scope of the audit. The auditee may request a follow up audit within a determined timeframe which would allow the auditor to determine both the effectiveness of the audit and the success of the applied corrective action on the part of the auditee.

The EMPF, due to its unique charter and highly diverse and highly qualified staff, is well prepared to conduct such audits. Engineers, chemists and manufacturing technicians from the EMPF have successfully conducted process audits to determine root cause of process failures, quality systems audits to determine compliance to specifications and survey audits in order to determine correct application and use of equipment to prevent damaging elecrtostatic discharge events in electronic assembly processes. For these audit services, please contact the EMPF at (610) 362-1200. You will be placed in contact with qualified personnel who can help you.

Note: References made in this article to IPC-J-STD-001D are relative to IPC-J-STD-001D, Joint Industry Standard, Requirements for Soldered Electrical and Electronic Assemblies, copyright 2005 by IPC, Association Connecting Electronic industries, 3000 Lakeside Drive, Suite 309S., Bannockburn, IL 60015-1249. Copies may be obtained for a fee from this address.