4.4 Asset Lifecycle & Spare Parts

Calibration Management

All measurement and test equipment (M&TE) affecting product quality must be calibrated against NIST-traceable standards.

Tracking Database: A centralized digital database must track the status of every serialized tool.
- Labeling: Every tool must bear a calibration label indicating: ID Number, Calibration Date, Due Date, and Technician Initials.
- Lockout: Tools past their "Due Date" must be physically removed from production and locked in a quarantine cage.
Calibration Cycles:
- Torque Drivers: Every 6 months or 5,000 cycles.
- Digital Multimeters: Annually.
- ESD Surface Resistance Meters: Annually.
Out-of-Tolerance (OOT) Protocol: If a tool is found to be out of tolerance during calibration, a Reverse Impact Analysis must be conducted on all products measured with that tool since the last successful calibration.

To minimize machine downtime, a strategic buffer of critical components must be maintained on-site.

Classification:
- Class A (Critical): Parts that cause immediate line stoppage and have lead times >1 week (e.g., conveyor motors, head control cards). Mandate: 1 unit on-site.
- Class B (Consumable): Wear parts with predictable life (e.g., nozzles, vacuum filters, belts). Mandate: Min/Max logic based on usage.
Inventory Control:
- Location: Spares must be stored in a dedicated, access-controlled "MRO Cage" (Maintenance, Repair, Operations).
- Checkout: Parts must be electronically issued to a specific machine Work Order (WO) to track consumption costs and update inventory levels automatically.
- Replenishment: Reorder points (ROP) must be set in the ERP system to trigger purchasing automatically when stock hits the minimum threshold.

Traceability of equipment configuration is required for change management.

Tagging: All capital equipment (Pick-and-Place, Ovens, Printers) must have a permanent metal asset tag.
- Data: Asset ID, Manufacturer, Model, Serial Number, Installation Date.
Configuration Management: A "Machine Passport" (digital log) must be maintained for each asset, recording:
- Software/Firmware Versions: Updates must be validated by Process Engineering before deployment.
- Hardware Upgrades: Installation of new heads, cameras, or rails.
- location: Current physical location on the factory floor.

SMT component feeders are the highest volume asset and the leading cause of pick errors.

Maintenance Interval: Feeders must be serviced every 1,000,000 picks or 12 months.
Validation: Post-maintenance validation must be performed on a Feeder Calibration Jig to verify index accuracy and pitch.
Status Flags:
- Green: Calibrated & Ready.
- Red: Defective / Needs Repair.
- Yellow: Due for Maintenance.