3.3 Component Genealogy

Genealogy is the forensic DNA of your product. While "Traceability" tracks where a unit went (Location),went, "Genealogy" tracksrecords exactly what went into it (Composition).is Withoutmade of. In the event of a precisecomponent parent-childfailure linkage,(e.g., a defectbad inbatch of capacitors), a $0.10robust capacitorgenealogy forcestree allows you to surgically recall $10M of finished inventory because you cannot isolateonly the specific500 serialaffected numbersunits, containingrather than the bad50,000 batch.produced that month.

The HierarchicalGenealogy Data StructureHierarchy

DoData must be linked hierarchically, not flattenflatly. The MES must construct a parent-child relationship tree that traverses from the final shipping box down to the raw material provider.

Level 1: The Product (Finished Good)

• Entity: The Top-Level Assembly (TLA).
• Key: Serial_Number (System SN).
• Contains: Housing, Accessories, and the PCBA.

Level 2: The PCBA (The Brain)

• Entity: The Populated Circuit Board.
• Key: PCBA_ID.
• Link: The PCBA_ID is scanned into the System_SN at Final Assembly.

Level 3: The Panel (The Array)

• Entity: The manufacturing frame containing multiple PCBAs.
• Key: Panel_ID.
• Logic: Components are placed on the Panel. Upon depaneling, the MES must "clone" the component links to every individual PCBA_ID.

Level 4: The Reference Designator (RefDes)

• Entity: The specific physical location on the circuit board (e.g., C14, U20, R4).
• Key: Ref_Des (Reference Designator, e.g., C14, R20) + Timestamp.
• Logic: The Splice Resolver. If a reel runs out in the middle of a board (e.g., Reel A empties at C10, Reel B starts at C11), this level captures exactly which Lot went to which spot. Without this, you cannot distinguish the boundary between two lots on the same board.

Level 5: The Feeder / Setup (The Source)

• Entity: The slot on the SMT machine.
• Key: Slot_ID + Feeder_ID.
• Logic: The machine tracks which Reel was mounted on Slot 4 at the exact time of placement.

Level 6: The Supplier Lot (The Root)

• Entity: The raw material package (Reel, Tray, Bag).
• Key: Manufacturer_Lot_Number + Date_Code.
• Constraint: No material enters the floor without a Unique Internal ID (UID) linked to this vendor data.

Capturing the Link: The SMT Interlock

The weakest link in genealogy intois athe singlehuman textoperator field.loading Structurethe machine. If they load Reel A but the system thinks it asis aReel relationalB, treeyour togenealogy handleis multi-level assemblies.corrupt.

The TreeValidation Logic (Replenishment Event)

1. Root:Scan Slot: FinishedOperator Goodscans Serialthe NumberMachine (Parent).Feeder Slot barcode.
2. Branch:Scan Part: PCBAOperator Serialscans Numberthe (Child).
   • Leaf:Reel/Component CPU Lot Code (Grandchild).barcode.
   • Leaf:MES Check: Resistor Reel ID (Grandchild).
3. Branch: Housing Lot Code (Child).

Integrity Rule

• If aComponent ChildPart isNumber "Scrapped" inmatches the systemActive Recipe for that Slot → TheAllow Parent must automatically lockLoad.
• If a Child is "Quarantined"Mismatch → TheTrigger ParentInterlock is(Stop flaggedMachine "Hold"/ Error Sound).

Panelization & Inheritance Logic (The "Split")

In SMT, you build Panels (Arrays), but you sell Boards.

Binding: The MES mustrecords: handleTime_Start, theSlot_ID, "Divorce" of the Panel ID and the "Birth" of the Unit IDs without losing history.

The Inheritance Flow

1. Panel Phase (Parent): Components are consumed against the Panel ID.
   • Record: Panel-123 contains Reel-A.
2. Depanelization Event (The Split): The router/saw cuts Panel-123 into 4 distinct units (SN-1, SN-2, SN-3, SN-4).Reel_UID.
5. Data Cloning:Exhaustion: The system must copyWhen the genealogyreel is empty (calculated by Component Count), the MES automatically closes the binding.

Handling Bulk & Consumables (Time-Based Traceability)

Not everything has a barcode. Solder paste, glue, and screws are often "Bulk Consumables." You cannot link a specific drop of Panel-123glue to alla 4specific children.

• Result:board SN-1via containsserial Reel-A;number.
  SN-2

  Strategy: containsTemporal Reel-A, etc.

The "X-Out" Handling (Bad Board Logic)Windowing

• Scenario: A 4-up Panel has one bad PCB (marked with a black dot/X).
• Logic:
  • If Panel has X-Out at Index 3 → Do Not Generate SN for Position 3.
  • Or: Generate SN-3 but immediately set status to Scrap.
  • Risk: If you generate a "Good" SN for a bad board, it might leak into the casing process.

Collection Granularity (Risk-Based)

Tracking every washer creates "Data Noise." Define scope based on component risk.

Class A: Critical / Safety (Serialize)

• Definition: High value (CPU) or Safety Critical (Airbag Sensor).
• Method: Unique Serial Number scan (1-to-1).
• Logic: Unit-ARecord containsthe exactly"Active CPU-SN-99.

Window"

Classof B:the Functional (Lot Trace)

• Definition: Functional components (Capacitors, ICs, Glues).material.
• Method: Batch/Lot ID scan (Many-to-1).
• Logic: Unit-A contains Capacitor-Lot-99 (shared with 5,000 other units).

Pro-Tip: For SMT lines, never scan individual boards for Class B parts. Scan the Reel when loading the Feeder. The MES maps "Reel A was on Feeder 1 from 10:00 to 12:00" and inherits the Lot Code to all Panels produced in that window.

Validation at Point of Scan

Genealogy is an active control. Validate the component before installation.

The "Three-Way Match"

Upon scanning a component, verify:

1. BOM Match: Does this Part Number belong in this BOM?
2. AVL Match: Is this Manufacturer on the Approved Vendor List?
3. Status Match: Is the Lot valid (Not Expired, Not Quarantined)?

Expiration Control Logic

• Context: Solder Paste, Epoxies.
• If (Current Time) > (Material Expiry Date) → Lock Machine.
• If (Current Time) > (Material Open Time + Pot Life) → Lock Machine.

The Rework Problem (Divorce & Remarriage)

Genealogy is fragile during rework. When a technician swaps a part, the system must "amputate" the old limb and "graft" the new one.

The Swap Workflow

1. Un-Marry:Input: Operator scans UnitSolder SNPaste ->Pot SelectsID at 08:00 (Start) and 12:00 (End).
3. Inference: Any board processed through that Screen Printer between 08:00 and 12:00 is linked to that Paste Pot ID.
4. Resolution: Granularity is lower (Batch Level), but coverage is 100%.

The "RemoveForbidden" ComponentActions

X".

Strictly police the following behaviors to preserve data integrity:

• Splicing without Scanning: Operators typically splice a new reel to an old tape to keep the machine running.
  • Action:Rule: LinkSplicing broken.requires Componenta Xmandatory markedscan "Consumed/Scrap".of the new reel.
  • Risk: If missed, the system attributes the new components to the old (empty) lot.
• Re-Marry:Tray Refills: Operator scans New Component Y.
  • Action:Rule: NewTrays link(e.g., established.for ICs) must be treated as "Lots." Do not top up a half-full tray with parts from a different lot. Clear the tray, then load new.
• Audit: History shows both: "Component X (Removed) -> Component Y (Installed)."

Final Checklist

Category	Metric / Control	Threshold / Rule
StructureHierarchy	HierarchyDepth	Multi-levelFull Parent/Childlinkage: supportProduct (Not→ flatPCBA text)
Panelization	Inheritance	100% of→ Panel Data→ clonedRefDes to→ ChildSlot Boards
Panelization	X-Outs	Bad→ BoardReel positions→ blockedSupplier from generating "Pass" SNs
Scope	Class A (Critical)	100% Serialized (1-to-1)Lot.
Validation	BOMMaterial Interlock	BlockMachine scancreates "Stop" error if P/Nscanned notreel in≠ BOMRecipe Part Number.
ReworkSplicing	SwapScan LogicDiscipline	"Un-marry"100% eventof requiredsplices beforerequire newa validation scan before the splice enters the head.
Inheritance	Panel Split	Genealogy data transfers from Panel ID to Circuit ID automatically.
Bulk	Temporal Link	Paste/Glue linked via Time Windows (Start/End times).
Integrity	CompletenessFIFO	ShippingThe BlockedMES ifassumes GenealogyFirst-In-First-Out countfor feeder consumption.
Recall	Search Speed	Ability to query "Where used: Lot A123" in < BOM5 Qtyminutes.