Merging Stock Lots SOP

• This Standard Operating Procedure (SOP) details how to merge stock lots at the Kitting Station.
• It provides step-by-step guidelines for accurate, consistent, and ESD-safe handling of electronic components during splitting.
• The SOP applies to the Kitting Station, operated by an associate with the Splitter Position.

Handling Requests

• Merge - Cut tape
• Merge to Reel - Cut tape
• Merge - Bulk, tube & tray

Definition

• A merge handling request combines two or more stock lots into one usable stock lot for production.
• The electronic component industry uses distinct terms for merging operations based on how components are packaged and stored.

Splice

• Industries use the term "splice" when components stored on cut tape are joined.
• Splicing is the careful joining of two separate stock lots on carrier tape.
• It requires precise alignment and specialized tools for proper component positioning.

Combine

• Combine is used when merging two or more stock lots in alternative packaging like bulk containers, protective tubes, or organized trays.
• This involves consolidating components while maintaining protective packaging and proper handling.
• Comprehensive training in cut tape knowledge is crucial for completing split training processes
• This provides a thorough understanding of procedures, techniques, and best practices.

Responsibilities

• The Warehouse Associate is responsible for performing the activities in the document.
• The Managed Services Supervisor has approval authority for the document.
• The Ops Dept is responsible for implementing the document.

Flow Chart

• Begins with an ESD Safety Check and Check Work Area & Tools.
• Branches based on package type: cut tape or bulk/tube/tray.
• Cut Tape: Scans stock lots, determines tape type (paper or plastic).
• Paper Tape: Splice with yellow tape.
• Plastic Tape: Uses a splicing tool and applies yellow cover tape.
• Bulk/Tube/Tray: Combines components, scans stock lots.
• All paths converge: Click 'Merge Complete', prints a new label, package according to guidelines, move to the target location, and ends the process.

Before entering the work area

• Test equipment at the testing station before entering the ESD area.
• Ensure adequate grounding.
• Footwear, Shoes or heal grounders.
• Wrist strap
• Smock or ESD tee shirt/sweatshirt

Checklist before starting

• Check kitting work cell tools and materials and remove nonessential, non-ESD objects
• Check supplies stock at the work station and refill if necessary

Checklist after finishing

• Log out of the station before leaving if taking a break
• Clean and sanitize all equipment and work surfaces
• Properly dispose of any waste materials
• Report issues or incidents encountered during the procedure
• Return all tools and equipment to designated storage areas

Get Started

• Precision and thoroughness are essential, execute each step diligently.
• Follow these instructions in sequence.
• Report technical issues or system errors to the supervisor asap

Merging Cut Tape

• Start by scanning the stock lots to merge.
• A check mark on the stock lot line confirms successful scan.

Splice with tape

• Only for paper tape

Process Using Appropriate Yellow Cover Tape

• Place the sticker with the splice in the middle.
• Rub sticker firmly to ensure adhesion.
• Select the correct splice tape size based on millimeters of the cut tape.
• The splice tape has two sides, each with a protective film.
• The front side has a darker, stickier film.
• The back side has a clearer film.
• Peel the film off from the front of the splice tape.
• Line the cut tape up with the first five holes on the left side of the splice tape.
• This will be the piece of cut tape with the higher quantity.
• Line up the second piece of cut tape (lower quantity) on the five holes on the right side on the splice tape.
• Fold the bottom half of the splice tape over the bottom of the cut tape.
• Press firmly to ensure spliced tape adheres correctly to the bottom of the cut tape.
• Remove the clear film from the splice tape.

Splicing with a Splicer (Plastic Tape Only)

• Get the splicing tool ready, refill staples if needed.

Reloading the splicing tool steps:

• Pull the latch back.
• Remove the old staples and, if needed, pull the staples out from the front of the splicing tool.
• Insert a new set of staples under the rails from the back, and slide them all the way in.
• Ensure the staples are aligned with the splicing tool's edge.
• Slide the lock forward to secure the staples.
• Ensure the lock is inserted correctly into the staples.
• Place the splicer with the handles facing you.
• Smallest stock lot goes on the right side of the splicing tool with the tape locked by the bracket.
• The next smallest stock lot goes on the left side of the splicing tool.
• Before proceeding, ensure the cut tape is correctly positioned in the sprocket holes.
• Make sure the ends of the tape line up exactly with no tape overlap, and the side locks are in place.
• Push down firmly on the handle to connect the two pieces of tape.
• Review the staple application, ensuring no bends, a complete flat contact, and a firm attachment to the tape.
• Select a yellow tape with the same width as the plastic tape and apply it directly on top of the splice.
• After merging the stock lots, click "Merge Complete" to print the new stock lot label.

Packaging the New Stock Lot

• Determines if the subsequent handling request includes adding a kit or checking the quantity is required.
• Move the stock lot to the Target Location.

Package Guidelines

• Stock lots need to be packed in the original bag type

Merging to Reel (Cut Tape)

• When the merge is completed following the Merge - Cut Tape steps, the stock lot is available to be Reeled.
• Click go to handling task
• Hold the printed label when completing the merge.
• Complete the reeling steps for Reeling.

Merging Bulk, Tube, & Tray

• Scan the stock lot to be merged.
• This provides confirmation that the two stock lots have been correctly checked.

Merge - Bulk

• Bulk components can be combined into one bag as long as they aren't packed too tightly.
• Discard the empty remaining bag.
• Securely seal the bag to prevent any loss of contents.

Merge - Tube

• For stock lots in trays, inspect the components to determine if they can be combined into a single tube with appropriate spacing.
• Ensure all components are properly seated, aligned, and oriented.
• Add all tubes to one bag

If there isn't enough room

• If components are components left after combining the components into all the available tubes that did not fit, they must be placed into a clam shell.
• Then place all tubes and the clam shell in a large bag.

When packaging

• Do not include loose components in a bag.
• All components must be included either in a tube, clam shell, or a combination of both.
• When using multiples packages such as 1 tube and 2 clam shells, ensure they are taped or bagged together

Merge - Tray

• For stock lots in trays, inspect the components to determine if they can be combined into a single tray while maintaining proper spacing and organization.
• Add trays to one bag
• If there is no space to fit all the components on the trays

If there isn't enough space

• If after combining components into all available trays, there are spares, place them in a clam shell,
• Then place all trays and the clam shell in a large bag

When packaging

• Do not include loose components in a bag.
• All components must be included either in a tray, clam shell, or a combination of both.
• When using multiples packages such 1 tube and 2 clam shells, ensure they are taped or bagged together
• Most parts found on trays are MSL 2 or higher
• After packaging select, the correct package and the new stock lot must go through MSL sealing

After Processing

• click the merge to complete the label for the new stock lot will be printed
• For kits (those with a kit, check quantity or blank selection) place the order in the bins

Packaging Guidelines

• Pack the stock lots in a bag with properties similar to the original bag
• If the originals are in an antistatic bag, the packaged stock bag must be as well
• The bag sizes do not matter but the same types must be used
• For MSL: if the the original the MSL bag is in a supplier packaging you must replace it with a new one
• The item can be repackaged if it is within a clamshell

Labeling Guidelines

• For the new stock lots, label added will apply depending on the stock's packaging, add those relevant to type

Position of Bulk Labels

• Place the label at the top of the bag as shipping requires more labeling

Position of labels in trays and tubes

• Visible while allowing code to be accessible while be aware other labeling requirements might be required

MSL and Repackaging

• Seal all the components if they are or above MSL 2
• Check the system's Impact Sealer to use the correct procedures
• After labeling physically move to target selected locations and in the appropriate bins, click done for final action

Quality Assurance (QA) Protocols

• The checks within are to ensure the integrity of the handling request and prevent defects
• They also are meant to sustain the automation of assembly with all electronic component tape, storage, and handling

Persons Responsible

• All inspectors, Warehouse, and Associate

Inspection Procedures

• For tape make sure that there is no visible damage or deformities that could damage the components
• Reject all stock because they cannot be retained or fed properly
• All actions are set to verify the accuracy of correct orientations for cut tape and the QA criteria that the stock is not oriented
• Inspect whether quantity is correct based on weight or estimates
• Rejection is mandated when below requirement

Inspection Procedures for Marking

• Ensure Legibility to component's sample

Inspections Procedures for Package Size

• Make sure the fit size works for trays tubes or more while unable to be displaced with QA Criteria is that movement in such should lead to failure

Material Compliance Guidelines and Environmental Control

• Verify tape to be compliant with material sheet as failing it leads to automated destruction

Moisture Handling and Sensitive Materials

• MSL Components need to be moisture handled per specs in dedicated barrier bags with desiccants
• ESD Handling requires working on stations with proper grounding

General Inspection Procedure

• Verify for ESD Packaging, traceability, and labeling clearly following all procedures for it

Revision History

• All changes must be in chronological order with reasons, details, and names of all parties involved for compliance and accountability.