Splitting Stock Lots SOP

• This Standard Operating Procedure (SOP) details the process of splitting stock lots at the Kitting Station
• It provides step-by-step instructions for accurate, consistent, and ESD-safe handling

Scope

• This SOP is for the Kitting Station, operated by an associate with the Splitter Position; it includes these handling requests:
• Split - Cut Tape
• Split - Bulk, tube & tray
• Split to Merge - Bulk, tube & tray

Definition

• A Split handling request involves dividing a single stock lot into multiple stock lots
• This allows to break down a larger stock lot into smaller quantities, providing greater flexibility

Responsibilities

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

Types of Split

• Split - Cut Tape: This type is for stock lots in cut tape, either in a reel or not.
• Split - Bulk, tube & tray: This is for stock lots in bulk form, tubes, or trays; components are counted manually (small quantities) or with a scale (larger amounts)
• Split to Merge - Bulk, tube & tray: Instructions continue the Split - Bulk & Tube; after splitting the original stock lot, one or more of the resulting stock lots is merged with other stock lots

Checklist Before Starting

• Before:
• Test equipment and ensure proper grounding
• Use appropriate footwear, wrist strap, and smock/shirt
• During:
• Check kitting work cell, tools, materials, and check/refill supplies at the workstation
• After:
• Log out before breaks
• Clean and sanitize equipment and surfaces
• Dispose of waste properly
• Report any issues
• Return tools and equipment to designated areas

First Steps

• Precision and thoroughness are essential at every step
• Follow instructions in sequence
• Notify a supervisor immediately if technical issues or system errors occur
• Navigate to the Warehouse App and select the Kitting app

Split - Cut Tape

• Initiate the process by scanning the stock lot
• A check mark on the stock lot line confirms the correct stock has been scanned
• Find the Quantity needed for the split
• Determine the correct measurement needed which must be verified by confirming the part pitch size
• Adjust the part pitch by clicking on the part pitch to match the tape measure
• Remove any empty slots
• Place the tape on the table and measure
• Double check the measurement before cutting with scissors
• Wind the cut tapes properly
• As standard procedure, place the new stock lot on the left side of the table and the OG on the right
• Click "Split Complete" to print the label for the new stock lot.
• These labels added depending on the subsequent handling request that the stock lot has on it

Pitch Calculation for Larger Parts (>12mm)

• Amount x pitch = X + 10= Y cm Amount = Pieces needed for the split Pitch = Space in millimeters between each electronic in the tape
• For example: 10(amount) x 4(pitch) = 40 = 4 cm

Package and Label stock lots appropriately

• Add labels depending on the subsequent handling request that the stock lot has on it: Merge, Kit/CheckQuantity/Blank, MSL
• If a merge or reel is requested labels will be completed in the Reeling station

Stock lots should be packed in this order:

• Priority 1: You should pack the stock lot that has Kit/Check Quantity as a handling request first
• Priority 2: If both stock lots have the same handling request, always prioritize packing the OG

Package Guidlines

• The stock lots should be packed in the same type of bag that it originally had
• OG in antistatic = anti static bag
• non-MSL = bag for the OG has to be damaged = new
  • If MSL bag has to be replaced if damaged
  • If supplier bag should be replaced
• The label for the OG stock can be kept if bag was not replaced

Labels

• After the label has been placed, the stock lots should be physically move to the selected target location.

  • If the split has a merge or a reel, the stock lot should be placed in the bin for the reeler.
  • IIf the split is a kit request, place it in the selected bin.

• Click "Done". to complete the split in the system.

Split - Bulk, Tube & Tray

• Ensure you do not confuse the OG stock lot quantity with the new (split) quantity
• Always use the ESD tweezers by the kitting station when moving components
• Exercise caution when handling these parts since many are fragile and susceptible to damage.
• Ensure you are always adequately grounded with ESD footwear and a wrist strap

Split - Bulk

• Quanity less than 30 - Manual Counting Method

  • Count manually one by one using the clicker. - Use the ESD tweezers at the counting station - Different types of bulk stock lots require different counting methods by - component in a box, components out of the bag

• Quanity More than 30 - Use the Scale

• Turn on the scale & Place the ESD dump tray on top

• Zero out the tray weight on the tare/cal button, Press the Pcs/Unit button

• The numbers 10, 20, 50, and 100 will appear on the screen one at a time - to calibrate with the correct weight

• Select one of these numbers to indicate how many pieces you will place on the scale to calibrate it to the weight of each component

• Click the Pcs/Unit button to confirm and set the weight to 10 units

• Proceed to package and label instructions

Split - Tube

• Add clam shell and follow instructions.

Split - Tray MSL

• Remove the tray from the bag
• Start transfering the components to the clam shell
• Leave enough spacing between each component (Approx. 1 cm)
• Number would always vary depending on the components size
• More clam shell boxes can bee added as needed
• Proceed to fold the clam shell
• Click "Split Complete" the label for the new stock lot will print and package as necessary

QA Protocol

This section outlines the Quality Assurance (QA) checks to ensure the integrity and suitability of the handling request split

Personnel Responsible for QA:

• QA Inspectors
• Warehouse Associate
• Supervisor

Visual Inspection checklist

• Tape Integrity: Inspect each reel of tape for visible damage, including tears, cuts, missing pockets, deformities, or contamination.
• QA Criteria: Reject any stock lot with visible damage that could compromise component retention or feeding.
• Component Orientation: For cut tape, verify that components are correctly oriented within the tape pockets as per the majority of the components in the carrier tape.
• QA Criteria: Reject any stock lot with disoriented components.
• Component Quantity: Verify the quantity of the split is correct.
• Use a component counter or weight estimation method, as appropriate
• QA Criteria: Reject if quantity is below the required amount.
• Component Marking Legibility: Inspect a sample of components to ensure that markings (part number, date code, etc.) are clear and legible.
• QA Criteria: Reject if markings are missing, illegible, or incorrect.
• Package Size and Fit: Check that components fit securely within the tape pockets, trays, tubes, etc. and are not loose or prone to dislodging
  • QA Criteria: Reject if components are too loose or too tight.
• Material Compliance: Tape Material: Verify that the tape material meets the required specifications (e.g., antistatic properties, tensile strength).
  • QA Criteria: Reject if material does not match the specification.
• Environmental Control
  • MSL Compliance: For Moisture Sensitive Level (MSL) components, strictly adhere to the manufacturer's guidelines for storage in moisture barrier bags with desiccant.
  • QA Criteria: Verify MSL compliance based on component specification.
  • ESD Handling Procedures: Always handle component tape in an ESD-protected environment (e.g., grounded workstations, wrist straps).
  • ESD Packaging: Ensure that components are stored in their original ESD-protective packaging until ready for use.
  • QA Criteria: Ensure ESD safe practices are followed.
• Traceability
  • Labeling: Verify that each stock lot is clearly labeled at all times. This includes having a Cofactr label after the act of splitting has been completed.
  • QA Criteria: Reject and report any stock lot that is not identified with a Cofactr Label.

Test Questions

• What is the primary responsibility of a Warehouse Associate as per the SOP?
  • Perform activities outlined in the Split SOP.
• What type of split involves stock lots that are in cut tape?
  • Split - Cut Tape
• Which of the following is a requirement for completing split training?
  • Comprehensive training in cut tape knowledge.
• What should you do before entering the ESD area?
  • Ensure proper grounding.
• How is the part pitch size adjusted for a split?
  • By measuring and selecting the correct number for the part pitch.
• What occurs after scanning the stock lot for splitting?
  • The quantity needed for the split is confirmed.
• In the event of a system error during the process, what is the immediate action to take?
  • Notify your supervisor for guidance and resolution.
• What is the priority order for packing stock lots?
  • When possible, pack the original (OG) stock lot first, then the new lot.
• When should you use a sharpie during the split procedure?
  • To mark the tape at the measurement obtained before cutting.
• When packing Non-MSL stock lots, what should be done if the bag for the OG is damaged?
  • Proceed with its replacement.
• What should be ensured before cutting the tape?
  • The measurement is double-checked.
• What is the purpose of a "Split Complete" action?
  • To finalize the split process.
• For MSL OG stock lots, what is required if the bag is in a supplier bag?
  • The bag must be replaced with a new one.