[PageStream 2 document SP_MFG_2.DOC: 8.50 x 11.00 in, 503 objects]

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2.0	Assembly flow chart

2.1
Incoming
Inspection

Receive materials

A

 Power supply
inspection

Fail

Reject lot

 PCB parts
 inspection

Fail

Reject lot

Pass

Pass

Accept lot

Accept lot

 Keyboard
inspection

Fail

Reject lot

Fab parts
spection

Fail

Reject lot

Pass

Pass

Accept lot

Accept lot

 FDD
inspection

Fail

Reject lot

Printed material
inspection

Fail

Reject lot

Pass

Pass

Accept lot

Accept lot

 HDD
inspection

Fail

Reject lot

other parts
inspection

Fail

Reject lot

Pass

Pass

Accept lot

Accept lot

 Elec parts
 inspection

Fail

Reject lot

2.2

Pass

Accept lot

A

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2.2
1/4MB DRAM PCB
assembly

Prep
materials

Screen
solder paste

Place SMD parts
Chip caps
SOJ ICs

IR reflow

Visual
 inspection

Fail

Repair

Pass

Install connectors
manual solder

Manual solder
1Meg select jumper

Cleaning

Visual
 inspection

Fail

Repair

Pass

1

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2.3
Falcon 030 PCB
assembly

A

Prep
materials

Glue bottom side
 SMD parts
chip caps
chip resistors

Apply solder
paste (top side)

Install thru-hole
resistors
inductors
diodes
transistors
capacitors
fuses
filters
crystals
DIP ICs
sockets
connectors

Place top side
SMD parts
chip caps
chip resistors
SO ICs
PLCC ICs
QFP ICs
PLCC sockets

Wave solder

Washing

Lead trim

IR reflow

Touch-up

Visual
 inspection

Fail

Repair

Visual
 inspection

Fail

Repair

Pass

Pass

A

2.4

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2.4
 PCBA
test

Install TOS

Repair

Troubleshoot

PCBA
In-circuit
test

Fail

use 14 MB
test card

Pass

PCBA
first functional
check

Fail

use 14 MB
test card

Pass

1

use 1 or 4 MB
DRAM PCB
(shipped w/ system)

PCBA
burn-in

Fail

Pass

PCBA
final functional
test

Fail

Pass

2.5

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2.5
System assembly

2.6
System test

Assemble PCBA,
insulator, & shields

Replace
defective
sub assembly

Fasten shields

Troubleshoot

Attach
I/O plate

System check
PSU, FDD, kbd,
PCBA

Fail

Fasten PCBA
to bottom cover

Pass

Fasten/connect
power supply

Attach/fasten
top cover assembly

Fasten/connect
floppy drive

System
aging

Fail

Fasten shield
cover

Pass

Attach/connect
keyboard

Safety
compliance
test

Fail

2.6

Pass

System
final test

Fail

Pass

2.7

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2.7
Shipping assembly

A

Cosmetic
cleaning

Affix
rubber feet

Pack accessories
mouse
power cord
diskettes
manuals
warranty card

Affix
rating label

Seal gift box

Affix
warranty seal

Pack into
shipping carton

Stack onto
pallet

Cosmetic
inspection

Fail

Repair

2.8
Final inspection

Pass

Install unit
into poly bag

Final
QA lot
inspection

Fail

Reject lot

Install
styrofoam end caps

Pass

Accept lot

Pack unit into
gift box

Ship to
customer

A

END

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SIZE

DRAWING NO.

REV

®

ATARI
CORPORATION

A

SCALE

NONE

C302758-001

SHEET

OF

1

_