As the globalization of supply chains leads to increased competition between companies, “productivity” becomes more important than ever, and many companies are trying to use digital technology to increase productivity.
According to the survey, more than 80 percent of customers think “improving productivity” is a problem, but they can’t feel any improvement in improving productivity. This paper will introduce a field improvement solution, IPQC Expert, to extract effective information from the production data of the patch machine, resolve the change points, and provide the best solution for the occurring problems.
Equipment operators in the general manufacturing industry mainly perform relatively simple operations, such as the components used when loading and unloading the production on the equipment, and the subsequent processing. In contrast, the SMT production line consists of multiple types of equipment, and the operator must learn the operation and switching operation of each equipment.
In addition, to produce a product with multiple parts, supplement and replace all these parts. In addition to these tasks, there are many operations that the operator needs to decide by himself, such as the error reporting processing of the inspection machine and the short stop processing, which requires the operator to have high skills. Outside the production line, in order to prevent materials from accumulation in the production workshop, the minimum required equipment must be timely prepared, allocated and recycled according to the schedule.
Because working hours are fluid and difficult to manage, in addition to the overall production scheduling plan. MT process topic
In a production site such as the SMT production line, the operator is responsible for multiple tasks and requires high skills, which inevitably leads to differences in the time and quality of work. Therefore, it is not easy to manage production well and do it as planned.
In response to this situation, more and more companies are introducing monitoring tools that can visualize production status to detect and deal with anomalies such as schedule delays and line stops early. However, while the monitoring tools can confirm the details of the production performance, such as from the overall condition of the workshop to the suction nozzle and component status of each equipment, they are not suitable for analyzing situations from short-term trends in case of anomalies. In addition, managers often leave their seats to attend meetings, and are unable to confirm the monitoring tools at all times. Therefore, it is difficult to give timely instructions on all misinformation.
Topic of the SMT process:
● Relies heavily on labor and is difficult to manage
● It is difficult to analyze short-term trends when occurs
● The monitoring information cannot be fully utilized
IPQC Expert is a field improvement solution that analyzes the actual status of SMT operation. Anomalies on the production line were analyzed
In the component mounting process, the component absorption rate is ideal at 99.95% or higher. However, in the actual production, even if the absorption rate drops below 99.94% (three errors occurred in 5,000 absorption operations), the situation may still be observed while the production continues. It must be kept in mind that learning is about when and how often mistakes occur. There may be serious situations that the monitoring tool does not see.
For example, if these 3 errors occurred in the last 30 suction operations, the suction rate was 90.0%, indicating that the situation is very serious. However, because the monitoring tools use cumulative withdrawals as the denominator, it is difficult to grasp this short-term deterioration trend, and there is a risk of ignoring serious situations.
Even in this case, the IPQC Expert can segment 30 suction operations in the short term, thus detecting a sudden deterioration trend in suction rates and alerting them at an early stage to respond.
When there are many mistakes in the production process or long waiting time before the process, the operator must take corresponding measures to make the production back to normal. In this case, the experienced operator can immediately take appropriate measures immediately, but the new operator may be at a loss, waste a lot of time before taking measures, and may cause a stop. The IPQC Expert eliminates these man-made differences, allowing every operator to take appropriate measures immediately.
IPQC Expert can register the operations of experienced operators as a knowledge base. If there is a problem on the production line, you will guide reasonable countermeasures with a warning. In addition, the IPQC Expert can specify a terminal displaying the warning and the job wizard to instruct an operator who can handle the situation reliably to prevent the situation from deteriorating.
IPQC Expert is a solution based on patch machine information. Therefore, there is no need to conduct data linkage with other equipment such as the inspection machine, and the import is very simple.
Even users who struggle to know senior operators in a short period of time can use it as soon as soon as the default registered data is used. You can now use the default data to start improving activities and gradually customize the job wizard that works best for your company.
IPQC Expert captures serious situations that monitoring tools are difficult to detect, prevents error stops and delays in processing, and maintains and improves productivity. Import is very easy to use immediately after import.
The following is the IPQC Expert usage in other scenarios.
● The waits before and after the operation occurs
● A cell-specific error has occurred with the Imbalance
● In the cycle balance
● An image processing error has occurred
Post time: Oct-27-2022