Networked Manufacturing Process in Electronics Production

Transcription

1 TAL Pilsen 2017 Networked Manufacturing Process in Electronics Production Alois Mahr Director Global Engineering Zollner Elektronik AG SOLUTIONS FOR YOUR IDEAS

2 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

3 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

4 Solutions for a Common Future Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

5 Locations Founded in 1965 Over Employees 17 Plants 7 Countries m² Production area Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

6 Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

7 Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

8 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

9 What Does Holistic Traceability Mean? Ensures continuous traceability of: COMPLETE SYSTEMS DEVICES MODULES PCB Regarding the production of: COMPLETE ORDERS SINGLE ORDER LOTS SINGLE PCB`S MOUNTING LEVEL Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

10 What Does Holistic Traceability Mean? unique labeling (RFID, Barcode, DMC;) of material & auxiliary materials, as well as products Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

11 MES / Traceabilitysystem Key Data 7 data bases productive 23 data bases in 3 testing systems approx User-Accounts approx LOCATIONS (machinery, storage, shuttle ta bles, ) no MES no production Hotline on standby 7x24h Ca marked UNITS (assembly units, modules, equipment) Ca assembly unit movements Ca batch-consumption postings Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

12 Traceabilty System-Pattern MASTER Reporting Server WWW USA DE HU RO China MFT/SFTP Costa Rica Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

13 Traceabilty System-Pattern Traceability Server Traceability Database Marking Siplace AOXI Test Island Repair Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

14 Requirements for a Holistic Traceability common challenges complete traceability clear labeling information process supplier manufacturer distributor production EMS OEM customer/ customer of the customer product development process Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

15 Requirements for a Holistic Traceability Labeling Interfaces- Data Security manual workstations repair data test systems material Traceability System room temperature, humidity auxiliary and operating materials production plants Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

16 The Zollner 5-Stage model STAGE 5 process optimization STAGE 4 STAGE 3 STAGE 2 STAGE 1 process interlocking Process - Traceability process data: screen printer, adhesive, placement module, reflow soldering, wave soldering, selective soldering, assembly, shipment, surrounding conditions Test - Traceability Test Data Optical (AOI, X-Ray, Man. opt. inspections, ) Electrical (ICT, FAT, HV-Test, Flying Probe, Boundary Scan Test, Run in Test, Burn in Test) Material- Traceability modules auxiliary and operating materials Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

17 Reporting elaboration, transfer, processing and storage of information about the company and its surroundings with reports Defining standardized reports (KPIs) Interpretation of figures Using reports as tools Online-Monitoring Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

18 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

19 master data / order data Production Backflush System Environment SAP SHOP-FLOOR Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

20 Industry 4.0 Soldering Paste Printing & Closed loop Soldering Paste Printing is the basis for good quality. ERP MES process- & control level Inspection of soldering paste print Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

21 Closed Loop Paste Printing / -Inspection - Validation of product, order, BoM, LP-batch - Request: assembly unit serial number - Feedback: marking results - Validation of order, assembly unit, BoM, solder paste, squeegee, stencil request at MES - Load program - Feedback: print result and process data 2 1 E R P M E S - Communication with XML interface - Paste printer transmits latest configurations to SPI - SPI inspects printed PCB 4 - Measuring the X- and Y-mismatch - Measuring height and volume of the paste - Monitoring the soiling of the stencil - Report results to the MES - Response of SPI to the paste printer with the corrective configurations quick and exact setup of the stencil position at the printer Constant corrections of the stencil position Mismatch at the stencil printer and subsequently downtimes at the SPI decrease Cleaning the stencil if necessary Savings in auxiliary production materials Higher throughput S H O P F L O O R 5 - Validation of assembly unit - Load program - Feedback test result - Validation of Batches - Feedback of material consumption and rejects - Feedback: placement result Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

22 Traceability Today and Tomorrow yesterday today tomorrow RISK MINIMIZATION Traceability of material batches test- and repair data process data SYSTEMATICAL PROCESSOPTIMIZING locking of processes (zero-defects principle) transparency in processes profound root cause analysis from traceability to MES Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

23 Which Data is required by our customer in the future? Test Records to some extent every 4 hours during production for ALL tests at every unit: test step test station test-slot test-period test status errors, TTF executing person The transparent company Traceability Data at least once a day or according to production schedule Debug Records at least once a day for every test, marked as FAIL: error description defective part actions taken? What, When, Where, Who? Information for replacement Header File Component File Attribute File manufacturer Serial & parts-nr. location Product family Business Group Date Code Lot Code Quantity Type future Commodity Code Differentiation assembly unit or module e.g.: MAC-address (e0:cb:4e:9f:fc:d3) All reports have to be created and transferred automatically in the Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

24 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

25 Data is the crude oil of the 21 st century Smart ( fast and clever ) Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

26 Competitive Advantage Access & Reporting Analytics Smarter Analytics maturity model react regulate foresee recognize predict/determine the best that can happen? optimization Different views of: What will happen next? What if this trend continues? forecast predictive analysis Why did it happen? statistical analysis alarms Drill down queries Necessary measures? Main cause and ID of the problem? Ad Hoc Reports How many, how often, who & where? Dash / KPI What did just happen and why? Smarter Analytics Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

27 What is Predictive Analysis Predictive Analytics Generated from data of operative actions, by drawing reliable conclusions to the current situation and to future events (Detect & Forecast) Customer Analysis Process Analysis Risk- / Hazard Analysis gain grow retain manage wait maximize monitor detect control Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

28 Application Areas of Predictive Analysis in PLZ Forecasting service intervals Analysis of merchant statements and subsequent measures Development Analysis of test data Identification of related problems, causes and measures Prevention of repeated repairs Product recommendations at the Point of Sales Automated surveys and direct analysis of the answers After Sales guarantee Marketing Sales Determination of customer requirements through segmentation Early Production Series Production Logistics Use of telemetric data for early identification of errors Automated analysis of texts Production optimization and -monitoring Reduction of rejects Predictive maintenance and warehousing Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

29 IT-Processes Data Quantity Growth: 50 70% per year Archiving of the data IT- PROCESSES Availability of the system (24/7) Support resp. Service-Hotline Rapidity when processing the data (cycle time in production) Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

30 Agenda brief presentation of Zollner Elektronik AG traceability for continuous material- and process data acquisition current customer requirements and realized projects future requirements towards Industry 4.0 conclusion and future prospects Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

31 Vision of Digital Networking distributor Forecast Purchase order Repair data customer Delivered quantity Inspection data Product Test data Assembly unit SNo Placement data Order Quality data Customer SNo Delivery note Delivery date Material data Process data supplier Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

32 Vision of a SMART Factory Self-optimizing production process TODAY FUTURE VISION Automation of production processes Optimization of production processes by innovative software systems and technologies Self-optimization of entire production by cyber-physical systems IMPLEMENTATION OF INDUSTRY Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

33 Target of a SMART Factory CUSTOMER TARGET: Master the complex process to improve yield, output, efficiency, turnover factor, etc. TODAY: INDUSTRY 3.X Automation of production processes Throughput Process Control Quality Inventory OUR SMART MOVE TO INDUSTRY 4.0 Optimization of production processes by innovative software systems and technologies VISION: INDUSTRY 4.0 Self-optimization of entire production network Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

34 The SMART FACTORY VISION SMART Factory PROCESS CONTROL Single Cyber-physical Systems Expert systems Controlled Closed Loop Systems Automation/Machines Manual Process EQUIPMENT THROUGHPUT QUALITY Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

35 It is not our task to predict the future, but to be well prepared for it. Pericles, approx v. Chr Zollner Elektronik AG A. Mahr Networked Manufacturing Process in Electronics Production

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39 Thank you very much for your interest in the Zollner company group. A. Mahr Director Tel.: Global Engineering (GE) Fax: Zollner Elektronik AG SOLUTIONS FOR YOUR IDEAS