SIPLACE SMT-INSIGHTS

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Sophie Wendy Skinner
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1 SIPLE SMT-INSIGHTS Progressive oncepts for Modern Electronics Production

Editorial SMT production is becoming increasingly complex, especially when the products, which have to be manufactured, are diverse and place great demands on the production line s changeover

2 Editorial SMT production is becoming increasingly complex, especially when the products, which have to be manufactured, are diverse and place great demands on the production line s changeover capabilities. The flexibility requirements range from one-time product changeovers per quarter with lot sizes in the millions to multiple setup changeovers per shift with single-digit runs and a planning horizon of just a few hours. That s why electronics manufacturers should also pay close attention to available setup concepts which can speed up their manufacturing processes. times play a rising role in operating costs When it comes to selecting a setup concept, the solution that achieves the greatest efficiency under the respective conditions is always the most desirable. Production efficiency is based on ratio of costs and output, i.e. the number of items produced. The costs in turn can be broken down into the one-time investment in the production equipment and the ongoing expenses for personnel and resources as well as for downtime, i.e. the time during which a line sits idle, for example because of a changeover from setup to setup. Particularly in a plant which manufactures many different products, this can make a constellation with lots of machines and fixed setups for all products financially inefficient. Instead it may make more sense to reduce the investment in machines and feeder modules and focus instead on smart setup concepts. Software becomes increasingly important eing open to new solution approaches is always a good thing. With intelligent combinations of software and placement solutions, today s users can implement setup changeover concepts that were nothing but wishful thinking only a few years ago. In view of the many options available, it is only natural that choosing the right setup changeover concept can be difficult, particularly since the product mix changes constantly for many producers. That s why it is advisable to monitor a longer period (one month, one year, etc.) and take the ratio between productive and non-productive line time into account. Many setup preparation steps can today be decoupled from the actual production time. Even the setup changeover on the machines themselves can be accomplished virtually onthe-fly. Selecting the best setup concept for a 2

new line can reduce the investment in new feeders or even entire modules by up to 30 percent as well as significantly lower the running placement costs.

3 new line can reduce the investment in new feeders or even entire modules by up to 30 percent as well as significantly lower the running placement costs. nalyzing the setup changeover concept Groundbreaking placement solutions provide the matching concept for any conceivable production requirement. Solutions with perfectly matched placement solutions and software are especially efficient. Within the framework of the SIPLE platform we offer three different solution concepts: the fixed setup, the family setup with static or dynamic changeover tables, and the floating setup in different variations. The SIPLE SMT Insights issue titled Progressive oncepts explains these concepts in detail and provides you as the user with important criteria that will help you to find the best fit for your production. Please do not hesitate to contact our experts to get answers to questions about your specific setup requirements. Your SIPLE Team Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix 3

1. Fixed setup Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix Fixed setup characteristics Production Environment Planning (Long planning

4 1. Fixed setup Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix Fixed setup characteristics Production Environment Planning (Long planning horizon: ; short planning horizon: - - -) verage lot size >1000 changeovers per shift <1 SIPLE Features SIPLE Pro Optimizer SIPLE enter (case by case) In some cases the most efficient setup changeover strategy is to have no setup changeovers at all. The prime example is a factory which handles lot sizes far in excess of 1,000 units and has to change the setup only once in a while. Under such circumstances, considering a single fixed setup for a product family still makes sense. With no setup changeovers, the placement time (net cycle time) becomes the efficiency-determining factor. When creating a fixed setup, it is therefore important to not only make sure that the line can handle all the components, but to calculate the setup in such a way that each machine achieves the same cycle time and follows optimized pickup and placement sequences to deliver the best possible performance. On top of this, the entire process must be prioritized in accordance with the planned lot sizes. 4

It can even calculate the output of a production line with ± 5% accuracy before a single component has actually been placed.

5 The SIPLE Pro Optimizer is able to analyze up to 1,000 different products for shared components and compute the best setup for the respective line configuration. It can even calculate the output of a production line with ± 5% accuracy before a single component has actually been placed. When a setup changeover finally becomes necessary, the time spent on making the necessary changes hardly matters relative to the total productive time. Fig. 1: Sample screenshot of results produced by the SIPLE Pro Optimizer 5

6 2. Family setup Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix Family setup characteristics: Production environment With changeover table, With changeover table, static pre-setup dynamic pre-setup Planning (Long planning horizon: +++; short planning horizon: - - -) verage lot size changeovers per shift SIPLE Features SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Siluster Professional SIPLE Siluster Professional SIPLE enter (case by case ) SIPLE enter (case by case ) Random (at changeover table) Random (at changeover table) Today s production conditions with their declining lot sizes and rising product diversity make working with single setups increasingly unproductive in most plants. One way to minimize setup changeover costs is by building setup families. In a production environment that operates with average lot sizes between 200 and 1,000 units and requires multiple setup changeovers per week, generating setup families is a must. To determine these families, optimization programs analyze the quantities to be produced for shared components and combine them into groups (i.e., the families). Thanks to their shared component spectrum, all the products in a family can be run on a specific line, taking the feeder capacity into account and without having to make a setup change. When the time comes to change the setup from Family to Family, the required effort should be minimized as well. Today s demands are even higher, however, because the lot sizes of the various products must also be taken into consideration. Managing these challenges requires innovative optimization algorithms, which is why the SIPLE Pro optimizer offers various scenarios to reduce the setup changeover times even further. 2.1 hanging the setup with constant changeover tables If large amounts of feeders need to be replaced, using changeover tables is recommended. Switching out entire changeover tables makes the changeover procedure as quick as it can be and reduces the line s downtime considerably. Factories with foreseeable and repetitive product family sequences can prepare fi xed setups on a group of changeover tables and keep them at the ready for the time when they are needed again. They are referred to as static changeover tables. To further minimize the need for components, feeders and changeover tables as well as setup changeover effort, supporting software like SIPLE Siluster Professional is available. 6

7 One of Siluster Professional s capabilities involves calculating product families with as many static changeover tables for shared components on the line as possible and reduce the number of cart changes. These constant changeover tables (see 2.2) can simply remain on the line when a new family is set up an approach that reduces the time and expense of setup changeovers further by a signifi cant factor. s another important benefi t, the user can decide what is more important: minimized setups, the shortest possible production time, or a compromise between the two. Other production-relevant factors such as the use of nozzle changers are taken into account and optimized as well. Product family Product family preparation area preparation area Fig. 2: Production with setup families and static changeover tables 7

8 2.2 hanging the setup with dynamic changeover tables If the production sequence of product families changes permanently and the number of setup changes increases, it is recommended to generate new product families as needed. These are then set up at an offline station (SIPLE enter) with no production slowdown on another set of changeover tables. These dynamic changeover tables are then switched out with the ones that are currently docked to the machines. Here, too, the Siluster Professional software provides significant relief. The software is able to specify as many constant changeover tables as possible for the product families taking a given planning horizon into account and thus reducing the number of setup changeover procedures to a minimum. Product family Product family preparation area preparation area Fig. 3a: Production with dynamic changeover tables 8

9 onstant changeover table onstant changeover table / / / / Product family (Siluster Professional) Product family (Siluster Professional) preparation area preparation area Fig. 3b: Production with dynamic changeover tables after the use of Siluster Professional Kitting links the data SIPLE enter in combination with changeover tables can be a critical component in the setup changeover concept for example, to get the setups for the next product ready in the setup preparation area. This is where the components arrive from the warehouse to be installed in the matching feeders and set up on the changeover tables. Part of this process involves linking the component data to the feeder ID with a barcode reader a step called kitting. To generate a detailed work plan with information about all required components, feeders and their setup location, SIPLE enter is highly recommended. setup verification feature makes sure that the right components make it to the placement line in order to ensure the final product quality. Normally the kitting will take place at SIPLE offline setup stations, especially if entire changeover tables are subsequently exchanged with those currently on the line. ut even simple kitting of individual feeders with a barcode reader and the Single Slot Edif (SIPLE data interface for feeders) is conceivable. 9

10 3. Floating setup Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix Floating setup characteristics Production environment With fixed setup on the line lock-wise Feeder-by-feeder Planning (Long planning horizon: +++; short planning horizon: ) + verage lot size 1/> changeovers per shift 1-3 >5 >5 SIPLE Features SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Siluster Professional SIPLE Split Table Mode SIPLE Split Table Mode SIPLE enter SIPLE Siluster Professional SIPLE Siluster Professional Random (on the line) SIPLE enter SIPLE enter Random (on the line) Random (on the line) SIPLE LES SIPLE LES Floating setup is a type of setup changeover that is executed without slowing down or stopping the line. Under certain conditions for example, if different versions of products with the same width have to be manufactured and the screen printers are decoupled from the line floating setup delivers non-stop production with maximum flexibility. -mix lines can achieve throughput rates that were previously only possible in large-volume environments. With this setup concept, a line can run with almost no interruptions to deliver a virtual maximum of line productivity. Users can choose whether they want a setup that is optimized in terms of head travel (for maximum placement performance) or a setup where they are able to position feeders conveniently in any open slot (called random setup) for very fast setup speed. With the latter option, the feeder position influences the placement program instead of the other way around. The benefits of random setup include shorter preparation times and faster setups. To use either setup changeover method, users must first generate kits by scanning the barcodes of the respective component IDs and feeder IDs in enter. Random setup is also recommended if a short rush job must be run on a line at short notice or if new products have to be introduced (NPI). In both these cases, having maximum flexibility is more important than operating with maximum placement speed (cph). Floating setup can now be performed randomly when time is of the essence. It doesn t matter whether the changeover is executed in a block-oriented or feederoriented manner or via changeover tables with enter. The preconfigured feeders can be positioned anywhere on the line. The combination of intelligent feeders, machines and software will always recognize the new setup and adjust the placement program accordingly. dapted to the new setup, the program continuously re-optimizes the pickup and placement sequence of the respective placement head. The sophisticated user interface of enter provides support for the operator and specifies the next steps in 10

11 order to make the setup preparations as easy and error-free as possible. 3.1 Floating feeder-oriented setup In this kind of setup changeover, feeder modules which are no longer needed are replaced with feeder modules for the next product while the line keeps running. This method is recommended for plants which produce very small lots (1 to 50 units) and have to change their setups several times per shift. To achieve the necessary setup performance and be able to plan an efficient production schedule, the use of SIPLE LES (Line Execution System) is highly recommended. SIPLE LES controls all setuprelated processes on the line, from job sequencing to material preparation to the actual setup changeover at the line (setup and tear down). In other words, it is supporting the whole workflow. The operators on the line and in the setup preparation area (with ctive Feeder Pool) are not only guided by monitor displays: LES and LEDs on the SIPLE X-feeders tell them whether they are active in the current setup, needed for an upcoming product, or available for removal. The system clearly indicates which feeder modules (and their components) can be torn down and which need to be installed. Feeder not needed Feeder not needed Feeder not needed Product family is being produced Product family is being produced Product family is being produced Docking stations Docking stations Kitting required Kitting complete preparation area Kitting required Kitting complete preparation area Fig. 4: Floating setup with SIPLE LES 11

12 The feeders for the next product family can then be positioned in any open slot as long as the associated placement head is able to handle the respective component (random setup). This approach is highly user-friendly and reduces the setup changeover time considerably. 3.2 Floating block-oriented setup reating setup blocks is an alternative method of simplifying setup changeovers. With setup blocks, the feeder table is split into two contiguous blocks of feeders, one for product group, which is currently running, and one for the upcoming product group. While is running, can be set up. To optimize the setups for and, the Split Table Mode in SIPLE Pro can be employed and combined with Siluster. The software computes and maintains a pathand time-optimized pickup and placement sequence. Since block-wise setups can eliminate the need for changeover tables, they make it possible to achieve maximum flexibility with minimal use of feeders and tables, provided the line has sufficient setup capacity and the kitting has been done beforehand. The positions of the individual feeders within the blocks are freely selectable (random setup), which means that this setup method can also be executed with exceptional speed. Since this option involves two separate and clearly defined setups, it can be the ideal Feeder not needed Feeder not needed Feeder not needed Product family is being produced Product family is being produced Product family is being produced Docking stations Docking stations Kitting required Kitting complete preparation area Kitting required Kitting complete preparation area Fig. 5: Non-stop setup changeover thanks to the block-oriented floating setup 12

13 solution if mixed OMs (bills of material) are not permitted or if components for leadfree and conventional processes must be set up separately. 3.3 Floating setup with fixed side of the line Using dual-track conveyors with suitable setup changeover concepts is an attractive way to increase efficiency when highvolume and high-mix requirements have to be combined. Let s look at just one example from many conceivable applications that let the user manufacture products with small lot sizes (such as prototypes) next to continuously running high-volume products with no loss in efficiency. In this case, the feeders for product, which is produced in large volumes, are set up permanently on one side of the line. On the opposite side some blocks are reserved for frequently changing products (,, D, etc.). Product is always run on the left conveyor track, where it is processed in SIPLE i-mode. t the same time, products with smaller lot sizes are produced on the right conveyor track. When the setup must be changed from product to product on the right side, the changeover can be accomplished while the line keeps producing product without interruption. Feeders can be exchanged without any hurry and a change of the changeover tables is not necessary. Product families and are being produced Product family is being produced Product families and are being produced preparation area preparation area preparation area Fig. 6: Side-by-side production of high-volume products (continuous) and small lots (with setup changeovers) with dual conveyors and SIPLE i-mode 13

14 4. ombinations with floating setup or use of changeover tables with random setup s explained in sections 2.1 and 2.2, changeover tables are a good solution for a variety of challenges. With random setup, changeover tables can now be set up with the feeders installed in any available slot. The results are outstanding, because this new setup method takes a lot less time in the setup preparation area and delivers more flexibility when it comes to balancing the line. lthough the line s speed drops minimally, its overall productivity receives a significant boost. 5. Summary No matter what the flexibility requirements of an SMT production plant look like today the SIPLE portfolio offers for each manufacturer a solution that will guarantee maximum output for his specific product mix and production schedule. The proper analysis and the right decision achieves huge time and cost savings in a complex production environment. Tapping this potential requires a detailed analysis of the product mix over a long period of time (including future requirements). Only on the basis of such an analysis and the current or planned production environment can the best available solution be found. Our recommendation: enefit from the know-how and experience of the SIPLE experts in the SIPLE team. They look at the general conditions in your production and conduct a detailed analysis of your production data to generate a highly accurate simulation of your individual production scenario. ased on the results, they can then develop and implement the best solution for an efficient and cost-effective production in close cooperation with your team. Our SIPLE experts are available to answer all your questions regarding innovative setup concepts. Or visit us at where you can find detailed information and get in contact with the SIPLE team with no obligation. 14

15 SIPLE setup concepts, an overview Quantity Fixed Single Family setup with static/dynamic changeover table concept Floating Low Product Mix SIPLE Pro Optimizer SIPLE Siluster Professional SIPLE Random SIPLE Split Table Mode SIPLE LES Fixed setup characteristics Production Environment Planning (Long planning horizon: ; short planning horizon: - - -) verage lot size >1000 changeovers per shift <1 SIPLE Features SIPLE Pro Optimizer SIPLE enter (case by case) Family setup characteristics: Production environment With changeover table, With changeover table, static pre-setup dynamic pre-setup Planning (Long planning horizon: +++; short planning horizon: - - -) verage lot size changeovers per shift SIPLE Features SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Siluster Professional SIPLE Siluster Professional SIPLE enter (case by case ) SIPLE enter (case by case ) Random (at changeover table) Random (at changeover table) Floating setup characteristics Production environment With fixed setup on the line lock-wise Feeder-by-feeder Planning (Long planning horizon: +++; short planning horizon: ) + verage lot size 1/> changeovers per shift 1-3 >5 >5 SIPLE Features SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Pro Optimizer SIPLE Siluster Professional SIPLE Split Table Mode SIPLE Split Table Mode SIPLE enter SIPLE Siluster Professional SIPLE Siluster Professional Random (on the line) SIPLE enter SIPLE enter Random (on the line) Random (on the line) SIPLE LES SIPLE LES 15

16 SIPLE Headquarters SM ssembly Systems GmbH & o. KG Rupert-Mayer-Strasse Munich Germany Phone: Fax: SIPLE South sia SM ssembly Systems Singapore Pte Ltd 2 orporation Road #01-03 orporation Place Singapore Phone: Fax: siplace.sg@asmpt.com SIPLE hina SM ssembly Systems Ltd 138, Pu Dong venue, Pu Dong New rea Shanghai hina Phone: Fax: info.china@asmpt.com SIPLE mericas SM ssembly Systems, LL 3975 Lakefield ourt Suite 106 Suwanee, G Phone: Fax: easales.sea@asmpt.com SIPLE South West Europe SM ssembly Systems SS Z Parc Gustave Eiffel 6 avenue Gutenberg ussy Saint Georges France Phone: Fax: marketing.siplace.fr@asmpt.com SIPLE entral Eastern Europe SM (ssembly Systems) GmbH & o KG Kürschnergasse Vienna ustria Phone: Fax: siplace.cee.at@asmpt.com SIPLE North West Europe SM ssembly Systems Sofielundsvägen Sollentuna Sweden Phone: Fax: siplace.se@asmpt.com Edition 2/ ll changes reserved Order No: SM-67-X-7600 Printed in Germany SM ssembly Systems GmbH & o. KG The information in this brochure consists only of general descriptions and/or performance features which may not always apply to concrete products as described or which may change as a result of technical developments or advances. ny specific performance features and/or capabilities will only be binding if contractually agreed upon. ll product names are brands or trademarks of SM ssembly Systems GmbH & o. KG or other suppliers. Their use by third parties may violate the rights of their owners.

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