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Do you realize that expensive SMT machine time and materials is wasted due to wrong feeders and components?
Do your SMT line operators spend hours to review information on a paper check list and still encounter errors?
Setup Center provides a simple and easy to use solution for a structured Setup preparation process and feeder/component replacement process.
Setup Center
Easily track the Setup preparation
Prevent human errors during Setup preparation and Feeder replacement
Setup Center
Setup Center provides a simple and easy to use solution for a structured Setup preparation process and feeder/component replacement process. Customers using Setup Center report that Setup preparation and feeder/component replacement errors are reduced drastically or even eliminated completely. in addition, they report that Setup preparation time is reduced from hours to less than 30 minutes, depending on PCB complexity. The quantity of FAI cycles is drastically reduced as a result of using the tool, resulting in substantial savings in materials.
Customers can access and manage information (like who does what and when, what components were in use, what SMT machine was in use etc.) collected automatically onto a central (SQL) server.
As part of a structured process, Setup Center displays a dynamic graphical view of line and cart positions, and updates views on barcode reading by user (see figure 1). Same screens and elements are used for Setup preparation process and feeder/component replacement process.
Figure 1. Graphical View
Features
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Setup Center allows to use multiple divided and optimized assembly files as source for PCB information.
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Barcode (such as Component, Carts, Machines, Functions etc.) can be entered using keyboard or barcode reader (Wireless, Bluetooth etc.).
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Setup Center allows printing/exporting of reports such as preparation lists and preparation status list (divided by machine and front/rear).
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Setup Center allows comparison between different sides of PCB and/or working IDs including viewing the delta and printing/exporting of delta reports (preparation list and preparation status list)
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Setup Center contains settings screens for work IDs (including assembly files, side and extra description), lines structures, cart (flexible and build-in) barcodes etc.
Figure 2. DataLogic PowerScan PM8300
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Setup Center supports different types of barcode readers (including support of 1D or 1D/2D):
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Simple barcode reader (wireless option is recommended)
The system treats the barcode reader as typing the keyboard and all messages (and instructions)
appear on the computer screen.
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Smart barcode reader
The system communicates with a barcode reader, and it displays messages
and instructions on a screen of reader such as place/P.N., errors and more.
Also, build-in reader buttons are used by the system for actions such as position
skipping, clearing and more.
In this case, we recommend using smart barcode readers with display, 3/4 buttons
and base station called Datalogic PowerScan PM8300 (see figure 2) or similar model
from same vendor such as PM8500/PM8700/PM9100/PM9300/PM9500/... etc.
Using this barcode reader raises the quality level (less human failures) and
saves time (operator, line etc.).
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Smart device with build-in barcode reader
The system communicates with a device (that looks like a mobile phone on the handle),
and our android application on device displays messages, instructions and buttons
on a screen of the device. Also, it brings more information than a smart barcode reader.
In this case, we recommend using a smart device called Point Mobile PM80 with handle (see figure 3).
Using this barcode reader raises the quality level (less human failures) and
saves time (operator, line etc.).
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Figure 3. Point Mobile PM80
Summary
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Offline - SMT Setup (feeders) preparation process
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Online - Replacing Feeders process
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Importing different SMT Setup file format
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Management of Line Structures, List of Carts etc.
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History of each Setup preparation and Feeder replacing
Business benefits
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Cleaner NPI loops and no reworks resulting from wrong feeder
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Lower production costs
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Higher productivity
F. A. Q.
Possible Extension: Traceability
Today, every medical, military, aviation, etc. product requires full serial number traceability. Setup Center includes extension, called Traceability, which allows collecting and crossing serial numbers on Setup preparation process, feeder/component replacement process and SMT production process (using fixed barcode reader of each PCB/Panel). The extension allows to cut these data and to know, for example, where and when serial number of component was in use (assemblies, PCB/Panel serial numbers, dates etc.) and so on. Our customers report that this extension is very critical on recall/RMA process and it saves a lot of time on detecting a right population of PCBs/Panels to be checked and fixed.
Figure 4. The ID of PCB/Panel
Possible Extension: Automatic warehouse
In recent years, the SMT production floor has been upgraded, including the addition of automatic warehouses. The Setup Center system can connect to an automated warehouse and order components directly from a barcode reader.
Figure 5. Automatic warehouse
Return on investment (ROI) calculator
We've created a simple ROI calculator to estimate the operating costs of not using the Setup Center system. Here are some guided questions:
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What is the average amount of SETUP preparation process per month?
This amount depends on the form of activity. Our customers with 2-5 SMT lines said that they perform about 150-250 SETUP preparation processes per month.
SETUPs
per month
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How long on average does it take to sort components on (or according to) carts / tables as a preliminary offline step per each SETUP preparation process?
This time depends on amount of feeders. Our customers estimated that such a sorting process takes about 2 hours in average per SETUP preparation process (about 90 feeders/components on average).
Hours
per SETUP
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How long on average does it take to perform a validation process per each SETUP process?
This time also depends on the amount of components. Our customers shared that this process takes about 1 hour on average for 2 people.
Hours
per SETUP
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Is the process validated on the machine or on the side (then a ready cart is loaded)?
Note that if a validation process is performed on the machine then the machine is disabled and not manufactured. Therefore, if the validation process is longer then production time decreases.
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How much time is spent on handling human malfunctions resulting from a manual process?
Our customers estimated that it takes about 10 hours per month.
Hours
per month
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Cost per person per hour:
$
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Cost of hour to stopped production line:
$
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Amount of SMT lines
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Amount of offline SETUP stations (for sorting/validating)
Total estimated costs to be saved:
27k$ - 36k$ per month
324k$ - 432k$ per year
ROI:
Immediately
Minimal hardware requirements (as a one-time investment):
4 PCs with LAN
4 Large Monitors
4 Smart Barcode Readers
Please note, a calculator does not consider the following costs:
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Bad case - a packet sent to the customer and returned due to a fault
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Additional delays due to malfunction such as production worker time to deal with the problem rather than production of another product and more.
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Feeder/Component replacing process and possible malfunctions