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People who continue to think in isolated technologies and standalone processes will be unable to fully exploit the benefits of the smart SMT factory and Industry 4.0.
Logistics are a prime example: It is not enough that printers and placement recognize the boards as they enter, load the appropriate programs and optimally configure themselves. To be able to produce something, the machine must have the appropriate components installed. This means that they must have been withdrawn from the component warehouse after being ordered, shipped and delivered. Accordingly, the smart SMT factory must have smart supply logistics. If it doesn’t, much of the line’s performance gets wasted.
Equipment makers are already working on integrated solutions. Orders are grouped in detailed production schedules and distributed over the individual lines as efficiently as possible. Based on the schedule, the system generates path-optimized pick lists and transmits them to the tablets of the warehouse staff. Automated storage systems are controlled accordingly and issue the components in the right order. Even SMT-specific details like MSD exposure times are taken into account. Thanks to the transparent networking of all activities, even a component package that just arrived in receiving can thus be forwarded to the line directly and without delay.
Normally, however, the logistics system uses driverless transport systems to carry the components early enough to the kitting area or the line, because it knows from historical data how long this process takes. On the line, the machines and feeders signal which components are needed for upcoming production runs and which can be torn down. Short-term changes in the production sequence are taken into account instantly.
The feeders can be installed randomly, which means that product B can be set up while product A is still running. Feeder registration, pitch settings—everything takes place automatically without operator interaction. When the time comes to switch to the new product, the line does so without stopping.
If you think that this scenario is nothing but wishful thinking, you are mistaken. Most of the technical components have already been developed. All that is needed is electronics manufacturers who push the networking of their machines and processes in order to take advantage of the smart SMT factory’s potential in cooperation with the suppliers of technology and equipment.
Editor's Note: This article was originally published in the proceedings of SMTA International.
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