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Case Study: Flex Smart Factory at Fuyong
August 24, 2016 | Jeff Li, et al.*, FlexEstimated reading time: 10 minutes
Smart office, Smart Supply Chain, External Cloud and Smart Operations, and the Smart Operations require good Technical and Operation Architecture. The Cross Function Interconnections include: Machine to Machine, System to System, Machine to System, Machine to People, and System to People. In this paper, we will only share practices and achievements for Smart Operations in five sections: SMT – Connection and Real Time, SMT – 1 Head Count 1 Line, Wave-Standardization and Systemization, ICT, and SMT – eDashboard which are shown in Figures 3 to 7 for each section.
Figure 3: SMT – Connection and Real Time.
First, we focus on the data system and work for the data connection and real time database, the expectations for the database should be: connected data allowing automation, connected data allowing efficiency, and connected data allowing lower cost. Figure 3 is our brief description of SMT – Connection and Real Time that listed the main machines and key measurement data items. All data should be connected and real time to the control tower by company site cloud.
There are five Phases for the Smart Factory project plan. The project currently is at Phase I.
In Phase I, the following goals will be accomplished:
- Manufacturing Environment Traceability
- Scatter Function to Connection
- Mobile Monitoring of Quality and Production
- MTBF– TPM.
These are the experiences gained in Phase I: Shop Floor Interconnection, especially for automatically collecting data from the test machines of SPI, AOI to ICT and Functional Test. We also focused on test data analysis, providing real time feedback to the SMT line and improving the process. The interconnection between machines, people and machine, people to people, optimization of human and their optimization for technical and management personnel.
There have been significant achievements in Phase I of the Shop Floor Interconnection Project, especially for flexible, reusable, deployed solutions providing many benefits across final assembly, testing and packaging operations at the platform connection. In this session, we have completed some machine connection, overall process mapping, data automatic feedback to SMT process machine and process improvement based on testing data.
Figure 4 shows several examples to reduce head count as a result of the Smart Factory project. The goal is to have one operator for one SMT line.
Figure 4: SMT – 1 Head Count 1 Line.
Figure 5 illustrates the standardization and systemization for the wave machine. Solder dross systemization and wave solder dross reduction are also implemented.
Figure 5: Wave-Standardization and Systemization.
Figure 6 lists standardization and connection and systemization for ICT. There is robot automation at ICT which has allowed us to reduce head count by 10. ICT also links to the MES database. This allows a $96,000 annual savings.
Figure 6: ICT.
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