PCBA Tech - About introduction to SMT pull production solutions

1. Project goal:

1. Through the integration with SMT production equipment, real-time production data is obtained, and the system automatically deducts and monitors the consumption of materials, so that the system implements warehouse JIT direct distribution according to the requirements of the production line;

2. According to the existing process of the factory, optimize the operation process, improve the execution efficiency, and reduce the labor cost;

3. Improve the current conversion/line efficiency of the factory and reduce the costs incurred;

4. Meet the requirements of the factory production department for the MES system;

5. Enhance the brand image of the factory, expand the influence, and improve the efficiency of the factory.

2. Design principles:

With MES as the core, the display of kanban and boss reports is realized through the Yunxuntong report data interactive platform

Starting from the actual business of the factory, optimizing the standard functions of the system in accordance with the needs of the factory

Data standardization, simplification of interfaces, integration of information systems

3. Description of the status quo:

1. Material is issued according to the work order, and the physical objects are manually matched;

2. The electronic warehouse is equipped with 5 people for material preparation. After the order is planned, materials are prepared and issued according to the points;

3. The work order return material inventory is carried out manually, and the material loss cannot be traced;

4. The production will prepare the materials in the workshop, and the current material inventory cannot be counted quickly;

5. Handwritten material access card is required for material access management.

4. After MES is implemented:

1. To send materials according to production needs, only need to prepare a few hours of materials for the production line, and monitor the shortage of materials at the production station in real time according to the amount of deducted materials from production. Only the materials that are short of materials need to be sent through the kanban warehouse;

2. The mobile PDA collects detailed records of materials in and out, without the need for manual point-to-point and handwritten records, resulting in data waste;

3. The system implements JIT to directly issue materials according to the requirements of the production line, which greatly increases the turnover rate of materials;

4. Record the usage status of all materials, the work order is completed, and the work order loss list is automatically generated to realize the work order inventory.

5. Current status of SMT conversion/line:

1. Work order transfer materials are prepared in electronic warehouses and in-line warehouses, and there is a waste of multiple turnover operations;

2. Warehouse material preparation relies on experience to find materials, and efficiency is greatly affected by the proficiency of personnel;

3. There are multiple processes from warehouse picking to material online and all need to be checked, counted, repetitive work, and wasted personnel;

4. Warehouse materials are prepared by work orders, and on-line side warehouses need to distinguish front and back sides, machines, and stations according to the material table;

5. All materials and parts have been manually checked many times during the transfer process, which is inefficient and cannot be foolproof; (only two lines are imported into the scanning system)

6. Mainly manual operations, and a large number of reports need to be recorded (there are a large number of paper reports in the production line and warehouse);

7. All converted models need to be first confirmed;

8. The conversion mode is the traditional work order return and material preparation for the next set of work orders;

A year is calculated as 12 months, a month is calculated as 22 days, and an hourly production value of 800 yuan is calculated. It is expected that the line change time will be reduced from the original 2H to less than 1H. MES intelligent production will increase the line transfer/production efficiency by about 50 %

6. SMT production line efficiency optimization (line transfer/production analysis summary)

Line transfer/production cost calculation:

The 4 production lines average about 6 times a day, and each shutdown is 2H

4 lines a year, a total of 2H/time*6 times/day*22 days*12 months=3168 H

The total cost of downtime due to line transfer in one year is 3168H * 800 yuan = 2.534 million yuan/year

Transfer line/production to increase efficiency by 50% and save cost calculation:

2,534,400/year* 50% = 1,267,200/year

Subtotal: It is estimated that the conversion to production/line after the system is optimized for production can save the company 1,267,200 costs per year

Seven, SMT production line efficiency optimization (refueling analysis-optimization summary)

Every day, employees of each line fail to detect material shortages in time and cause equipment downtime losses, which account for 12% of the total refueling. The loss costs are calculated as follows:

A production line is about to replace about 40 reels of material in 24 hours

It takes 4 minutes for each plate of material to be changed

Each line is calculated according to the output value of 800 yuan per hour

Calculated based on 22 working days per month

4 lines a year due to staff inspections failing to discover material shortages in time, resulting in equipment downtime and lost man-hours:

4min/tray*40 trays*4 lines*22 days*12 months*12%=337.92H

Annual cost of refuelling loss:

337.92H*800 yuan/H=270,000

It is estimated that after the optimization, the cost can be saved by about 270,000 yuan/year

8. SMT production line personnel optimization (current situation)

1. The system is connected to the equipment, real-time acquisition of the material usage status, and automatically reminds the feeder to pick up when the pre-warning value is reached. All personnel are managed in a centralized manner according to the electronic kanban to prompt the online picking, which can optimize the feeder’s 70% inspection time and realize the personnel Streamline

2. The system is connected to the equipment, and the PDA moves and scans to automatically check the materials and automatically record the feeding process. Fully optimize 30% of the workload of the feeder;

3. Increase the centralized management and control of the distribution area to install the Feeder, and prepare the work order to transfer the solder paste steel mesh;

9. Real-time monitoring of placement machine equipment production