Modern analytical tools used in surface mount assembly help reduce downtime and increase production line efficiency by identifying defect sources and suggesting corrective actions.
Although surface mount assembly is a precise and reliable process, complications can arise when working continuously at high speeds. When errors or other issues occur, the production management team must restore normal workflow as quickly as possible. Each time the production line is halted, the company incurs losses that reduce profitability. These losses include not only direct costs from lost production but also labor costs during downtime, overtime costs, and urgent orders to catch up after resuming production, as well as rework or disposal costs for defective products that caused the stoppage. Waiting for deliveries also generates costs, and disruptions to normal operations can lead to inefficiencies. Additionally, it can impact commitments to customers, potentially leading to financial penalties.
On the other hand, detecting a problem may necessitate halting the line to avoid continuing the production of defective units. The operator or production manager must be promptly informed of the error. Downtime is undesirable, so manufacturers should do everything to minimize its occurrence to ensure optimal productivity and minimize unwanted costs. If halting production is unavoidable, the priority becomes resuming the production process as quickly as possible.
Troubleshooting tools
Today’s assembly equipment is equipped with systems that detect issues such as dirty nozzles or incorrect pickup point settings. Automated checks can be performed at various points along the line, including after screen printing, component placement, and reflow soldering, using the results to assist in real-time troubleshooting.
Manufacturers rely on software tools to help manage production equipment, detect any defects, and relay information to production supervisors. These include dashboard applications that provide an instant assessment of equipment and production status. Value-added tools, such as Yamaha’s quality control options and the associated Mobile Judgment application, are also available. The Mobile Judgment application can send detailed information about any detected defects, including inspection images, directly to a supervisor’s smartphone, helping assess the severity of the problem. Based on their assessment, the supervisor can recommend immediately halting the line if necessary until the issue is resolved.
Human-Machine Interface
These applications represent the interface where machines and humans collaborate to address problems that inevitably arise during a normal shift. The responsible team must use their skills to deliver the required quantity of each batch and ensure production proceeds on schedule.
This approach can depend on the quality of tools provided to visualize data collected from various locations across the line. Quickly identifying fault causes and resolving them swiftly also depends on the skills and knowledge of those overseeing factory operations. If, for some reason, the main supervisor is not on duty – perhaps working another shift, on vacation, or on sick leave – productivity can decline.
The latest advancements in data analytics can help eliminate reliance on individual judgment by automatically identifying the causes of any defects or other production issues. Directing operators to these causes enables more consistent production performance. For example, Yamaha’s latest YSUP Analytics dashboard includes advanced tools that use statistical techniques to identify the most likely causes of detected faults. It also recommends appropriate corrective actions. Analytical tools work in conjunction with graphical tools that help visualize equipment performance on the production line (Figure 1).
The new YSUP Analytics dashboard presents information in an easy-to-read format that can be interpreted at a glance. Ultimately, this enables each work shift to consistently ensure high production throughput and end-line efficiency while drastically reducing downtime. Based on a relational database with built-in querying functions that analyze data on-site, the software identifies probable causes of recorded exceptions in near real-time using statistical techniques. The automatic analysis capabilities of the new Dashboard application allow any authorized user to extract necessary information, analyze errors, and check corrective actions at any time.
Available tools include automatic pickup error analysis, which uses analytical methods including flow assessment, error code diagnostics, check data diagnostics, and image recognition diagnostics. Users can check the time and circumstances of pickup errors, see the exact location, and verify corrective actions (Figure 2). Yamaha verified the accuracy of automatic pickup error analysis using this tool in experiments conducted with a leading first-tier automotive manufacturer. Built-in features also facilitate root cause detection, including managing automatic judgment results and tracking corrective action content.
The capabilities of the base platform allow for adding further analytical tools, such as component placement analysis and print analysis. Moreover, the platform is open to utilizing artificial intelligence (AI) in future distributions, providing additional analytical capabilities and further speeding up troubleshooting directly on production lines.
Conclusion
Automation has enabled electronics manufacturers to remove human limitations from many production line activities. However, intervention remains necessary when judgment and assistance are required to handle exceptional circumstances and restore normal operation. The latest data-driven dashboard tools provide additional assistance in identifying and rectifying the causes of errors, helping to overcome operator knowledge limitations and shorten recovery times, ultimately enabling further productivity improvements.
**RENEX Group**, known as the exclusive distributor of Yamaha robots in the Central and Eastern Europe region, offers advanced surface mount assembly machines for SMD components, which are essential elements of production lines in the electronics industry. The company’s product range includes a wide assortment of Yamaha surface mount assembly models, including the YSM10, YSM20, YS12F, I-PULSE S20, I-PULSE S10, I-PULSE M20, and YSM40R. These machines stand out for their high efficiency, modular design, and ability to handle large PCBs, making them a versatile solution for various production processes.
As one of the leading players in the Polish electronics market, RENEX does not limit itself to supplying equipment but also offers comprehensive post-sales support. This service includes training, equipment servicing, and technical consultations to help clients fully utilize the potential of the purchased machines. The company also allows personal viewing and testing of Yamaha devices and robots at its Technology and Training Center. An added advantage is the Authorized Yamaha Training Center, which provides specialized knowledge on operating and programming industrial devices and robots.
Experts from the RENEX Technology and Training Center are readily available to help identify production challenges and suggest appropriate technological solutions. It is also worth noting that RENEX’s Service Department was recognized by Yamaha as the best European Production Equipment Service in 2020. This prestigious award is a testament to the world-class services offered by the company, reflecting the high level of service support provided by RENEX Group, both during and after the warranty period.