András Kozma, ASM Assembly Systems, Austria
With 15 years of experience in the electronics industry, András Kozma (born in 1980) has been an account manager of ASM Assembly Systems in Hungary for six years, responsible for the sales of SMT production systems, such as DEK screen printers, SIPLACE placement systems, process control as well as material management solutions. He has collected extensive experience and knows the daily challenges of electronics manufacturers, such as the implementation of Industry 4.0., Big Data Management or Material Logistics, which have a huge impact on productivity. András supports Industry 4.0 aspiring customers to develop their smart SMT factory by creating innovative and user friendly solutions serving today´s and future industry needs.
The Smart #1 SMT Factory, does not just need inventory data, but intelligent control of material flows and all material-related processes – from material receiving and storage to pick processes, withdrawals and innovative, highly flexible setup processes to special procedures for MSDs or customer-supplied materials. ASM’s presentation explains how to provide transparency in your production and to open the door to new opportunities, by supporting your production processes with modern material management systems. These systems are vital for Industry 4.0 factories by introducing more efficient warehousing processes and the minimization of material-related downtimes. Gains in flow of material, flexibility and process reliability on the shop floor will be even greater.
On the move to the Smart #1 SMT Factory:
New demands on material logistics and material management
High-mix electronics production requires new material logistics systems that meet the special needs of SMT production environments. New solutions like the SIPLACE Material Manager link material-related processes and raise material logistics to a new level.
The SIPLACE Material Manager represents the new generation of SMT-specific material management systems. It uses no paper, but works with mobile scanners and handheld devices to link all material-related process steps in electronics manufacturing – from receiving to warehousing and setup processes to track-and-trace.
Component packages are labeled with unique IDs featuring clear text and a machine-readable barcode as soon as they enter the plant. Via these UIDs, the system assigns additional properties to each package, such as MSD data, manufacturer and batch information for track-and-trace applications, production or delivery dates for FIFO-based removal from stock, brightness classes for LEDs, and a whole lot more.
This metadata is then used and updated in all process steps. Examples the tracking and tracing of reels and/or packages across each station on the production floor, and MSD components are automatically blocked as soon as they exceed their exposure time.
More room in automated storage systems
The UID changes the inventory management processes radically. For example, it makes “chaotic warehousing” possible, because employees can place component packages in any coded shuttle or lift bin. As soon as the UID and the bin code are scanned, the system knows what is where. This speeds up transfers from and to the warehouse, prevents errors, and puts the rack systems to more efficient use.
Flexible setup concepts
The transparent material management system reduces the amount of “parts tourism” and actively supports modern, flexible setup concepts. For example, the SIPLACE Active Feeder Pool in the setup preparation area indicates with blinking LEDs which feeders and components will be needed in upcoming production jobs. As a result, many components don’t have to be returned to the main storage site because the material management system treats the setup preparation areas as storage locations. Another benefit: By interfacing directly with the placement machines, the system records the component consumption instantly and accurately, including rejects. This minimizes discrepancies between target and actual inventory numbers and makes the planning process much more reliable.
Inserting rush jobs
Squeezing in rush jobs in traditional environments is expensive and risky. It requires lists to be reprinted and jobs to be rearranged. The SIPLACE Material Manager, on the other hand, operates in real time. As a result, all changes are re-sequenced correctly and reassigned automatically to the appropriate workstations.
SIPLACE Material Tower: the compact, fully automated storage system
Additional benefit offers the compact SIPLACE Material Tower, an automatic and MSD-capable system for storing components next to the line, which is totally integrated into the SIPLACE Material Manager and optimizes the component supply system for SMT lines and kitting areas.
Paperless, real-time-capable and networked – the SIPLACE Material Manager raises SMT-specific material management to a new level and significantly enhances the process support at each workstation.