Mr. Jonas Ernst is Sales Engineer and expert for set up concepts within the Fuji Team. After the study of electrical engineering, he works as a Technical Sales for active Parts like microcontroller. With four years Fuji affiliation still relatively new in the industry, he is responsible for completely West Germany as well as key accounts in the EMS and semiconductor sector.
Fuji Machine MFG.(Europe) GmbH
Peter-Sander Str. 43
55252 Mainz-Kastel (Germany)
Fon : +49-6134 / 202 143
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Fax : +49-6134 / 202 200
There are several points which cause doubts when thinking about the AB Mode. Is there enough feeder space? How does it work with prototypes? Is there enough time for side A or side B. is the printer fast enough….
Jonas Ernst, Sales Engineer at Fuji Machine explains the secrets behind the AB mode, gives detail information how the software supports the operator, says where is potential to save money and what else needs to be considered.
Fuji Multi Job Line Balancer AB Mode
The right Setup concept saves Money and time
The electronics manufacturing characterized more by small to medium-sized quantities with frequent product changes. Short changeover times and flexibility are the most important requirement in the foreground. Machine stoppages caused by setup changeovers like the pallet exchange affecting the performance of the whole line negatively. Complicate setup plans stealing flexibility.
Producing quicker, cheaper, in smaller lot size with same quality – this is part of Industry 4.0 and target of every manufacturer. The right tools to achieve that target is delivered with Fuji’s NXT and the Software Flexa Multi Job Line Balancer.
The current Situation when changing Jobs
If you have a look at a SMD production line, you see a lot of machines working in line. These are set up to the requirements of the job they are producing. If you change the jobs on the production line, settings have to be changed in most cases. The printer becomes a new stencil, the oven a new profile. New materials have to be loaded on the pick and placing machine. These operations take time in which the line is not producing. This lead to the long-time goal, to minimize stoppages affected by changing settings. There are already existing ways to achieve this goals. For example, through standardisation, using the same oven profile for multiple jobs, or through better handling like fast changeable stencil frames and automated conveyors. Don’t forget the smd mounter, especially here intelligent set up solutions have led to a shortening of stoppages.
An important example is the usage of the so called family set up where more jobs mostly with similar parts are put together on a feeder pallet. By doing this, the benefit is that more jobs can be produced without stopping the machine. If the change of the pallet is then done by movable feederunits, you can minimize the downtime of the machine down to a few minutes per pallet. The concept changing feeder pallet unfortunately comes along with some negative points. Pallets have to be set up in advance. It also means that additional pallets, feeders and parts are needed. High cost for dead capital. The feeder pallets have to be set up by additional persons. If you take a closer look to the arrangement of the individual feeders, you can see that the optimal performance will be reduced because of not optimised feeder positions in order to use family set up. Another negative point is that you will lose flexibility because the set-up have to be prepared in advance. What happens when unscheduled orders arrive or prototypes have to be produced? Especially with the rise of high mix low volume production, set up concepts like family set up and changing feeder pallet with family set up show dramatically how less flexibility is given. There is a demand for a new concept.
Multi Job Line Balancer AB Mode
The idea behind the set up concept of ab mode is to separate the feeder pallet in two areas, the area A and the area B. The kind of separation can be chosen freely, for example 50:50. First task is to load parts on area A. By doing this, jobs are put together in a family set up based on production time. As soon as to the family belonging parts are loaded to the machine, the production begins. While the machine is production, the area B is set up. As soon as the programs on side A are produced finish, the machine starts with producing the jobs on side B. the changeover works with almost no stoppage. In the upcoming time, it’s the responsible of the operator to empty side A and reload it with new feeders. When side B is finished, the machine then switches back to side A production. The construction of side A, B, A2, B2 is made by the Multi Job Line Balancer. And moreover the software is able to help the user to consider special wishes when creating the AB Set-ups.
It is the aim to deliver a set-up concepts which provides following requirements:
a) Non-stop production. ->No stoppage caused by feeder-exchange for setup.
b) Absolut high flexibility. -> Prototypes and sudden orders should be able to be produced efficient without stopping the machine.
c) Lowest invest. ->Eliminate the use of additional feeders and parts and total saving of additional pallets.
Since the NXT series, Fuji Machine provides a concepts which allows the operators a production without stoppages. The software and the concept behind this enormous time saving method is called multi job line balancer. The MJLB provides unlimited flexibility and eliminates additional pallets, feeders and parts because pallet preparation is not needed.