Optimizing the SMD process management of surface mount components:
To optimize the cost and quality of surface mount component (SMD) production, we must focus on the overall production method. Today, progress can only be made when production lines and supply chains are considered as a whole. The work of process engineers and the use of special tools are becoming increasingly important.
These days, when optimizing the cost and quality of surface mount device production, it is necessary to look at the entire production process. In the past, improving individual machines and selecting in-house processes might have been more than enough, but now progress can only be made in this regard when the production line and supply chain (from supplier to customer) are considered as a whole. The work of a process engineer and the use of special tools are becoming more important every day.
Process engineers don’t like to hear this. In the past, their job has been to solve problems themselves and respond to emergencies. People come to them when inexplicable problems arise, when scrap rates suddenly and unexpectedly increase dramatically, or when quality and efficiency decline. In most companies, their role remains unchanged.
However, in modern surface mount device production, things have begun to change. Price competition forces companies to proactively solve process problems. In the field of electronics, rapid technological progress also requires continuous advancement of technology. For example, we need to continue to introduce smaller (0201 and 01005) and more complex (μBGA) components, or environmentally friendly processes such as lead-free soldering. In safety-related fields, such as the automotive or medical device industries, laws require products to be reliable, requiring the use of more complex and comprehensive tracking systems to track products.
Figure 1 There are eight processes before or during the launch of a new product. Cost savings are possible through these processes and the right software programming and tools.
In all these cases, it is not just the individual machines or internal processes that are changing. The entire production process – including the selection, procurement and storage of components – must be improved and adapted. Because companies can no longer afford traditional trial-and-error methods, the traditional role of process engineers in electronics production is changing.
Predictable process
Predictable cost and quality production process:
The main job of the process engineer is still to prepare, execute and monitor the production process, but , with higher requirements. Today, process engineers must be able to accurately define or predict the consequences of these changes in the process on important performance indicators before they are implemented.
In order to successfully complete these tasks, as a process engineer, he must obtain the highest level of qualifications. They are enthusiastic about making improvements. They also need to have a clear direction, be open and good at collaboration. As a process engineer, he must manage quality and proactively prepare plans. He needs to have strong analytical skills and statistical process management (SPC) technology. Knowledge.
The arsenal is expanding
The arsenal is expanding:
The requirements for craftsmanship have increased, and at the same time, the tools that can be used are also improving. Recording and collection of data, which used to take a lot of time, can now be done automatically by the latest machines and tools. Steady process improvements and increased effectiveness help you analyze large amounts of data and automatically monitor the most important process parameters. When a process changes, these tools can calculate the impact of that change on the entire process in seconds. Therefore, engineers can use data models and scenario technology to simulate new processes outside the production line, without having to conduct repeated trials on the production line.
Tools for the product
Tools for all phases of the product lifecycle:
The design phase of the product. Leading technology suppliers have long recognized that process technology will become an important factor in improving the competitiveness of their customers. Some of today's new placement machines have many software modules and system solutions that process engineers can use to design, control and monitor the SMT process of many production lines.
The most important prerequisite is that these machines must use the same software and data structures, and their interfaces must be open and can be connected to other systems. Utilizing software capabilities that correspond to specific requirements at each stage of the product's life cycle, the process engineer's job becomes simple. This approach begins at the level of the product design phase, when launching a new product. A well-prepared set-up and placement procedure by the circuit board developer can actually avoid problems: CAD data and bill of materials (BOM) can be automatically written and converted into machine programs and installation instructions. But what happens if only one circuit board sample is provided? Through the software, programmers can call components from the database and place them on the image obtained by scanning the sample in various ways. The software automatically generates placement procedures and materials lists. Then, use the software's help function to search for missing components or misaligned components offline.
Figure 2 The management of changes in modern production lines has evolved from the change module, from requiring several people to using intelligent methods to change through software. With today's comprehensive software tools, product orders can be quickly and efficiently allocated to production lines with production capacity.
The process of launching new products has many benefits for electronics manufacturers. There is no need to occupy the machine, nor does it need to be dedicated to testing and running the NPI production line for a long time. Most of the work is not performed on the production line. A software-based approach to board inspection speeds up the start-up phase and is highly efficient from first production. Every change made using the software is automatically reflected in the program files. At the same time, users can also determine the range of program parameters, errors and limits, which can be monitored and checked later through the machine program.
Once the placement and installation programs pass offline testing, they can be directly downloaded to the production line for use, eliminating the need to manually debug the machine using traditional methods.
Running-in and maturity stage
Engineering data management (EDM) is a powerful tool for managing production data. It combines the advantages of central data management for multiple production lines with the ability to change programs on the production line. As a result, normal production was accelerated. All changes made on the production line are recorded, documented, explained and automatically sent to the master data management system. Whether these changes will be added to the central database is determined by the EDM's clearing pool. By modifying the version history and control system, it is possible to track the process, make all corrections, and limit these corrections to specific machines. When data is moved out of the master database, the production line-specific templates determine, for each product, which portion of the placement data and installation procedures are specific to the production line and which portion to the master database. In this way, the system can ensure that any changes in procedures resulting from engineering change requests (ECRs) are repeatable for all production lines and will not lead to accidents when executing these changes. Production progress. These features, which make processes safer and more reliable, are exactly what process engineers need. There are even more advantages for installed software. This software not only replaces products, but also checks components through barcodes every time components need to be replenished during production. At the same time, the software will help operators monitor the replenishment of components, while ensuring that component tapes are replaced and optimized according to process needs.
Once production is on track, process engineers start working on the next step of process improvement. Here again, the right software can be of invaluable help. Machine-generated reports provide detailed and in-depth information. For example, if scrap rate trends at a company, production line, or within a production shift lead to suspicion that a flaw in the process is the problem, a process engineer can analyze the data down to the machine or batch data. . Engineers can also discover whether any process modifications are producing desired results or causing undesirable effects elsewhere.
Finally, the time-consuming management reporting and preparation of key performance indicator (KPI) reports is almost completely automated. Not only does the software eliminate errors and improve the objectivity of reporting, it also allows process engineers to spend less time fussing with numbers, giving them more time to do what they do best – analyze and improve processes. .
Principles of maintenance and phase-out
Maintenance and phase-out:
At this stage of the product life, process engineers use the same tools, but process monitoring and Reporting is mostly automated. Routine reports gradually became prepared for the needs of specific target groups (operators, inspectors, administrators, quality control, etc.) and were essentially trend reports.
Phasing out involves removing infrequently used data from the operating system to make room for new data and improve system performance, but we must also ensure that the data can be restored to use at any time. For example, historical data can help new products accelerate the formation of stable processes.
Prospects
Two positive development trends will please SMT process engineers. On the one hand, their jobs are becoming more important to the bottom lines of the companies they work for. Their work focuses on improving the factors that determine a company's competitiveness - namely, cost, quality, efficiency and flexibility of the entire electronics production process.
On the other hand, machine manufacturers are increasingly recognizing this development and supporting it with the right tools. The activities in the development method reflect the main trend of the future: Internet-based tools and software modules can make process and management data available anytime and anywhere. Therefore, it is more effective and economical to use optimization experts, who can monitor and manage production processes in various factories from a distance. At the same time, network-enabled software can link otherwise separate programs. For example, a machine manufacturer's service personnel will be able to access the system remotely to check the status of the machine and adjust scheduled maintenance intervals. At the same time, the counter on the placement machine can be directly connected to the purchasing department or even directly to the supplier's ordering system.
Conclusion
As people increasingly need tracking capabilities, this has also strongly stimulated the integration of SMT processes with production execution systems (MES) and enterprise resource management (ERP) systems. Here, the job of the process engineer is to provide the appropriate process technology foundation during the launch of a new product, especially the required degree of accuracy. Combining confirmation of settings with barcode identification on printed circuit boards, there are technologies that provide all the necessary data for reliable tracking of products and components. Using an open XML interface, this data can be easily transferred to higher-level systems.
Another core concept for future development is real-time. Systems and software increasingly need to process and serve data in real-time to improve response times at all levels. This relies on process engineers to collect large amounts of data and compile it into manageable and content-rich information packages, making them more valuable to specific users.
*Siemens’ SIPLACE platform.