How to apply MES system to realize SMT feeding error prevention?

- Jan 15, 2019-

Before SMT equipment patching, it is necessary for operators to put the tray on the right Feeder, and then put the Feeder on the right SMT equipment station. In this process, misuse of materials or misuse of Feeder often occurs. Because SMT equipment is running at high speed and continuously, if this mistake can not be avoided in advance, it will cause rework or scrap, which will bring huge losses to the enterprise, we should avoid it. In order to avoid this situation, the best way is to compare the corresponding relationship between the feeding tray, the Feeder and the station to be loaded with the feeding table during the feeding process.

In order to achieve the purpose of comparison, the basic data of material station table in MES system should be established first. A complete material station table data basically includes product code [or work order code], material code, Feeder specifications, production line code, equipment number, station number, for the double panel also includes panel information [A/B plane], for the double table equipment also has Table number. Material table data are generally maintained by technicians and entered into the computer connected with SMT equipment in advance. Before material comparison, only import this information from the computer of SMT equipment into MES system.

Speaking of this, you may consider another problem, that is, what if the data of the material station table itself is wrong? In the electronic assembly industry, a product consists of hundreds of electronic devices. These electronic devices have many substitutes or designated materials. In order to reduce costs and maximize the use of stock surplus, the material may be changed frequently in the production process, so the material station table needs to be changed frequently. In view of this situation, it is necessary to minimize the possibility of errors in the material table of the material station. There are two ways to achieve this goal: first, after changing the material table, the system forces users to compare the material contained in the material table of the product with the invoice list of the current work order. Only when the results of the comparison are consistent or the user accepts the difference, can the material be allowed to continue to be used. Secondly, the material table data entering MES system itself is composed of two parts, one part is BOM (including material code and Symbol number) of the work order, the other part is process BOM data prepared by technicians. The process BOM data does not contain specific material information, but only gives the site and Feeder specifications of a SMT equipment corresponding to each Symbol. The process BOM data is basically fixed for each type of machine, and only the BOM data of work order batching are changed. The BOM data of work order batching are often generated and adjusted in ERP system, and the possibility of error is very small.

After having the data of the feeding station table, we need to consider how to prevent errors in the process of feeding scanning. Simply speaking, feeding error prevention means that the system compares the material label, Feeder label, station label scanned in the process of user feeding with the material table data, and gives clear warning information when discrepancy is found, so as to achieve the purpose of checking and warning. The seemingly simple SMT feeding operation has its own complexity. A complete and practical SMT feeding error prevention system needs to provide at least the following functions: First, during the whole production process of SMT workshop, feeding scanning can be summed up into four business types: feeding, feeding/feeding, blanking, QC sampling and comparison. The feeding error prevention system should first provide a system that meets these business types. Secondly, many electronic products produced by customers involve single-panel, double-panel and mixed jigsaw with many kinds of products. The feeding error-proof system should be able to support various complex product structures and maintain the coordination with customers'business habits to the greatest extent. The feeding error prevention system needs to collect label information scanned by the operators before comparing the data of the feeding station table. The system must consider how to prevent the leakage of the operators, so that the system can really play a role, while reducing the complexity of the operation of the system as much as possible, and reducing the resistance of the front-line personnel to the system.

The above is mainly from the software point of view, it is worth mentioning that most MES software provides a special sub-function module for SMT feeding error prevention. There are many kinds of hardware available for SMT to realize feeding error prevention function. One of the equipment with the smallest investment is to configure only an off-line inventory machine, which downloads the data of the feeding station table to the inventory machine. Secondly, we can use the combination of wireless scanner and PC, which has lower investment cost, and the error-proof software running on PC can realize various complex applications and easy to expand the functions. The disadvantage is that the combination of wireless scanner and PC can be used. The location of scanning acquisition may be far away from the computer, and the interactivity is not very good. If customers have higher requirements for all aspects, they can also consider using PDA equipment supporting WinCE platform, which can solve the problem of interactivity very well, and does not occupy the production line space, and is easy to arrange. The disadvantage is that the software development cost is high and the equipment investment is high.

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