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May, 2016
The Benefits of a Connected, Intelligent and Traceable Production System
By Davina McDonnell, Saline Lectronics, Mitch DeCaire and Anouk Hurbutt, Cogiscan
communicate with each other and share data seamlessly. Leading man- ufacturers are gaining a competitive edge by exploiting machines equipped for Industry 4.0 to create a connected and intelligent manufacturing envi- ronment. These machines not only collect and analyze immense amounts of data, but communicate directly with each other in a smart and unified production system. Saline Lectronics, an electronics
O
contract manufacturer based in Michigan, has organized its surface- mount assembly operations around this concept. By using software to in- terconnect its factory, the company has seen positive improvements in job setup, changeover time, defect rates, and overall throughput.
Track, Trace and Control Sensitive to changing trends
and emerging advanced traceability requirements, Lectronics installed Cogiscan’s track, trace and control (TTC) system, which offers traceabil- ity of the materials used, traceability of all test results and management of any required repair steps during PCB assembly. It is also used to er- ror-proof line setup, monitor stock
TTC system software links the production process from raw materials to final assembly.
throughout the factory. The software links the various machines together that are used to produce a final PCB assembly. The company must keep track
tomers. Careful management of this inventory, including correct stocking, precise counts and inventory move- ment, is crucial for daily operations. With the TTC system’s inventory
nce a scenario seen only in sci- ence fiction, the production ma- chines of today are designed to
levels and provide real-time visibility of products and raw materials
of an enormous amount of raw part numbers for a large group of cus-
management software, Lectronics now has real-time information re- garding the location of parts, exactly how many remain and when to refill a machine. Setting up a job for production is
one of the most critical tasks in a manufacturing environment, and be- ing able to locate parts accurately al- lows for a smooth set-up process. If an error is made during set-up, or if set- up is delayed due to missing materi- als, it has the potential to wreak hav- oc on the rest of the assembly process. Cogiscan’s inventory tracking system has significantly improved set-up op- erations at Lectronics, and in certain cases of assemblies with large num- bers of components, it has improved set-up time by 33 percent. Now that the company has real-
time visibility of inventory, techni- cians no longer waste time looking for parts, because the software tracks the location of components. The company has expanded the soft- ware in such a way that component locations are displayed down to the very bin they are in. Before develop- ing this inventory system, a techni- cian pulled a part from the stockroom for set-up, and the system would dis- play the part as stocked, but not show its precise location. Now, the
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