Case Study: Reducing recall risk down to no more than three PCB panels
All incoming SMT components are regis-
tered to a unique reel or tray ID number.
The database links the vendor name, part
number, date code/lot code and incoming
quantity to each reel/tray ID number.
2. Storage & retrieval
Registered material is managed in auto-
mated bin elevators for easy storage and re-
trieval. Quantity on each reel is maintained
automatically by the system, including
reels returned to stock through continuous
Figure 1. A de-paneling machine cuts the tabs Figure 2. All the trace data collected by vManage is
countdown based on placements, dropped
between each PCB to separate the panel into single now linked in an unbroken chain to the top assembly
parts and waste. boards. The vManage system knows the step & SN (i.e. the unit sold by Meta System). This process
repeat pattern (including bad board marks) from the of collecting and linking the data gives Meta System
3. Kitting
program run on the SMT machines during assembly. the robust traceability they need.
Material required for each production
program is listed and then pulled from bin
elevators and sent to the kitting area. Here
number. number and assures the correct quantity
Once separated, the individual PCB is
the reels are mounted on feeders and the
for the lot size. Part numbers and feeder
assigned a new serial number (SN) printed
reel ID is then linked to the feeder ID in the
locations are acquired from the machine
out on a label applied to the PCB cover or
vManage database.
interface based on the actual program.
chassis. At Meta System, the new label is
applied to the center of the molded plastic
4. Setup & changeover
3. Automate standard process for handling
cover of the unit. All trace data is now
The machine interface guides the opera-
stock
transferred to the new SN automatically by
tor through setup/changes. The system is
Only registered material is allowed into
the system.
closed loop because the interface knows the
the bin elevators, and vManage controls
program running on the machine and the
this process and manages the quantities in
summary of benefits in addition to
required feeder position for each part num-
the transactions. Since the process is now
traceability
ber. Sensors on the carriage alert if a reel is
standardized, there is no more variability in
Even though traceability was the primary
loaded into the wrong position.
the data from different styles or techniques
requirement at Meta System, the solution
used by different people.
provided several other key benefits that cre-
5. Splicing Control
ated the return on investment.
The system alerts the operator when a reel
4. Eliminate counting parts by hand
The vManage solution that the
is nearing the exhaustion point and forces
Manual counting is error prone and costly.
company chose, from Valor Computer-
the registration of the spliced reel within
vManage handles this automatically as
ized Systems, was easy to implement. Meta
a preset quantity of placements past the
materials are consumed on the machines,
System management has a high degree of
exhaustion point. An incorrect reel (i.e. PN)
including waste. When excess materials are
satisfaction with this solution implementa-
stops the machine. The closed loop system
returned to stock, the remaining quantity is
tion and the resulting ROI. vManage modu-
calculates the splice point based on actual
known accurately. Lost time is also reduced
larity and scalability allows Meta System to
placements and dropped components.
since the machines do not stop due to an
progress and expand at the level that works
“unexpected” shortage.
best for them. Today they have two factories
6.User Interface
installed for traceability on their SMT lines,
An easy to read interface to the machine
5. Eliminate setup errors on parts with
with plans to expand into box build. Next
keeps the operator informed on kitting,
identical shapes
they will roll out to two more plants. So far,
machine setup, low level warning, splicing,
Machine vision systems work based on
in less than two years, Meta System is al-
moisture sensitive device expiration, pickup
images captured of the component shape.
ready receiving a return on their investment.
errors, feeder errors, feeder maintenance
Many parts can share identical shapes, while
The ROI at Meta System comes from
and machine performance. Each machine
their electrical values are very different. The
five primary areas.
has its own standardized display of the user
human eye can also be fooled, especially
interface.
when parts themselves are too small to have
1. Minimize accounting problems
discernable markings. vManage controls
ERP systems frequently fall short on manag-
panel iD linked to pcB iD
the part number linked to a reel ID from
ing material once it leaves the stock room.
A critical element in the unbroken chain
the beginning of the process and follows
vManage keeps an accurate accounting of
of trace data is connecting the visual panel
the part number continuously throughout
material quantities on the shop floor and
ID found on the panel barcode with the
assembly and any subsequent return-to-stock
feeds real-time accurate data back into ERP,
temporarily invisible PCB ID maintained
and kitting cycles. When a reel is placed
adding significant value to the ERP system.
inside the database. Before a panel is
into a machine a closed loop systems insures
separated into single PCBs, the software has
the correct part number is loaded into the
2. Eliminate kitting errors
already assigned an internal serial number
correct position according the program run-
vManage creates a standardized process that
to each PCB in the array, and all the trace
ning on the machine at that moment.
integrates with actual machine programs
data is continuously linked and updated to used in production. vManage controls the
each individual PCB by this internal serial use of the correct feeder type, correct part
www.globalsmt.net Global SMT & Packaging – June 2009 – 35
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