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Yamaha, Trans-Tec and ADCO Continued from page 21
Electronic & Engineering Materials
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Yamaha machines offered until after they had installed and put them on- line. In one example Barrett cites, “We had a customer who had three different products. With our old equipment, this required three differ- ent setups. Now, with the Yamaha placement system, we combine these different products in the software and have one common setup for all three products. Most importantly, if there is a change to any individual product, we can make these changes on the fly. We have separate teams, and we always try to have three jobs in the queue at any one time — one running, one tearing down, and one ready to go. The optimization soft- ware has been key to keeping this process flowing for us.” The scan software linking the
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part to the feeder and its cart has al- lowed ADCO to perform one-step veri- fication. He says that the company has not had a single issue with wrong parts in the four years since purchasing the Yamaha equipment. Every aspect of how they did things changed, including how they wrote the programs, loaded feeders, ran the machine, debugged the setup, implemented changeovers on the fly, and more. ADCO experienced improvements across the board.
Next-Level AOI When ADCO looked at investing
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in AOI, they knew that they needed to go to the next level. The company looked at three vendors, but since they had partnered with Yamaha and Trans-Tec, they were not going any- where else. “With our previous AOI equipment the main issue had been false calls,” Barrett says. “We had components that the
software could not figure out, and had to be inspected manually. Our initial problem was that the AOI was not failing every board. This was be- cause our new Yamaha placement equipment was not producing many defects. As an experiment, we pro- duced some defects manually to see if the AOI machine was working, and we discovered that indeed it was. It took us a while to get used to this!” In one example, the company
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had a BGA component that was fail- ing height inspection. Everything looked fine, but on closer examina- tion they discovered that the BGA in- correctly had no-lead ball-leads and these were not completely reflowing. The AOI picked up on this issue, which would have gone uncorrected otherwise. Due to their previous ex- periences with unpredictable AOI system performance, Barrett admits that they did not trust the AOI at first; but after some time, some test- ing and catching the BGA problem, they came to trust the machine. “We found that Yamaha had re-
ally excelled in the software develop- ment, which was an area that we were focused on,” Damman says. “We came to realize that the Yamaha ma- chines were the best available, based on what we saw and how they had performed. We were on the learning curve for the technology of 3D inspec- tion, which our new system has, and when we needed help, Trans-Tec and Yamaha came in and supported us. We learned that we could make 3D AOI work, and work perfectly.”
Support -- a Major Factor “When we were getting started,
we needed help getting the ball rolling,” Barrett says. “I made a call to Trans-Tec and the next day we had support. We were asked what our plans were, and I replied that we were committed to Yamaha and that we needed to see the same commit- ment from Trans-Tec. The response that I received from Jason Yi at Trans-Tec was, ‘I’m not leaving until you’re happy, no matter if it takes a week, a month or a year.’” “I’m pleased to say that the lo-
cal Trans-Tec service engineer stops in every time he passes this way,” says Barrett. “He spends a couple of hours on our floor and catches up with what we’ve been doing, because he may notice something that we were missing. The extra effort has not gone unnoticed.” In the end, both Damman and
Barrett say that the key factor isn’t the equipment, it’s the partnership — companies working together for mu- tual benefit. “In our view, Trans-Tec has experienced tremendous growth in recent years. They have added some great people to their existing team, and we feel very comfortable with that,” adds Damman.
Two Paths to EMS Growth According to Barrett, growing
an EMS business begins one of two ways; either you obtain the business from someone else, or you start at the ground floor. With NPI, there are al- ways challenges in design and compo- nents, he says. “The Yamaha ma- chines gives us the flexibility to adapt to new components — I put the part on the nozzle, scan the part, and it’s in my library. It’s as simple as that.” Sometimes, he says, they only get a strip of a few inches of taped compo- nents, but the Yamaha feeders han- dle these with no problem. ADCO has steady customers, but a large part of their business is new product devel- opment. “We see significant issues in this
business, but we are positioned cor- rectly to handle them,” he says confi- dently. “A troubling trend that we are seeing is that many established com- panies will bring their product to us, but during discussion it becomes obvi- ous that they don’t understand how to manufacture the product. The intent of the design functions is correct, but we have to work with the designers to get it right and correct the manufac- turability issues.” ADCO works in partnership
with its customers to drive down manufacturing costs — a critical part of the relationships the company de- velops. Therefore, it is extremely im- portant to be in front of the design so that it can address these many issues before the product goes into produc- tion. In any case, the company’s tech- nicians operate these machines every day and would not run anything else. They respect the machines because the equipment supports the compa- ny’s goals. In turn, Yamaha and Trans-Tec have given ADCO every- thing it needs to be successful. Contact: Yamaha Motor IM
America, Inc., 1270 Chastain Road, Kennesaw, GA 30144 % 770-420-5825 E-mail:
info-yima@yamaha-motor.com Web:
www.yamaha-motor-im.com and ADCO Circuits, Inc., 2868 Bond Street, Rochester Hills, MI 48309 % 248-853-6620 Web:
www.adcocircuits.com r
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