Page 72


www.us- tech.com


September, 2019


Automating Stencil Changeover to Improve Line Uptime


By Miguel Arroyo Colomer, CSMTPE, Yamaha Motor Corporation USA


realize maximum performance, proper line opti- mization is critical. It would be wonderful if a pro- duction line could run a single product virtually nonstop shift after shift, but that simply is not pos- sible yet. Today’s high-mix manufacturing in -


T


volves running multiple products in varying volumes every day, and each time there is a change in the product run, the set up routine for that individual product must be run, and these set ups take time. Obviously, when setting up, product is


not being run. It is the goal of every good manufacturing engineer to make set ups as brief, as correct and as efficient as possible. The more efficiently this can be done, the more smoothly the production operation will run day in and day out with the highest pos- sible yields and the least delay. The goals of reducing lead time and


work in progress are of critical importance regarding a high-mix manufacturing envi- ronment. Lead time is the complete times- pan from the moment the order is issued to warehousing. Adapting the manufacturing line and


the SMT assembly process to product vari- ety is always a challenge. In a low-mix envi- ronment, creating specific setups for high- volume production helps keep costs down. Those days are behind us, for the most part.


Yamaha YSP10 stencil printer with automatic changeover.


he SMT PCB assembly production line runs smoothly when equipment in the line runs efficiently and at optimum speed. But, to


The order of the day is high-mix. Today’s manufacturing engineer does have an


ally, however, in IT and automation, working together. Properly utilized, IT automation helps providers deliver high-mix batches of goods in a short period of time, without large amounts of inventory. This can be achieved by designing a


flexible production line that is capable of adapting promptly to demand fluctuations.


Improving High-Mix Setups The most critical part of a high-mix produc-


tion line operation is set up. There are two basic types of set ups — indirect and direct. The indirect set up includes all of the activities that can be performed while the line is running. Its pur- pose is to maintain continuous operation of the line. Direct set up involves those activities


necessary for the line to run, and are per- formed during interruption of production. Direct set up includes such operations as changing tooling, replenishing materials, loading programs, and other similar types of procedures. The goal is to convert direct set up proce-


dures into indirect set up procedures if it is possible. This includes procedures that relate to solder paste printing, such as automating stencil changeover and removing or adding solder paste — steps that normally require operator intervention. By minimizing opera- tor involvement, the entire process can be sped up.


Multi-Role Workers Production line efficiency can be


improved through the standardization or elimination of tasks. Complex processes that require specialized personnel must be identi-


Continued on page 76


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82  |  Page 83  |  Page 84  |  Page 85  |  Page 86  |  Page 87  |  Page 88  |  Page 89  |  Page 90  |  Page 91  |  Page 92  |  Page 93  |  Page 94  |  Page 95  |  Page 96  |  Page 97  |  Page 98  |  Page 99  |  Page 100  |  Page 101  |  Page 102  |  Page 103  |  Page 104  |  Page 105  |  Page 106  |  Page 107  |  Page 108  |  Page 109  |  Page 110  |  Page 111  |  Page 112  |  Page 113  |  Page 114  |  Page 115  |  Page 116  |  Page 117  |  Page 118  |  Page 119  |  Page 120  |  Page 121  |  Page 122  |  Page 123  |  Page 124  |  Page 125  |  Page 126  |  Page 127  |  Page 128