February, 2020
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Material Handling To help bridge the connection
between material handling systems and machine operation programs, Javad purchased and deployed 10 In- ovaxe SMT reel and tube storage sys- tems. These products were intro- duced to the market five years ago. With Inovaxe’s help, Javad was
able to modify their existing systems to accommodate its current WIP ma- terial handling processes. This al- lowed more automated material stor- age systems within Javad’s defined framework. Inovaxe has been Javad’s material handling solutions partner since 2014 and has been key to help- ing the company take its ideas and turn them into a defined and function- al shop floor process. By using automated material
storage and handling systems, Javad significantly reduced feeder set up time by over 50 percent with the new process, eliminating one handling step of feeder set up position search- ing. The handling efficiencies in both kitting and WIP return processes were also significantly improved.
Control and Traceability Software
Automated material handling
systems are package-based, such as reels, tubes and trays. The material handling software guides the opera- tor to pull or return a package from a unique storage location. Javad established a unique iden-
tification (UID) numbering system in 2010 and had been using it for mate- rial tracking and identification. By us- ing the new material storage system, the company found that with the ben- efit of UID, it could leverage its mate- rial tracking capability at the package level, throughout the entire material and manufacturing processes. After collaborating with Ino-
vaxe to customize the software, a re- al-time UID-based WIP scanning system was deployed at Javad in 2015, which was tailored to its WIP handling processes. For many customers, the com-
pany builds more than 50 PCBs, with many using the same raw compo- nents. When building multiple jobs for a customer in a short period of time, efficiently and accurately refer- encing large amounts of common parts in WIP from job to job became a challenge. In many cases, one job is being taken from the line and the next is scheduled immediately after. WIP referencing has been the
biggest beneficiary since the UID sys- tem was integrated into the new auto- mated material storage and handling systems. The WIP referencing time was reduced by 80 percent. According to Javad’s studies, a job with 100 SMT part numbers, on average, 15 feeders would be referenced to the new ma- chine positions for the next job in line, without tearing down the feeders. This process can be time con-
suming, as once the job has been com- pleted, operators must locate the 15 referenced feeders from the 100 used. The referenced feeders then need to be placed in new locations. In the new system, the operator can simply ac- cess the “WIP Referencing” interface from a tablet for locating and reas- signing the feeders to the new job. Package level traceability was
also achieved by using the UID num- bers throughout the entire manufac-
1 See at IPC APEX, Booth 1048 1 9:33 AM
Give us a call for more info 856.324.6776
turing process, from incoming receiv- ing inspection to WIP return. A de- tailed report can be easily generated for any part number or UID, includ- ing the name of the user who han- dled it during the entire manufactur-
ing process with timestamps. Component manufacturing in-
Page 23
Achieving “QualFiciency” in a High-Mix EMS Environment Continued from page 21
could be used for investigating quali- ty issues or potential recalls.
formation was also tied to the UID number including manufacturing part number, purchase order num- ber, and lot code number, which
Material Control Goals
First in, First Out. Many studies have shown that component aging can cause poor solderability and product reliability issues. Javad integrates a date code into its UID numbering sys- tem for each package it receives, en- suring that the packages with the old- est date codes are used first.
Time study result comparisons of non-value-added and low-value-added processes.
Error Proofing. During feeder set up, operators are required to scan the UID number of the package on each feeder to a designated feeder po-
Continued on page 25
manufacturing, take control of your materials with Vision.
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materials analysis device improved control in your manufacturing environme performing rapid assessm materials on location and
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