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Page 72


www.us-tech.com


May, 2021 Integrating Automated Component Storage Towers


into the Factory Environment in Industry 4.0 By Robert J. Black Jr., Essegi Automation S.r.l.


between the warehouse and the production floor, ensuring that all components reach the production lines accurately and at the proper time. The automated component storage sys- tem has come to play a major role in improving productivity and efficiency for many electron- ics OEM and EMS companies. Combined with a comprehensive data-


O


base of all materials, processes and procedures necessary to manufacture these products and software to handle the data, these automated towers are a powerful tool for both high-volume manufacturing and high-mix environ- ments. While most companies use an


enterprise resource planning (ERP) system to help manage the business, they may also use a manufacturing execution software (MES) system on the factory floor. Also, the many pieces of equipment used in the manufacturing lines may have their own operating software, main- tenance software, individual machine con- trollers, and line controllers. The integration of these various systems


is a challenge, but can be overcome with com- plete, accurate information in the database of materials, processes and procedures.


Connecting to ERP ERP is the integrated management of


main business processes, often in real time and mediated by software and technology. ERP provides an integrated and continuous- ly updated view of core business processes using common databases maintained by a database management system. ERP systems track business resources — cash, raw materi- als and production capacity — and the status of business commitments, such as purchase orders and payroll.


Component reels in trays to be handled in an automated storage tower.


The most important pieces of informa-


tion transmitted from the storage system to the ERP are the numbers and quantities of all components held inside. This includes the unique ID of each reel, the manufacturer’s part number, lot number, date code, and any other special information. Through this link, the ERP can be


updated as frequently as desired. The storage tower can confirm with the


ERP system the components by reel, tray and unique ID that are in production, their cur- rent location and the jobs and bills they are assigned to. For moisture-sensitive devices (MSDs),


tracking is available to the ERP system at any time. Each time the component was withdrawn for use, the time it was outside the controlled environment, when it was returned, and the remaining validity time for the component before expiration is all record- ed and shared as needed.


ne of the key requirements for “lights out” manufacturing in the smart factory is streamlining the material flow


The automated component storage sys-


tem can be connected with the ERP system easily, as well as with MES, pick-and-place lines, etc. Through its API interface, any soft- ware can easily communicate and receive information from the storage system, and automatic file sharing with other software is possible. The result of these connections is that all company systems immediately are updated to inventory availability, allowing for a more efficient and timely production cycle.


If the manufacturer uses the ERP sys-


tem to manage production and generate orders to pull kits, it can send the bill of materials (BOM) directly to the storage tower to automate the collecting of parts.


Communicating with MES MES systems are used to track and docu-


ment the transformation of raw materials to finished goods. MES provides information to help managers understand current conditions on the factory floor, and where to optimize to improve output. MES also works in real time to enable the control of multiple ele- ments of production, including inputs, per- sonnel, machines, and support services. In most cases, when MES software is


used, the automated component storage system communicates primarily with the MES, which then passes information to the ERP. The MES sends the BOM and


requests the pulling of kits from the auto- mated storage systems and also receives the


input from the automatic MSD component monitoring system run by the storage system.


Pick-and-Place Data The storage system can communicate


directly with the pick-and-place systems’ line control software. It will deliver the kit of components specified by the ERP system or the MES to the proper line. The kit then can be loaded onto feeders and onto the line. At the end of the production run of that


assembly, the components can be removed from the feeders, loaded into cases barcode- side up, and returned to the automatic stor- age system. For most modern pick-and-place systems,


the placement machine data can be used to update the components in each reel or tray as they are returned to the automatic storage system. When a reel is returned to the storage tower the unique ID is read, and the storage tower requests the quantity information from the pick-and-place line control. Each pick-and-place system


knows how many parts from each reel have been placed and how many mispicks occurred during the picking from that reel. These numbers can be added


together and combined with an attrition number that accounts for the number of parts on average lost when a reel is loaded onto a tape feeder. By combining these numbers and subtracting the total from the previous inventory count for that reel, the inventory quanti- ty can be kept up to date.


Supplying Components Another exciting feature of


the automated storage system is its ability to supply components to the production line in anticipa- tion of its need. Users can set a warning level on their pick-and- place machines so that the pro- duction line alerts the storage system when a component reel or tray is approaching empty. Even if the storage system is


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