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RMS Enable Modular Manufacture
December 31, 1969 |Estimated reading time: 5 minutes
Reconfigurable manufacturing solutions (RMS) are more than a concept or collection of modules and machines; however, because the reconfigurable manufacturing solution for any assembly or manufacturing challenge will be unique, the concept can be difficult to convey and understand.
By Ken Lento
An RMS includes integrated con-veyor modules and manufacturing logistics software. The software links the modules and assembly stations together for a specific job. These modules can be reconfigured as manufacturing needs change. Thus, RMS can be used in high-product mix manufacturing environments with varying lot sizes, from low to high volume.
Manufacturers setting up an RMS can purchase systems module by module to create a plug-and-play assembly process. Each section of the RMS system is stand-alone, with its own controls, and connected to other modules with a communication and power cable. Lines can be set up quickly, meaning more flexibility and minimal downtime or setup time.
Figure 1. A modular approach to manufacturing.
Manufacturers in the medical device, electronics and consumer products industries are implementing RMS systems to maximize profits through lower or staggered initial equipment investment and less setup time. RMS saves floor space, as well as reduces labor costs and inventory needs. A system can be fully reused or modified for changes in production or from one production cycle to another. (Figure 1)
RMS Software
In some cases, an RMS is operated without software, such as in a straight, progressive assembly line, or when control and tracking of the pallet is needed. RMS software can route pallets, with each pallet having its own route through the system, as well as provide operator work instruction, inventory tracking and connectivity to the product, and line statistics and real-time communication with the customer's MES or ERP system. The software makes it possible for an RMS to be operated in batch or mixed-production modes.
RMS software includes several independent "modules," each with different purposes and functionality. Each module can be added separately.The more common RMS software modules include:
- AFM — Pallet routing and tracking. Using a smart pallet system, production can be set up in batches or by individual pallet. Each pallet or product can have a different route through the system.
- QAS — Automatic work instructions for operators. When a pallet arrives at a workstation, work details, instructions or other information is immediately displayed on the screen.
- SFM — Manages points of inventory in the RMS system to allow real-time inventory visibility and automatic replenishment. Production is not released to the line unless the RMS system confirms that all the correct components are available.
- ERP — Connections and database exchange with the user's host system. RMS allows real-time information exchange and updates to better plan, execute and drive the production process. (Figure 2)
Figure 2. The RMS software role and its connections.
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SMT and PCB Assembly
The RMS can be applied to SMT printed circuit board (PCB) assembly. For example, one manufacturer needed to create a modular system layout that would allow demand flow technology from their SMT lines to the box build assembly area. Using direct attached storage (DAS) as the platform design, an assembly line was created that would meet the following requirements:
- Handle a variety of products in a mixed flow (up to 1,000 different SKUs)
- Every product coming down the assembly line was unique (batch size of one)
- The feed from five SMT board lines to any one of three assembly lines was key
- Test fixture equipment also had to be brought to the line just ahead of the assembled product, then exchanged after testing was complete
- All product would flow automatically without employee intervention
- Modularity was needed to expand or change flow scenarios, based on new designs and future products
- Complete tracking of production, as well as communication with line assembly personnel as to what product they were working on in real time. (Figure 3)
Figure 3. Example assembly line of a box build from an SMT feed.
This DAS assembly line allows a PCB to arrive and be kitted with the correct component parts for assembly. Once the kit is assembled, the pallet travels to the correct and available assembly station. After assembly, the pallet travels to the test station, then to packaging. Each module is stand-alone and can be exchanged, or the line can be made longer or shorter. The pallet flow can be in a specific sequence or can be done for the first available position (assembly or test).
Modularity is defined in this case as a random number of stations placed together in an assembly line. After setting up the modules in the correct sequence and quantities, pallet routing can be made for that product on a PC-based system. All routes become unique each time that product is assembled on the line. The number of personnel needed to manually handle and move products in a facility is reduced. The information delivered to each operator or work step also is more timely, and the initial investment is reusable. This all results in overall increased productivity of the facility.
Expanded Roles
RMS can be expanded to include pick-to-light systems for pallet kitting or point-of-use picking to ensure the correct com-ponents are picked during an assembly operation. RMS also includes modular au-tomation modules.
As mentioned earlier, RMS has been implemented for medical device manufacturing; as such, medical device manufacturing systems must comply with FDA requirements for tracking product assembly, electronic signature and other stringent controls. RMS pallets are managed by RF technology readers, and the RMS software itself is PC-based.
In one actual scenario, implementation of RMS enabled the user to automatically route pallets to process machines while maintaining critical identification of each product and its manufacturing history. RMS reduced labor and provided real-time visibility for all products in production, as well as a production history, and enabled new products to be ordered for any that would fail during the machining process. RMS also provided the user with a solution that could be expanded when additional process machines are brought online for volume growth. The user already has expanded the line by adding additional modules.
Conclusion
A complete RMS includes RMS modular conveyor sections, RMS robotic cells to load and unload the process machines, and RMS software for manufacturing logistics. Manufacturers wanting to implement their own RMS should work closely with supplier companies who can determine how the system is to be planned, installed, and brought up and running, as well as maximize its flexibility and application to individual product assembly needs and scenarios. The supplier's engineering personnel will work with the customer to determine the potential for improvements, layouts and justification for implementing an RMS solution.
For more information, contact Paul Jarossy, marketing manager, FlexLink Systems Inc., Allentown, PA; (610) 973-8230; E-mail: paul.jarossy@flexlink.com.