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NPI Runs and Volume Production on One Machine?
May 30, 2012 |Estimated reading time: 3 minutes
Editor's Note: This column originally appeared in the April 2012 issue of SMT Magazine.Equipment specializing in new product introduction (NPI) runs is normally different from equipment used for volume production. NPI machines offer an entire set of features for handling new product or evaluation runs efficiently. Unfortunately, all the tweaks needed to get a working product out of the NPI line are lost when translated into the program used by the volume production equipment. That means re-doing many steps. Even using the same make or model of equipment for NPI is no guarantee for success if the actual production line differs in options, head types, runs other software, or requires tweaking per individual machine. Volume production lines usually have too high an output to be used as a dedicated NPI line. But, with careful line design, the two can be combined on a single machine.
NPI and volume production simultaneously in one machine is only doable with more than one lane. Dual-lane machines are quite common and are regularly used in very-high-volume products. For mobile phones, for example, producing top and bottom simultaneously can boost factory efficiency. This is more widely applicable with a feature called independent dual lane.
Setting Up NPI Correctly
Setting up NPI can be time-consuming, particularly when it must be repeated on other equipment. Many parameters may have to be redefined (vision files, process parameters, pick positions, feeder types, pick angles, and more). And you don’t want to repeat the work for every module in your factory running the same component type. No, things should be done only once!Figure 1: One alignment type for small components and one alignment type for larger components can cover the entire range for any existing equipment.
Performing a step only once for each machine not only saves time, but also tests the repeatability of your equipment. No production variation should exist between similar equipment types. That means no differences in heads, camera types, equipment software, nozzles, or anything else--and particularly no difference in software versions that may influence process parameters. Less choice paradoxically contributes to more production flexibility. This is also true for similar equipment in the same production line.
An independent dual lane has two lanes functioning fully independently and asynchronously to each other. The lanes produce boards with their own program at their own pace which also allows lane-independent set-up and changeover. This differs from standard high-volume, dual-lane production where the rear and front lane always run a combined program, not allowing other programs in between.Figure 2: Asynchronous transport system where the rear and front lane are fully independent.Figure 3: Easy switch from dual-lane to single-lane operation and vice-versa.
By using the same hardware, but different numbers of robots, all NPI changes and tweaks performed on any one module should be valid for all similar modules within the factory--eliminating repetitions involved in preparing NPI and ramp-up actions. Guaranteeing process stability among all machines in the factory demands that software not be installed on individual machines, but, rather, uploaded to the machines from a central location. That frees SMT production from variations in individual machines, with software playing an increasingly important role. It helps guarantee identical processes factory-wide, site-wide or even worldwide.
Dual lanes will bring board size limitations. True flexibility, however, means that the machines should switch easily from dual-lane independent to single-lane production with larger board sizes. Here, too, all process data on this new large board which is known, authorized, and released should simply be reused. And, again, it should be possible to release new data for use anywhere in the factory or on similar lines elsewhere.
Independent dual lane sets a new standard for flexible manufacturing.About the author: Eric Klaver was born in Rosemere, Quebec and, via Oklahoma, he moved with his family to Holland at the age of 12. After finishing school, he became a radio officer for the merchant navy. After studying computer science where he learned how to program and design ICs Klaver enjoyed a career at Philips. This was followed by a move to Assembléon in 1998. As Commercial Product Manager he translates high-level technical developments into easy-to-understand commercial material. Klaver specializes in vision technology and feeding and is currently the Chairman of IEC work group TC40WG36, which specializes in component packaging.