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Yamaha Motor Revs Your Heart

SMT ASSEMBLY SYSTEM

Recipes for Building Fully Automatic Setup Lines

In order to achieve Non-Stop, Operation Free process, we need the fully automated lines. Yamaha introduce our own secret recipes.

Recipes for Building Fully Automatic Setup Lines

Do problems like these get under your skin?

For example,
Customer

We would like to reduce the loss due to changeovers. But not so easy to improve its efficiencies because of the system specifications.

It is time consuming to change over the machines one by one.

The error message pop up and the system stops by loading the wrong programs.

Even finishing change over for the printer, we face the change over for the mounters, then the system must stop for more than 30 minutes.

 

Customer

We want to increase the productivities even 0.1%, but we don’t know how!

 

Customer

We want to improve our man-hours and efficiencies, and also want to achieve the maximum productivities by minimum numbers of the operators. But how!

YAMAHA

Yamaha can suggest our "1 Stop Smart Solution," YAMAHA's SMT Concept, to the customers, who face these issues.

YAMAHA Solution Recipe

YAMAHA's Proposal

We introduce Our 1 Stop Smart Solution," the YAMAHA SMT Concept “Recipes for Fully Automated Lines”

Solution Recipe 1

Receiving the next model`s recipe from the upstream machine, and improve the productivities

Solution Recipe 2

We can communicate to Major SMT system manufacturers. We can improve the productivities by linking the information with other manufacturers.

Solution Recipe 3

By Common Setups optimization, we eliminate the mounters` changeovers.

Solution Recipe 4

Printer`s Fully automated setups and changeovers

Solution Recipe 1

Automatic setup
Receiving the next model`s recipe from the upstream machine, and improve the productivities

While under production of Model A, the system automatically can change to Model B. The operator just do the setting at the most-upstream machine.

Case 1

Specify the program at the most-upstream machine

Automatic Changeover at the downstream machines

Setting up by choosing from the program list at monitor operations

Case 2

Kanban setting up at the most-upstream
machine

Automatic Changeover at the downstream machines

Set up by reading the barcode from each program

Case 3

Reading 2D barcode at the conveyer before the most upstream Yamaha machine

Automatic Changeover at the downstream machines

Set up by reading the QR code from the flowed PCB
YAMAHA

Aligning all machines to Yamaha in one line, you can achieve the fully automated line from the printer to pre-reflow oven.
equipment to equipment from other makers! We have a lot of experiences on communicating from our machines to the other manufacturers` ones.
We can communicate with other manufacturers such as conveyors, in-line inspection machines, and reflow ovens.
YAMAHA SMT Concept "1 Stop Smart Solution has the solutions!

Solution Recipe 2

Automatic setups linking equipment from different companies
Experience major SMT-related equipment manufacturers working together! Setups transferred between machines from different company improves availability!

This recipe enables M2M linkage not only PCB transferring signals but also PCB identify information, automatic program changeovers, and inspection results from inspection machines between equipment from different manufacturers. YAMAHA realizes M2M function which is linked with major SMT-related equipment manufacturers.
Solution Recipe 3

Common Setups optimization
minimize changeovers for the mounter

1 head solution which can mount various components by one head and YAMAHA mounter(YRM20) which can set maximum 128 feeders are very effective for Common setup. The time of replacing feeders may take longer than 30 minutes at changeover but by setting feeders in advance if uses this Common setup optimization, it eliminates the time of machine stop by feeder replacing.

Wide component range without head exchange

Many components can be set at once

YRM20

Feeders can be set at front and rear side both
Feeder capacity per machine is up to 128 feeders (conversion for 8mm type).

Compact, lightweight feeder carriage

• Easy-to-handle, compact, lightweight feeder carriage
• Feeder capacity per carriage is up to 32 feeders (conversion for 8mm type)/figcaption>

30-tier tray feeder (non-stop exchange type)

Tray feeder can be set up to 30 different tray components
YAMAHA

Common Setups optimization that only YAMAHA can provide with its 1 head solution!
Our 1 head solution supports components from 0201mm at minimum to 55×100mm at maximum without head exchange(for the HM head). By setting components in advance based on the common setups, you can run a variety of production programs without extra setup by operators!

Common Setups optimization is…

A function that simulates the optimal feeder arrangement for PCBs for the number of component types that can be set on 1 line

Common Setups optimization with setting feeder carriage groups

Reduce the number of setup by exchange the entire feeder carriage . In addition, the grouping function, which automatically sorts which combinations of PCBs should be used for common setup, automatically calculates efficient combinations.#5

The grouping function is…

Automatically determines which PCBs are similar to which, and groups them to minimize the number of setups

Realize to plan optimal setup groups and production sequences that take into account detailed conditions obtained from data on multiple PCBs, such as PCB sides, reflow conditions, and solder types.
Solution Recipe 4

Printer’s fully automated setups and changeovers
Provide fully automated setups and changeovers for printers

The changeover process, which consumes the most time and labor in printing process, is fully automated. The automatic stencil replacement, solder transfer, and push-up pin replacement functions enables operators to set the stencils for the next production run and set to reserve production and the machine automatically performs a setup.
No operators needed setups!
YAMAHA

The automatic replacement of push-up pins delivers four zeros!
It eliminates the need for jig storage space, which has been bothering operators, reduces the jig costs to zero, eliminates jig procurement and arrangement, and reduces misarranged pins to zero!

Customer

Enabling machines to perform the changeover process substantially reduces operators' workload, which is expressed as 1 step = 1 second = 1 yen, leading to increased productivity.

Introducing examples of 1 Stop Smart Solution, YAMAHA's SMT Concept

Revealing Recipes for Building a Fully Automatic Setup Line!

Introductory example 1
Production Line for PCBs for Industrial Equipment

Before

・Loader
・YSP
・Conveyor
・YS24
・YS24X

・Conveyor
・YSi-12
・Conveyor
・Reflow oven
・Cooling conveyor
・Buffer conveyor
・YSi-12 (with a laser inspection capability)
・OK/NG sorting conveyor ・Unloader

Problems
1.
Changes to programs associated with changeovers for equipment and changeover for the printer mean that production has to pause for 20 minutes or so.
2.
Defective products with a floating lead, for example, caused by unskilled workers, flow out to the inspection machine after the reflow process. Repairing them is troublesome.
3.
Components cannot be refilled in time. This causes the equipment to stop, reducing productivity.

After

・Loader
・PCB cleaner
YSP10(with an extension conveyor)
YSi-SP(with an extension conveyor)
YRM20
YSM20R
YSM20R

・Conveyor
YSi-V
・Conveyor
・Reflow oven
・Cooling conveyor
・Buffer conveyor
YSi-V
・OK/NG sorting conveyor
・Unloader

Solved!
1.
Solved!The automatic setup including even the printer has shortened the downtime for the changeover, which previously took 20 minutes, to 5 minutes.
2.
Introducing 3D inspection before the reflow process has enabled the user to detect floating leads and other defects, achieving an average in-process defect rate of 1 ppm.
3.
The combination of web remaining quantity monitoring and autoloading feeders has improved the efficiency of component refilling and substantially reduced short-term machinery stoppages.
YAMAHA

The technical points YAMAHA used in this line are…
Machines:YSP10YSi-SPYRM20autoloading feeders,YSi-V
Software programs:Automatic setupDashboardWeb remaining quantity monitoring
Printer:Support for fully automatic changeovers、12-oz syringe PSCprinting position shifting feedback
Inspection machine: QA option, Mobile decision function, Process correlation

Introducing automatic setups, autoloading feeders, and so on has substantially shortened the production downtime. Moreover, introduction of 3D inspection before the reflow process keeps the number of defects after the reflow process low.

 

Feedback from an operator

YAMAHA's key benefit is that it provides easy changeovers while offering high productivity.
We have introduced automatic setups in the kanban setup + transfer mode. Just reading the barcodes on production items at the leading printer enables automatic setups up to the SPI and mounter, making it possible to handle PCBs to be produced and perform other tasks during the waiting time. This has substantially reduced the setup time. We also use optimized shared setups that take advantage of the characteristics of the 1 head solution, which has enabled us to do changeovers without having to replace feeders or trollies.

In addition, introducing the 3D AOI(YSi-V)before the reflow process has enabled us to detect most defects before the reflow process. This has resulted in an in-process defect rate of less than 1 ppm even if unskilled operators are involved, eliminating almost all repair work that uses soldering irons.
The Process correlation on a per-process basis, which can be used in dashboard and i-ProDB, has increased the number of defects whose causes we can identify. We think this has also contributed to the improvement in quality.

Regarding component refilling, web remaining quantity monitoring displays remaining component quantity information on large screens on the line or on mobile devices for the entire line. In addition, combined use of the autoloading feeder has led to efficient component refilling, resulting in almost no line stoppages caused by refilling delays.

I think it's YAMAHA's abundant set of functions substantially increased machine productivity that has enabled us to continue production on a one-operator-per-line basis despite the rising production volume. We'll continue to introduce effective functions with the aim of building more efficient, higher-quality production lines.

Case Study #2
Automotive customer with 24/7 high-mix high-volume production

Before

・Loader
・PCB cleaner
・YGP(with extension conveyor)
・SPI
・YG100
・YG100
・YG100

・Reflow oven
・Cooling buffer conveyor
・Unloader

Problems
1.
The average defect rate in the process is 15ppm, and it is difficult to identify the cause of defects and make improvements, since only one operator per line…
2.
It takes time to change the setup and causes availability loss.
3.
Availability loss due to inability to replenish components on time.
4.
If one operator is responsible for magazine setup on loader/unloader, solder replenishment, and program changeover, the number of steps taken by each operator is nearly 20,000 steps per day (per shift).

After

・Loader
・PCB cleaner
YSP10(with extension conveyor)
・SPI
YSM20R
YSM20R
YSM20R
・AOI (YSi-V) as pre-reflow process
・Repair & remote station
 (work conveyer)

・Reflow oven
・Cooling buffer conveyor
・Unloader

Solution!
1.
In-process defect rate averaged less than 1.00ppm. In the best month, the rate was less than 0.1 ppm (only one in-process defect in one month.)
2.
Changeovers are fully automated. Once the loader reads 2D codes, changeovers are done automatically. Changeovers for the printers are now fully automated by the YSP10, and are completed in 2.5 to 4.5 minutes.
3.
Introducing the Auto Loading Feeder has dramatically reduced availability losses in component replenishment.
4.
Reduced the number of visits to the printer by 80% by automated solder replenishment and fully automated changeovers. As a result, the number of operator steps was reduced by 20%.
YAMAHA

YAMAHA’s technical key points in this line:
Machines:YRM20,YSi-V,YSP10,Auto Loading Feeder
Software functions:QA option, mobile judgment, and N-point verification
Printer:12-oz syringe PSC and support for fully automated changeovers

The reduced burden on operators has boosted efficiency, resulting in higher productivity.

 

Feedback from an operator

YAMAHA's key benefit is high speed even in high-mix production!
We have four lines, only one of which is a YAMAHA line, but in any case it's faster than the others.
Before the update, the YAMAHA line had the almost the same production capacity as the other lines. Since introducing the YSM20R, though, the capacity has almost doubled despite the fact that the space remains unchanged. Also, the number of operators remains unchanged. Although the frequency of component replenishment has nearly doubled, using the Auto Loading Feeder has minimized cases of components run out. As a result, we can operate the YAMAHA line with an overall equipment efficiency of more than 90%.
Also, the number of in-process defects has been reduced and kept at a level of 1/10 or less.
The important point is that we have introduced the YSi-V, a 3D AOI at pre-reflow process.
When the YSi-V detects a defect, we immediately cycle-stop the mounter to check the cause of the defect what caused the problem (QA option). This arrangement operation has eliminated a large quantity of defective products and enabled operators to take action for improvement action, such as nozzle maintenance, which has greatly improved quality.
With fewer defects, we no longer have to bother our suppliers, and everyone in the field, in the production engineering department, and in the management department is happy. Of course, the president, general manager, and other executives are also happy.
We will continue to use the Yamaha equipment in the field to make the line even better!

And more! Automatic replenishment of materials for "unstoppable" and "operation-free" solutions!

1.Printer with a 12-oz syringe PSC

This stabilizes the solder rolling diameter, which affects printing quality. The newly developed 12-oz syringe enables long time non-stop production.

2.Mounter with Auto Loading Feeder

The auto loading function makes it easy for anyone to refill easily tape components parts at any time. Tape loading time takes as little as is only about 5 seconds.*
*From the start of tape feeding until it is ready for pickup.

3.Mounter with a non-stop tray replenishment function

The mounter supports non-stop tray parts supply in pallet or magazine, enabling efficient tray parts supply and production without stopping the machine.

4.Mounter with stacked supply solution (stick feeder, stacking tray feeder, etc.)

We have a lot of experience in supporting stacked stick feeders, stacked tray feeders, etc. according to customer requirements and target components. For more detailed information, please contact our distributors or the following inquiry page.

Our line-construction support engineers are ready to consult with you

YAMAHA's line construction support engineers provide free consultation services (telephone, e-mail, visits, showroom tours, etc.) to customers (regardless of whether they use YAMAHA equipment or not).

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