Recipes for Building Fully Automatic Setup Lines

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.

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!