1、自動(dòng)化SMT系統(tǒng)解決方案建議書一、項(xiàng)目背景1.1 概況由于電子產(chǎn)品差異化需求的加劇，導(dǎo)致電子元器件的模塊化、細(xì)小化速度加快。多品種、小批量制造模式是大部分企業(yè)目前面臨的挑戰(zhàn)。同時(shí)SMT設(shè)備昂貴，如何在多品種、小批量制造模式下提升設(shè)備的利用率、操作的準(zhǔn)確性將是企業(yè)是否可以持續(xù)發(fā)展的根本所在。制造企業(yè)除了對(duì)制造工藝更高要求的壓力外，更重要的壓力來源于傳統(tǒng)的SMT制造方式將較難適應(yīng)未來SMT信息化生產(chǎn)的發(fā)展方向。根據(jù)目前我們了解到的情況，對(duì)現(xiàn)有的SMT生產(chǎn)線進(jìn)行了深入的分析，其主要生產(chǎn)流程如下圖所示：具體流程及潛在的人工操作風(fēng)險(xiǎn)分析：序號(hào)工序具體操作流程描述潛在的人工操作風(fēng)險(xiǎn)Spear Statio

2、n由操作員手工掃描每一塊PCB板的條碼，錄入Spear系統(tǒng)Printer選擇相應(yīng)的Printer 程序進(jìn)行PCB印刷錯(cuò)誤調(diào)用程序、糾錯(cuò)操作造成延時(shí)PlacementPCB進(jìn)入Placement前需進(jìn)行掃描確認(rèn)，再手工調(diào)用相應(yīng)的程序錯(cuò)誤調(diào)用程序、糾錯(cuò)操作造成延時(shí)Reflow進(jìn)入Reflow前需要人工選擇相應(yīng)的程序，加工好后手工掃描每一塊PCB板的條碼進(jìn)行品質(zhì)管理錯(cuò)誤調(diào)用程序、糾錯(cuò)操作造成延時(shí)WAVEWAVE前后需要人工掃描每一塊PCB板，并調(diào)用正確的工作程序錯(cuò)誤調(diào)用程序、糾錯(cuò)操作造成延時(shí)TEST StationTEST流程檢測后再人工掃描每一塊PCB板錯(cuò)誤調(diào)用程序、糾錯(cuò)操作造成延時(shí)由此可見，在目

3、前的整個(gè)作業(yè)過關(guān)鍵步驟中，手動(dòng)操作仍然起到主導(dǎo)作用，如何加快操作流程，提高操作的準(zhǔn)確率是對(duì)目前SMT生產(chǎn)線提出的一個(gè)急需解決的課題。1.2 潛在人工操作風(fēng)險(xiǎn)及相關(guān)建議通過對(duì)照上述流程可以清楚的看出，一個(gè)完整的生產(chǎn)流程需要操作人員進(jìn)行手工調(diào)用程序的有5處，即：在Spear Station后所有流程（）均需要手工調(diào)用程序，無論操作人員多么嫻熟都可能因?yàn)楦鞣N外在原因出錯(cuò)，況且SMT行業(yè)人員流動(dòng)非常大，培訓(xùn)換人等引起的崗位不確定性無疑更會(huì)加大誤操作的概率，當(dāng)然也會(huì)相應(yīng)延長產(chǎn)品生產(chǎn)周期，危害產(chǎn)品質(zhì)量的穩(wěn)定性，造成不必要的損失和隱患。如果在以上5個(gè)潛在風(fēng)險(xiǎn)點(diǎn)處安裝相應(yīng)的自動(dòng)化SMT掃描系統(tǒng)，顯然的改善效果

4、和受益如下：1、避免操作人員誤操作，保證產(chǎn)品質(zhì)量的穩(wěn)定性；2、避免不必要的物料，人工，時(shí)間等各種損失；3、縮短操作人員的相應(yīng)操作時(shí)間；4、提高機(jī)器利用效率。增加了自動(dòng)化掃描系統(tǒng)的工序流程如下圖：其中加黑色框的Scan為增加自動(dòng)化掃描系統(tǒng)的地方()。加入自動(dòng)控制系統(tǒng)后不但原有的操作流程沒有改動(dòng)，也沒有增加操作人員或操作動(dòng)作，而且還在原有流程的處理速度和自動(dòng)化程度方面進(jìn)行了優(yōu)化，具體的優(yōu)點(diǎn)如下：1、 減少了Spear Station，原有的相應(yīng)功能由Printer的自動(dòng)化掃描系統(tǒng)兼任，由Printer端掃描到條碼并自動(dòng)傳送到IT Spear 系統(tǒng)中進(jìn)行相應(yīng)的數(shù)據(jù)操作，這樣可以節(jié)省生產(chǎn)線上Spear

5、 Station的成本和操作時(shí)間，縮短產(chǎn)品制造周期，同時(shí)讓Spear系統(tǒng)更加自動(dòng)化；2、 由于采用了自動(dòng)化掃描系統(tǒng)，提高了需要全部掃描PCB流程的效率，即Printer、WAVE和TEST，三個(gè)流程的單塊PCB掃描到調(diào)用程序確定操作時(shí)間由原來的大約60秒減少到10秒左右，提高了機(jī)器的利用率，降低生產(chǎn)成本；3、 由于從掃描到條碼到調(diào)用相應(yīng)程序全面實(shí)現(xiàn)自動(dòng)化，保證了調(diào)用程序的正確性，降低了對(duì)操作人員的要求，減少了人為因素，杜絕了人員手工選取程序帶來的誤操作風(fēng)險(xiǎn)，保證了產(chǎn)品的質(zhì)量；4、 任何一臺(tái)設(shè)備的控制電腦都可以通過該自動(dòng)化掃描系統(tǒng)連接到網(wǎng)絡(luò)，進(jìn)行網(wǎng)絡(luò)化數(shù)據(jù)管理，不再受控制電腦操作系統(tǒng)版本的影響，

6、減少了單機(jī)設(shè)備的維護(hù)工作量；5、 每一塊進(jìn)行自動(dòng)化掃描系統(tǒng)的PCB板都能查詢到LOG，并能進(jìn)行相應(yīng)分析，提供生產(chǎn)線或生產(chǎn)流程進(jìn)一步優(yōu)化的可能性；6、 減少了工廠相關(guān)設(shè)備及數(shù)據(jù)流程的維護(hù)工作量。二、技術(shù)方案分析及報(bào)價(jià) 鑒于工廠內(nèi)的設(shè)備、實(shí)施環(huán)境的客觀性和多樣性，我們提出兩套解決方案，一個(gè)是針對(duì)現(xiàn)有設(shè)備操作系統(tǒng)滿足聯(lián)網(wǎng)需求（配置XP及以上操作系統(tǒng)的設(shè)備）的方案，另一個(gè)是基于IT Policy的設(shè)備操作系統(tǒng)無法支持聯(lián)網(wǎng)需求的解決方案。靈活使用兩個(gè)方案即可滿足絕大部分設(shè)備的自動(dòng)化要求。2.1Network version with upgrade to XP OSSystem Architecture

7、Diagram-2: Architecture for Network version with OS upgradeArchitecture description:This solution is based on network foundation. Each stations OS will be upgraded to XP and all the MES also be upgraded to XP version. Each station can communicated with IT program control server and Logging server di

8、rectly by router. Meanwhile, IT can maintain these machines easily.The Logging server can stored the operation log and do the statistics analysis with Gant chart or Pie chart. Such as results will be classified by types:Ø How many stops generated by wrong programs?Ø How many wrong operatio

9、ns made by wrong bar-code?Ø Which station, when operate the barcode?Ø .Advantages & DisadvantagesWith this solution, the advantages and disadvantages are summarized by as below:Advantages:n Easily to install or un-install the systemn Easily to monitor/control the production statusDisad

10、vantages:n High cost to upgraded the OS and MESPricing & CostBased on this solution, the pricing will be as below to implement this solution:Product pricing:考慮到系統(tǒng)開發(fā)的復(fù)雜性和成本等客觀因素，此方案如低于20個(gè)安裝點(diǎn)則無法進(jìn)行開發(fā);12K RMB for each workstation if purchasing amount is 1140 stations;10K RMB for each workstation if

11、purchasing amount is 4180 stations;8500 RMB for each workstation if purchasing amount is 81120 stations;8000 RMB for each workstation if purchasing amount is more than 121 stations.Hardware cost:Each station need a scanner(instead by keyboard) and the price is about 3K RMB for each one (two dimensio

12、n is to support the barcode)One LOG Server is required for this solution and the price will be about 10K RMB2.2Using transit exchange (XP or above OS) for each workstationArchitectureDiagram-4: Architecture for Transit Exchange VersionArchitecture description:This solution is based on standalone mod

13、el and one transit exchange machine (with XP or above) will be added for each work station. The work flow will be explained as follows: The input equipment (keyboard or scanner) get the right barcode to system The system sent the message to transit exchange server to get the program name( communicat

14、ion way between workstation and transit exchange is serial port) The transit exchange send the message to IT program server to get the program name IT program server response the right program name to transit exchange server The transit exchange server response the program name to workstation, the c

15、ontrol system will automatically invoke the MES to run the program. The transit exchange server will send the operation log to Logging server to record all the operations( including getting program names with barcode, when to start run the program, etc)The Logging server can stored the operation log

16、 and do the statistics analysis with these data. Such as result will be classified by types:Ø How many stops generated by wrong programs?Ø How many wrong operations made by wrong bar-code?Ø Which station, when operate the barcode?Ø .All the analysis can be illustrated by Gant cha

17、rt or Pie chart.Advantages & DisadvantagesWith this solution, the advantages and disadvantages are obviously:Advantages:n It is easy to implement the auto program control according to current status and IT policyn It is easy to record the operation log and do the data analysisn It is realistic w

18、ay to implement auto program control without changing the current system status.Disadvantages:n Transit exchange machine will be added for each work stationn Cost will be added to implement the auto program controlPricing & CostBased on this solution, the pricing will be as below to implement th

19、is solution:Product pricing:考慮到系統(tǒng)開發(fā)的復(fù)雜性和成本等客觀因素，此方案如低于20個(gè)安裝點(diǎn)則無法進(jìn)行開發(fā);13K RMB for each workstation if purchasing amount is 1140 stations;11K RMB for each workstation if purchasing amount is 4180 stations;9500 RMB for each workstation if purchasing amount is 81120 stations;8500 RMB for each workstation

20、 if purchasing amount is more than 121 stations.Hardware cost:Each station need a scanner(instead by keyboard) and the price is about 3K RMB for each one (two dimension is to support the barcode)Each station need a transit exchange (PC or box like VIA+EPIA-P700，windows XP Professional English Version) and the price is about 2-3K RMB for each machineOne LOG Server is required for this solution and the price will be about 10K RMB特別說明：These two programs are not affected