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1、自动化SMT系统处理方案建议书一、工程背景1.1 概况由于电子产品差异化需求的加剧，导致电子元器件的模块化、细小化速度加快。多品种、小批量制造形式是大部分企业目前面临的挑战。同时SMT设备昂贵，如何在多品种、小批量制造形式下提升设备的利用率、操作的精确性将是企业是否能够持续开展的根本所在。制造企业除了对制造工艺更高要求的压力外，更重要的压力来源于传统的SMT制造方式将较难习惯将来SMT信息化消费的开展方向。依照目前我们理解到的情况，对现有的SMT消费线进展了深化的分析，其主要消费流程如下列图所示：详细流程及潜在的人工操作风险分析：序号工序详细操作流程描绘潜在的人工操作风险Spear Stati
2、on由操作员手工每一块PCB板的条码，录入Spear系统Printer选择相应的Printer 程序进展PCB印刷错误调用程序、纠错操作造成延时PlacementPCB进入Placement前需进展确认，再手工调用相应的程序错误调用程序、纠错操作造成延时Reflow进入Reflow前需要人工选择相应的程序，加工好后手工每一块PCB板的条码进展质量治理错误调用程序、纠错操作造成延时WAVEWAVE前后需要人工每一块PCB板，并调用正确的工作程序错误调用程序、纠错操作造成延时TEST StationTEST流程检测后再人工每一块PCB板错误调用程序、纠错操作造成延时由此可见，在目前的整个作业过关键
3、步骤中，手动操作仍然起到主导作用，如何加快操作流程，提高操作的精确率是对目前SMT消费线提出的一个急需处理的课题。1.2 潜在人工操作风险及相关建议通过对照上述流程能够清晰的看出，一个完好的消费流程需要操作人员进展手工调用程序的有5处，即：在Spear Station后所有流程（）均需要手工调用程序，不管操作人员多么娴熟都可能由于各种外在缘故出错，况且SMT行业人员流淌特别大，培训换人等引起的岗位不确定性无疑更会加大误操作的概率，所以也会相应延长产品消费周期，危害产质量量的稳定性，造成不必要的损失和隐患。假如在以上5个潜在风险点处安装相应的自动化SMT系统，显然的改善效果和受益如下：1、防止操
4、作人员误操作，保证产质量量的稳定性；2、防止不必要的物料，人工，时间等各种损失；3、缩短操作人员的相应操作时间；4、提高机器利用效率。增加了自动化系统的工序流程如下列图：其中加黑色框的Scan为增加自动化系统的地点()。参加自动操纵系统后不但原有的操作流程没有改动，也没有增加操作人员或操作动作，而且还在原有流程的处理速度和自动化程度方面进展了优化，详细的优点如下：1、 减少了Spear Station，原有的相应功能由Printer的自动化系统兼任，由Printer端到条码并自动传送到IT Spear 系统中进展相应的数据操作，如此能够节约消费线上Spear Station的本钱和操作时间，缩
5、短产品制造周期，同时让Spear系统更加自动化；2、 由于采纳了自动化系统，提高了需要全部PCB流程的效率，即Printer、WAVE和TEST，三个流程的单块PCB到调用程序确定操作时间由原来的大约60秒减少到10秒左右，提高了机器的利用率，降低消费本钱；3、 由于从到条码到调用相应程序全面实现自动化，保证了调用程序的正确性，降低了对操作人员的要求，减少了人为要素，杜绝了人员手工选取程序带来的误操作风险，保证了产品的质量；4、 任何一台设备的操纵电脑都能够通过该自动化系统连接到网络，进展网络化数据治理，不再受操纵电脑操作系统版本的妨碍，减少了单机设备的维护工作量；5、 每一块进展自动化系统的
6、PCB板都能查询到LOG，并能进展相应分析，提供消费线或消费流程进一步优化的可能性；6、 减少了工厂相关设备及数据流程的维护工作量。二、技术方案分析及报价 鉴于工厂内的设备、施行环境的客观性和多样性，我们提出两套处理方案，一个是针对现有设备操作系统满足联网需求（配置XP及以上操作系统的设备）的方案，另一个是基于IT Policy的设备操作系统无法支持联网需求的处理方案。灵敏使用两个方案即可满足绝大部分设备的自动化要求。2.1Network version with upgrade to XP OS2.1.1System ArchitectureDiagram-2: Architecture f
7、or 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 directly by router. Meanwhi
8、le, 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: How many stops generated by wrong programs? How many wrong operations made by wrong bar-code? Which stat
9、ion, when operate the barcode? .2.1.2Advantages 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 statusDisadvantages:n High cost to upgraded the OS and MES2.1
10、.3Pricing CostBased on this solution, the pricing will be as below to implement this solution:Product pricing:考虑到系统开发的复杂性和本钱等客观要素，此方案如低于20个安点缀则无法进展开发;12K RMB for each workstation if purchasing amount is 1140 stations;10K RMB for each workstation if purchasing amount is 4180 stations;8500 RMB for eac
11、h 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 dimension is to support the barcode)One LOG Server is requ
12、ired for this solution and the price will be about 10K RMB2.2Using transit exchange (XP or above OS) for each workstation2.2.1ArchitectureDiagram-4: Architecture for Transit Exchange VersionArchitecture description:This solution is based on standalone model and one transit exchange machine (with XP
13、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( communication way between workstation and transit excha
14、nge 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 control system will automatically invoke the M
15、ES 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 and do the statistics analysis with these da
16、ta. Such as result will be classified by types: How many stops generated by wrong programs? How many wrong operations made by wrong bar-code? Which station, when operate the barcode? .All the analysis can be illustrated by Gant chart or Pie chart.2.2.2Advantages DisadvantagesWith this solution, the
17、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 way to implement auto program control without changing the current syst
18、em status.Disadvantages:n Transit exchange machine will be added for each work stationn Cost will be added to implement the auto program control2.2.3Pricing CostBased on this solution, the pricing will be as below to implement this solution:Product pricing:考虑到系统开发的复杂性和本钱等客观要素，此方案如低于20个安点缀则无法进展开发;13K
19、 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 if purchasing amount is more than 121 stations.Hardware cost:Each stat
20、ion 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 r
21、equired for this solution and the price will be about 10K RMB特别说明：These two programs are not affected and will not change the original operating software, it will also not conflict with the existing machine operating software.三、系统维护效劳1、该系统完成安装调试正常运转后，将提供1年的免费维护期，提供724小时效劳，并在2小时内赶到毛病现场进展毛病排除；2、假如自动化系
22、统有更新版本，我司将进展免费的晋级；四、自动化SMT系统对伟创力将来的好处 在自动化SMT系统实现的根底之上，能够灵敏的开发更多后续功能，从而优化消费流程、缩短产品消费周期、降低制造本钱以及提高产质量量，最终实现精益制造，比方：1、消费设备网络化：便于对复杂的设备进展统一治理，设备的网络化开展方向将越来越重要，通过网络对工厂进展远程监控，统一治理。如此就能够及时理解各个设备的运转情况、设备利用率、毛病状态等信息，为合理安排消费运营提供依照。2、消费流程信息化：通过自动化SMT系统搜集和处理消费现场的信息，为后期实现诸如“通过计算消费线各道工序的运送时间，预测将会在什么位置发生滞留”、“各道工序所需时间在理论值与实测值之间的差异，相差较大时会报告可能发生毛病”等如此的信息化功能，针对每个消费环节的异常事件做到早期预警和做出相应的正确的处置措施和触发机制，为进一步优化消费流程提供可分析数据。3、消费产品多样化：为了应对多品种、小批量的产品消费方式，提升快速新产品导入才能至关重要，通过自动化物料识别，在极短的时间内完成新产品导入工作，为柔性消费提供保障。