HOW TO REDUCE MACHINE SET-UP TIME???

when we run a pilot run it usually takes a lot of time because it needs to be properly adjusted so that on production time everything could be set up easily and run smoothly. on a no feeder situation, components for the next model should be already labeled by numbers so that if the model being run is finished you can exchange feeders with the next model, you say you have 4 lines and if one line dont have any schedule of production yet you can use the feeders on that line. for faster output components should be prepared and double checked first.....

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James, I have worked at a couple of different companies and both have reduced their changeover times significantly. What type of placement machines do you have? Do you use customer part numbers or do you have your own internal part number for components?

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If your boss can't figure-out that buying feeders is cheaper than having a machine idle, then it's good that he has time available to torment you on why you're not developing other solutions.

On the other hand, if you don't have enough work to load the machine, it doesn't matter how many feeders you have.

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Do you have any parts dedicated on the machine? 100n 0603 or 0805 is probably used on almost everything you build. So why take it off and put it on the machine several times a day. Even if you dedicate only 20 parts to never come off the machine, that should help a bit. Where I was we had over 200 parts that never came off the line. It does slow down the machine a little but done properly it isn't even close to being significant when compared to 4 or 5 changeovers a day on each line.

Another major thing is preloads. As much as possible have the feeders for the next run ready

And don't overlook making sure everything and I mean everything is as close to perfect before SMT even hears about a job.

Some people think the manufacturing process starts at SMT but I say it is the halfway point.

I visited a CM on a one day tour. They were running one job, had the next loaded and were loading the one after. I think it is the only place that looked pre-SMT for issues that everyone else just assumes is SMT. Any complete solution to SMT changeover times will look at pre-SMT as much as they look at SMT.

enough of my rant, remember we are all in this together and keep your stick on the ice.

Steve

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This sounds like exactly what I am going through here. If you come up with a nice solution please post it. One of the things I have done is make top and bottom programs similar as possible. No I didn't say all programs the same overall just each job has its own similarity. It says about 20 feeders for changeover sometimes but others it might be less than 5. With contract manufacturing there is no real easy way to do this. Just curious what programming platform you use and type of machines?

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Once upon a time I worked for an equipment rebuilder. While employed there I installed many SMT machines. By far the best solution I ever experienced was more feeders preloaded with the next job. The next best solution I experienced was some custom planning/optimization software that examined the day's build, made programs (just changed the feeder location on an existing program) and schedules to minimize feeder changes. They would set-up for job #1 and run. To set-up for job #2 they just had to add a few feeders. This went on until there was no space left to add feeders. At that time the software had them remove all of the feeders and start the process all over. This customer was a large company and had in house programmers to create and maintain this software. I was told it took them a year to work out all of the bugs.

Jerry

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Hi James, As my companys process/manufacturing engineer, I set up a program that dramaticly reduced machine down time. Some base numbers; we went from an average of 4-6 hrs set up on our Mydata to setups of under 15 minutes on average and some below 9 minutes. Specifically, we set up the next job while the current one is still running. We don't allways use all of our magazines so the ones that aren't being used are pulled for our off line set up. Additionally we have a fixed magazine with common parts. Keep in mind that we are an OEM, but with more than 70 SMT assemblies of varied complexity. This process works well in a Contract Manufacturing setting also, My last gig was with a CM. Currently I am working on identifing like assemblies to group them into process families so we can run like assemblies with less set up. We set up the next job as much as possible while the machine is running. In Lean speak this process is called Single minute exchange of dies, (SMED. If I can be of further assistance please feel free to email me. Best regards, Jay

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Is your machine programs gang picking? Work out a machine set-up for commonly used components to have a fix location on the machine ( preferably on the side the operator spends the least time ).Most of your change overs take place on the front of the machine.

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Dear James 1)Standby the part for next model. 2)during the convention period,replaced the part for the machines. 3)All the programme are following the CAD data.It's help to reduced the situation. 4)All the feeder must be in the good condition. 5)The value confirmation by QA must be in the shortest period. 6)Using the same reference offset at machine,such as stopper offset,PCB layout offset.....

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James, sounds like you need one of these:

Feeder Arrangement Feeder arrangement problem concerns assigning components to the feeder slots

Placement Sequence Placement sequencing (or insertion order) problem concerns determining the sequence in which the components are printed on the board

Nozzle assignment Nozzle assignment problem concerns the tool changes for the placement head

Component retrieval Component retrieval problem concerns determining from which feeder slop the component is retrieved if it has been assigned to more than one slop.

check out at http://www.asprosoft.ca you might find info there very and very useful, especially with free trial account.

Cheers

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