自动化SMT系统解决方案建议书

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1、自动化SMT系统解决方案建议书一、项目背景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、小批量制造模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、小批量制造模式下提升设备的利用率、操作的准确性将是企业是否可以持续发展的根本所在。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制造方式将较难适应未来SMT信息化生产的发展方向。根据目前我们了解到的情况，对现有的SMT生产线进行了深入的分析，其主要生产流程如下图所示：具体流程及潜在的人工操作风险分析：序号工序具体操作流程描述潜在的人工操作风险Spear Statio

2、n由操作员手工扫描每一块PCB板的条码，录入Spear系统Printer选择相应的Printer 程序进行PCB印刷错误调用程序、纠错操作造成延时PlacementPCB进入Placement前需进行扫描确认，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，加工好后手工扫描每一块PCB板的条码进行品质管理错误调用程序、纠错操作造成延时WAVEWAVE前后需要人工扫描每一块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流程检测后再人工扫描每一块PCB板错误调用程序、纠错操作造成延时由此可见，在目

3、前的整个作业过关键步骤中，手动操作仍然起到主导作用，如何加快操作流程，提高操作的准确率是对目前SMT生产线提出的一个急需解决的课题。1.2 潜在人工操作风险及相关建议通过对照上述流程可以清楚的看出，一个完整的生产流程需要操作人员进行手工调用程序的有5处，即：在Spear Station后所有流程（）均需要手工调用程序，无论操作人员多么娴熟都可能因为各种外在原因出错，况且SMT行业人员流动非常大，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，当然也会相应延长产品生产周期，危害产品质量的稳定性，造成不必要的损失和隐患。如果在以上5个潜在风险点处安装相应的自动化SMT扫描系统，显然的改善效果

4、和受益如下：1、避免操作人员误操作，保证产品质量的稳定性；2、避免不必要的物料，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。增加了自动化扫描系统的工序流程如下图：其中加黑色框的Scan为增加自动化扫描系统的地方()。加入自动控制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行了优化，具体的优点如下：1、 减少了Spear Station，原有的相应功能由Printer的自动化扫描系统兼任，由Printer端扫描到条码并自动传送到IT Spear 系统中进行相应的数据操作，这样可以节省生产线上Spear

5、 Station的成本和操作时间，缩短产品制造周期，同时让Spear系统更加自动化；2、 由于采用了自动化扫描系统，提高了需要全部扫描PCB流程的效率，即Printer、WAVE和TEST，三个流程的单块PCB扫描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，降低生产成本；3、 由于从扫描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，减少了人为因素，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、 任何一台设备的控制电脑都可以通过该自动化扫描系统连接到网络，进行网络化数据管理，不再受控制电脑操作系统版本的影响，

6、减少了单机设备的维护工作量；5、 每一块进行自动化扫描系统的PCB板都能查询到LOG，并能进行相应分析，提供生产线或生产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、实施环境的客观性和多样性，我们提出两套解决方案，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解决方案。灵活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 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: How many stops generated by wrong programs? How many wrong operations made by w

9、rong bar-code? Which station, when operate the barcode? .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 statusDisadvantages:n High cost to upgr

10、aded the OS and MESPricing & 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成本等客观因素，此方案如低于20个安装点则无法进行开发;12K RMB for each workstation if purchasing amount is 1140 stations;10K RMB for each workstation if purchasing amount is 4180 statio

11、ns;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 dimension is to support the barcode)One

12、 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 model and one transit exchange mac

13、hine (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( communication way between workstation and

14、 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 control system will automaticall

15、y 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 and do the statistics analysis

16、 with these data. 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.Advantages & DisadvantagesWith this sol

17、ution, 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 way to implement auto program control without changing the c

18、urrent 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 this solution:Product pricing:考虑到系统开发的复杂性和成本等客观因素，此方案如低于20个安装点则无法

19、进行开发;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 if purchasing amount is more than 121 stations.Hardware cost:E

20、ach 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 Ser

21、ver is required 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、系统维护服务1、该系统完成安装调试正常运行后，将提供1年的免费维护期，提供724小时服务，并在2小时内赶到故障现场进行故障排除；

22、2、如果自动化扫描系统有更新版本，我司将进行免费的升级；四、自动化SMT系统对伟创力未来的益处 在自动化SMT系统实现的基础之上，可以灵活的开发更多后续功能，从而优化生产流程、缩短产品生产周期、降低制造成本以及提高产品质量，最终实现精益制造，比如：1、生产设备网络化：便于对复杂的设备进行统一管理，设备的网络化发展方向将越来越重要，通过网络对工厂进行远程监控，统一管理。这样就可以及时了解各个设备的运行情况、设备利用率、故障状态等信息，为合理安排生产运营提供依据。2、生产流程信息化：通过自动化SMT系统收集和处理生产现场的信息，为后期实现诸如“通过计算生产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别，相差较大时会报告可能发生故障”等这样的信息化功能，针对每个生产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，为进一步优化生产流程提供可分析数据。3、生产产品多样化：为了应对多品种、小批量的产品生产方式，提升快速新产品导入能力至关重要，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，为柔性生产提供保障。