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DIP insertion and Axial insertion old equipment poka yoke

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#84268

DIP insertion and Axial insertion old equipment poka yoke | 23 January, 2020

Due to couple of customers who still have some products that are completely through-hole, we use our Universal DIP and Axial equipment on a somewhat regular basis. Our machines are pretty old, but they work pretty well, and we don't do enough through-hole work to warrant upgrading. But these old-school machines aren't the most user friendly, and there's a lot of human interaction. There is a lot of room for operator error. Bent leads, wrong parts, swapped parts, you name it, it can happen with these machines. Has anyone done any poka yoke projects with your DIP or Axial insertion machines? Any advice or suggestions?

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#84269

DIP insertion and Axial insertion old equipment poka yoke | 23 January, 2020

It's hard to poka-yoke loading reels onto the machine (either a inserter-sequencer or a sequencer, then getting the sequenced reels properly indexed). The only way I know of to make sure they've been set up properly is with visual inspection of EVERY PART on the first board.

Of course if you have AOI that you can dedicate to through-hole that would help. It didn't exist when I used those machines.

As far as bent leads and such, regular maintenance and attention to the timing and alignment adjustments (weekly BEC alignment with the plate, for example) goes a long ways towards avoiding those things.

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#84272

DIP insertion and Axial insertion old equipment poka yoke | 24 January, 2020

Depending on your equipment. If you are running stand alone equipment. Separate Sequencer and Axial Inserter there's not much you can due expect check the process. The axial should still catch at least most of the defects. If you have a combination unit 6241B of higher you may have a verifier already on the machine. That can take away allot of errors. We're currently working with a customer on a similar project. The Dip nothing you can really do aside from keeping it well calibrated.

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#84349

DIP insertion and Axial insertion old equipment poka yoke | 31 January, 2020

One concern with DIP insertion is making sure the operator inserts the correct tube into the correct feeder. Has anyone ever tried pick-to-light or anything similar?

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#84350

DIP insertion and Axial insertion old equipment poka yoke | 31 January, 2020

We had a custom bar code storage and feeder setup.

Stores material handlers would bring the parts to the line, scan the part number on the kanban card (always accompanied the parts), and the storage location LED flashed so they knew where the place the parts.

Machine operators would scan the empty feeder slot and the storage location flashed, so they knew which tube to grab.

Operators also had to verify that the human readable labels on the kanban card matched the labels on the storage location.

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