Hi-Speed SMT manufacturing

SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !!

The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to.

My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated.

Eric.

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| SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | Eric. | Eric,

I think I hear/see you right. Yes, it's a great idea to fit mile long strips to CP6's. Hell, you won't have to buy anymore $1,000 plus feeders. I would have your management patent the idea on your behalf and split the royalties.

Seriously, I currently work for a very large OEM/CM. That is the CM serves the OEM customer with required product of so many types and product mixes, it really is mind altering.

Our answer is to buy more reels and feeders with dedicated material management and handling processes. Flexibility takes many turns, but limiting high speed output is not one of them as the only other answer is to get rid of the the Fuji's and go with cheaper and more flexible equipment capable of doing your business plan's business.

The IP's are almost another issue. They are more application specific for your "clearly defined process capabilities."

I may be wrong, it may have happened before (though I doubt it), but so may your management,

Earl Moon

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| SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | Eric. | | | Eric. | Eric, I work in a C/M, we have the same FUJI equipment(CP6 & IP3). It has been proven that the down time on the CP6 & IP3 doesn't not compare with the cost of the component that come in reels. For example: estimate that a FUJI line cost about $2000.00 an hour for been down, where a reel of smd's cost a few dollars. In other words If we load strips of component we estimate that we will spend an average of 3 minutes to add a leader, not to mention the amount of time it will get stuck in the feeder.

thanks

Tony A

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| SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | Eric. | Hi Eric. I have some questions. Are your machines used for high thruput / low mix / low changeover? Or low thruput / high mix / high changeover?

From an inventory management perspective I can understand the migration to controll inventory in this manner. It is possible this system could work if your manufacturing system could support this. Example. What is your attrition (loss ) rate for these machines? If a cp6 has a marginal PD it could easilly reject a higher quantity than the overage issued by your current inventory model. Hence the machine runs out of parts and the machine sits idle (waiting for a resupply) . This would be rediculous for 0.3 cent parts. The CM I work for tried this. In some cases it worked (active parts IP3) but the lidle time loss for passive (CP4.3) parts outweighed the value of the parts by 1000 to 1. I use pareto analysis of the machines dump box to tune my programs and keep my attrition (loss) down to 300 PPM. This requires a lot of upkeep initially but once the programs are tuned - they run till the end of the product life. The bottom line is the engineer and/or technician must work closely with the buyers and inventory folks to convey your machine requirements. Then you can begin to collect data and alter your strategy from there. The fact is your machine are speed demons and in order to pay for themselves (massive floor space / utilities / overhead) they must run...run...run. PS I have my feeder changeover times down to 15 seconds.

Dean.

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| | SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | | | Eric. | | | Hi Eric. | I have some questions. | Are your machines used for high thruput / low mix / low changeover? Or low thruput / high mix / high changeover? | | From an inventory management perspective I can understand the migration to controll inventory in this manner. It is possible this system could work if your manufacturing system could support this. Example. | What is your attrition (loss ) rate for these machines? If a cp6 has a marginal PD it could easilly reject a higher quantity than the overage issued by your current inventory model. Hence the machine runs out of parts and the machine sits idle (waiting for a resupply) . This would be rediculous for 0.3 cent parts. The CM I work for tried this. In some cases it worked (active parts IP3) but the lidle time loss for passive (CP4.3) parts outweighed the value of the parts by 1000 to 1. | I use pareto analysis of the machines dump box to tune my programs and keep my attrition (loss) down to 300 PPM. This requires a lot of upkeep initially but once the programs are tuned - they run till the end of the product life. | The bottom line is the engineer and/or technician must work closely with the buyers and inventory folks to convey your machine requirements. Then you can begin to collect data and alter your strategy from there. The fact is your machine are speed demons and in order to pay for themselves (massive floor space / utilities / overhead) they must run...run...run. | PS I have my feeder changeover times down to 15 seconds. | | Dean. |

Thanks Dean, Tony, and Earl. I appreciate your time in replying to my posted question.

Dean, as far as your questions back: We run a low volume / high mix (and obviously - high change over) business. I'm not certain if all that are involed here fully understand that conciept. You did give me some ideas to consider, dump box analysis (more closely), attrition, etc.

Again, thanks, Eric.

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| | SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | | | Eric. | | | Eric, | | I think I hear/see you right. Yes, it's a great idea to fit mile long strips to CP6's. Hell, you won't have to buy anymore $1,000 plus feeders. I would have your management patent the idea on your behalf and split the royalties. | | Seriously, I currently work for a very large OEM/CM. That is the CM serves the OEM customer with required product of so many types and product mixes, it really is mind altering. | | Our answer is to buy more reels and feeders with dedicated material management and handling processes. Flexibility takes many turns, but limiting high speed output is not one of them as the only other answer is to get rid of the the Fuji's and go with cheaper and more flexible equipment capable of doing your business plan's business. | | The IP's are almost another issue. They are more application specific for your "clearly defined process capabilities." | | I may be wrong, it may have happened before (though I doubt it), but so may your management, | | Earl Moon | Eric, if you are going to attend the NEPCON show, Look for companies that have smart feeders and good management data. I know that the Sanyo Intelligent Feeder will give you a constant count on the feeders/machine etc. It is set up to be a step in the direction of a Lights out factory. We also have the bulk feeders that will cut help to cut down on your replenishments. The Sanyo booth is 2557 at Nepcon west.

Dave Kalen

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| | SMT Mfg. Equipment: Fuji CP-6/IP-3 - but please all hi-speed chip placer users input are appreciated !! | | | | The company that I work for is a C/M which offers both consignment but mostly turnkey work. I am currently running 3 Fuji lines. All parts for the CP-6 are issued on 7" and 11" reels. We utilize the IP-3's for trayed, QFP's and larger PLCC's. New management here would like to implement a change in the way SMT controls material by issuing components on 'strips' verses full reels. Exact quanties, plus shrinkage, and a leader/followind to be added to the component strip - then placed onto the feeder is the process that they wish us to go to. | | | | My question: Is there anyone out there that may be utilizing what seems to be (this) a cumbersome and awkard method? And if so, could you possibly submit a process on how you are doing this efficiently. If there are any comments on this subject, please feel free to reply. All comments and futher information would be greatly appreciated. | | | | Eric. | | | Hi Eric. | I have some questions. | Are your machines used for high thruput / low mix / low changeover? Or low thruput / high mix / high changeover? | | From an inventory management perspective I can understand the migration to controll inventory in this manner. It is possible this system could work if your manufacturing system could support this. Example. | What is your attrition (loss ) rate for these machines? If a cp6 has a marginal PD it could easilly reject a higher quantity than the overage issued by your current inventory model. Hence the machine runs out of parts and the machine sits idle (waiting for a resupply) . This would be rediculous for 0.3 cent parts. The CM I work for tried this. In some cases it worked (active parts IP3) but the lidle time loss for passive (CP4.3) parts outweighed the value of the parts by 1000 to 1. | I use pareto analysis of the machines dump box to tune my programs and keep my attrition (loss) down to 300 PPM. This requires a lot of upkeep initially but once the programs are tuned - they run till the end of the product life. | The bottom line is the engineer and/or technician must work closely with the buyers and inventory folks to convey your machine requirements. Then you can begin to collect data and alter your strategy from there. The fact is your machine are speed demons and in order to pay for themselves (massive floor space / utilities / overhead) they must run...run...run. | PS I have my feeder changeover times down to 15 seconds. | | Dean. |

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