Issue
The frequency and implementation of maintenance were determined based on manuals and experienced operator's intuition. Under such circumstances, there were sudden equipment stoppages and excessive maintenance.
Solution
Heads, nozzles, and feeders, which have a particular impact on mounting quality, are monitored in real time by using APC -5M software to visualize equipment conditions. Warnings were issued and equipments were automatically shut down not to occur big problem.
“The APC-5M is a very effective tool that our operators are happy with. They say it is easier for them to plan their operations because we can now see what we couldn't see before.”
Background
SMT Lines are shut down everyday for maintenance
Until now, daily inspections and periodic maintenance had been performed based on the intuition and experience of the operators, who decided the frequency and details of implementation. During this time, the operation of the mounting machine had to be stopped.
Excessive maintenance to keep stable production
We were not able to catch the signs of defects in advance, which led to sudden equipment stoppages. And productivity sometimes did not increase.
Reason for introduction
"We can do maintenance in a short time." (Shinji Kawakami)
Real-time monitoring of components such as heads, nozzles, and feeders, which have a big impact on mounting quality, allows maintenance to be performed in a short time without stopping the line for maintenance.
“We can visualize what is likely to happen and when, which makes it easier to make predictions for production and maintenance plans," (Migifumi Tanaka)
Since the APC-5M has the function to issue warnings before equipment operation is affected and to automatically stop the system if it is determined to have a significant impact on production. These functions can now be effectively utilized to perform maintenance at more appropriate times.
Effects
Continuous production while maintaining the best condition of equipments
"This is a great software that has made all the operators, including myself, very happy because we can now see things (problems) that we couldn't see before.”（Shinji Kawakami）
Everyone can predict what is likely to happen next
“The Process Automation Business Division and we have created user friendly screen that is easy for anyone to understand.”（Shinji Kawakami）
Mounter NPM-WX realize high productivity and high quality SMT line.
Mixed parts are mounted on a PCB, from 0603 size chip to 70mm size connectors.
Monitoring can be done from a location away from the site.
Case study video
Voice of customers
Create enough time to spend with customers by improving production processes
“By accelerating DX and automatically acquiring, visualizing, and analyzing data on people and facilities, we are able to identify issues and make immediate improvements to improve the accuracy of forecast management.”
<br />Kobe Factory, SMT production section, Manager
<br /><span class="small">*The organization/post was at the time of the interview.</span>
Answers to work problems are on the site.
“I was very impressed by their earnest efforts to make the APC-5M easier to use. I was very impressed by their sincere attitude.”
<br />Kobe Factory, SMT production section, Assistant Manager
<br /><span class="small">*The organization/post was at the time of the interview.</span>
Mainly manufacturing and selling Let's Note
Panasonic Connect Mobile Solutions Business Division manufactures Let's Note business mobile devices, Toughbook rugged field mobile devices, 5-inch rugged handhelds, and payment terminals.
Kobe factory is positioned as the global mother factory. We also collaborate with three overseas configuring bases that customize products according to customer requests and ship directly to consumption areas.
Modular mounter combining high efficiency and high productivity NPM-WX
Supports a wide variety of supply sections and expands production ranges.Various softwares that realize smart factory can be installed. APC-5M, which realizes high quality production and stable operation, is also available.
"APC-5M" 5M process control for good production and stable operation
Real-time monitoring of 5M variations and detection of line changes. Focusing on the condition of heads, nozzles, and feeders, the system determines the units that need to be corrected and when, and performs maintenance functions on equipment at timing that does not affect operation, or provides replacement instructions, in conjunction with higher-level systems to achieve predictive maintenance. The more you use the system, the more it will grow into a highly accurate system in your plant.
Panasonic Connect Kobe Factory
Modular mounter NPM-WX, SMT line system APC-5M
Visualization of SMT equipment condition by using the APC-5M system.
By detecting signs of defects in advance, maintenance can be done in the spare time, resulting in high productivity.
Introduction: From 2022 Location: Hyogo prefecture, Japan