With ever smaller batches and frequent product changes, the efficiency and productivity of SMT assembly are increasingly determined by the costs and downtimes of changeovers. As a result, expensive high-performance lines have only 30% or less production utilization. The optimal, affordable set-up concept becomes the decisive factor.
BRAUN GmbH in Waiblingen was faced with exactly this challenge. More and more products and variants led to the minimization of batch sizes. Typically, these are now only between 30 and 200 pieces with a few long runs. In production, 345 active SMT components are in use. 134 different products must be produced at least once a year, in addition to prototypes.
As Mr Müller, Technical Manager at BRAUN GmbH, explained, it was necessary to develop a new production strategy. The aim was to minimize downtimes in the entire production chain and to do this while keeping the number of employees in production to a minimum.
At the same time, traceability had to be introduced. After several evaluations, it was determined that it was not the absolute placement performance that was decisive, but rather the drastic reduction of stop times.
1. Defined Objective
- Enable at least 400 x 8 mm feeder positions plus trays
- Increase placement capacity through scalable head configuration
- Provide in-line dispensing process capability without additional machine
- “On-the-fly" changeover during production
- Line optimization using a smaller number of parts easy manageable from the storage
- Ensure communication between the machines during production and ensure process control to minimize production down
2. Solution
- Install 3 FOX machines with 400 feeder lanes and 4-8 tray changers
- 1 machine equipped with dispensing module for gluing and solder paste, including 2 placement heads
- 2 machines provided with 4 placement heads each
- Theoretical output 49’600 Be/h, although the output is not decisive factor
- Approx. 300 belt and bar feeders, as well as trays can be used in various sizes
- Despite the series production line, samples can also be run on it at short notice, as the system has all the necessary sample tools, such as "snip feeders".
- Set up concept
- 90% of the components required by BRAUN’s electronics production are set up permanently on the entire production line
Components with high quantities are set up on different modules. The optimization with the intelligent feeders shows which of these feeders can be removed during production and where the storage feeder with the newly required components is located. The quantities are also managed with pick-accuracy. - The concept is designed as follows:
If a downstream machine has upgraded a part that is being assembled by the upstream system, the PCB is moved on as soon as the downstream machine is free. This machine finishes assembling these components. This minimizes the machine downtime.
3. Result
Using Essemtec’s solution, BRAUN was able to reduce changeover times to practically zero. The assembly performance was rated as secondary. At the end of the month, only the required quantity of perfect PCBs is assembled. The new solution saved the customer further investment. Mr. Müller confirms that the system has been fully established and the high expectations of BRAUN GmbH have been met.
At SMTconnect 2023, Essemtec will showcase extensions to the concept, especially related to the material management.
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About BRAUN GmbH:
• Trend-setting and innovative product development
• Highest quality, 100% tested
• Technological market leadership
• Customised, tailor-made solutions
Who we are
As an owner-managed family business in the second generation, we are your reliable supplier of protection systems for rotating equipment, especially for overspeed protection. With over 50 years of experience, BRAUN sees itself as a trustworthy and competent partner for tailor-made solutions.
What we want
We offer a wide range of suitable protection systems for rotating equipment, for measuring and monitoring speed. Main applications are in the protection of turbines, pumps, compressors, expanders and similar equipment.
How we act
Environmental aspects play an important role in the development of new products, in the selection of production technologies and in cooperation with our suppliers. We consider it our responsibility to conserve important resources and preserve them for future generations in the interests of sustainability.
https://www.braun-tacho.de/
