Camtec develops and produces state-of-the-art power supplies and components for the electronics industry. In Pfinztal, Germany, a high number of different products are manufactured. To produce this mix efficiently, the company has invested in a 4-module FOX4 placement line from Essemtec.
With ever-shrinking batch sizes and frequent product changes, the efficiency and productivity of the Surface-Mount Technology (SMT) placement line are increasingly determined by the cost and downtime of changeovers. As a result, expensive, high-performance lines have only 30% or less production utilization. The optimal, affordable line concept becomes the decisive factor. EMS companies today have little interest in taking orders for small batches.
Camtec, an SME company, was facing this dilemma. Their goal was minimizing the downtime in the entire production chain with the lowest number of employees. The aim was to master the complex production requirements with least effort and to decrease the production costs. It was found that the reduction of downtime was more important than the absolute placement performance. To meet these requirements, Essemtec developed the "Turtle vs. Rabbit" concept.
The requirements:
655 active production programs with an average batch size of 1-50 must be produced. Approx. 600 different components are used. The goal is zero changeover time. The production must get by with one operator for the entire SMT line including setup. The space requirement must not exceed 5x2m for the assemblers, and the concept must be financially viable for an SME. Production quality and production reliability must meet the highest requirements.
The Essemtec solution:
4 absolutely identical FOX4 machines are used. Each machine can run the entire SMT spectrum. Each module can use all feeders such as trays.
On the line, a maximum of 560 x 8 mm reels can be randomly upgraded plus additional trays. If necessary, 20% are added online. The FOX4 needs only 1.2 m2 space. The line is therefore smaller than 5 x 2 m2. The line is controlled by the eMis Manufacturing Software.
Frau Brändle, production manager, remarks:
“With the old system, we kept having production interruptions due to minor problems with the feeders and the systems. Our goal was to have more feeder space in a smaller area (minus 30%) and to achieve a 30% higher output. The placement quality must be impeccable as well as the running quality of the line. With the new Fox line from Essemtec, we have achieved all these goals. Our high expectations were met, and I am very satisfied with the solution.”
Image: Mrs. Brändle, Production Manager, Camtec GmbH
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About Camtec GmbH
CAMTEC develops and produces state-of-the-art power supplies and components for automation, mechanical engineering and the electronics industry. The portfolio includes UPS, battery chargers and charging rectifiers for DC UPS, up to the upper kW range. For the power train of automation, we offer redundant modules, inrush current limiters and electronic, completely wear-free solid state DC relays. CAMTEC produces exclusively in its own factory in Germany. The company is regularly certified by the German TÜV according to DIN EN ISO9001:2015, CSA and UL standards.
https://www.camtec-powersupplies.com/
