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Fuji parts out Signal for poka-yoke component replenishment

Views: 5229

#48616

Fuji parts out Signal for poka-yoke component replenishment | 24 March, 2007

Hi there. Ok, i have a little big question for fuji Erudites: when machine run out of parts on any device it tells to machine "parts out (and part number)" So, a signal from anywhere (maybe a PLC output) will tell to the machine "hey i'm out of parts" and it stops; another kind of processing (I think by software) tells you in which device and of course, the part number of current device. Is there a way to know where is this output located or some of you knows how really works this thing so I can get this signal in order to connect it to an external PC?; then get back another signal to be able by relays or something to disconnect any interlock in order to not allow to the operator run the machine unless he follow a procedure in the PC (part verification by barcode scanner) This is basically what I want, force to operator to follow a reel verification procedure; currently we have a system (developed by our IT department) where you have to scan both new and old reels and it compares to a given program and device location in order to verify reel load and prevent wrong components.BUT is operator dependent, so if he feels lucky just change the reel without verification and machine will not stop if he didn't follow the procedure having a high probability of Wrong component. I know that actually Fuji have FUJITRAX and another companies like COGISCAN have a very smart software by RF-ID tags to prevent misloadings but... they are EXPENSIVE!!! (about $100K i think) and also Fuji does not have supported CPIV and IP's (II & III) because of their age.

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#48677

Fuji parts out Signal for poka-yoke component replenishment | 27 March, 2007

Nobody???

Regards.

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#48833

Fuji parts out Signal for poka-yoke component replenishment | 3 April, 2007

Hi,

I think the only solution would be to contact Fuji and ask if there is an interface to the machine to write software for it. I read somewhere that FujiTrax allows a IT system type connection which software could be written for.

Another solution I would use is to write some software that knows what parts are used per product, and then with a sensor on the in feed, you could estimate how long for parts to run low. You would know low, but not really out, as you might get some parts reject that throw your estimation out.

Then as you load reels, the operator clears the reel qty on a computer as they load the reel on the feeder. Then you could work it out.

Is this the kind of thing your after?

Regards,

Grant

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#48860

Fuji parts out Signal for poka-yoke component replenishment | 3 April, 2007

Manuel, Try http://www.bartector.com/. I consult at a company in my hometown and they have this in place and works very well with their old and new Fuji equipment. I doubt that it costs 100K. I have no ideea how much it is but I think is worth checking them out.I had Fujitrack and Cogiscan at other places I worked. This seems to be a much simpler solution.

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#48874

Fuji parts out Signal for poka-yoke component replenishment | 4 April, 2007

Don't think much of the people who run the line do you mate?

"BUT is operator dependent, so if he feels lucky just change the reel without verification and machine will not stop if he didn't follow the procedure having a high probability of Wrong component."

High probability? Something's wrong there. Crap pay. No training. Lousy work environment. Unrealistic expectations. Monkey attitude.

No amount of software or interfaeces is going to fix that.

Write a dummy program that involves 80 reels, 10 tubes and 4 trays. 400 placements. YOU run it for two 8 hour shiftsdays. No full reels allowed. If you don't achieve 80% of rated CPH with 95% first pass yield; you lose your job. Sayonara

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#48880

Fuji parts out Signal for poka-yoke component replenishment | 4 April, 2007

Totally agree on what you said, but there's some other things involved:

There's not enough training, here in Juarez, Mexico, the level of pesonal turnover is very high so when you train on certain procedure, they leave for some reason and always is you have new people training.

here, production departament say, claim, exige for something engineered "poka-yoked" so the personal dependence is at the lowest level; and the worst thing, they have the management support (but does not want to spend money, of course) I know that following the actual procedure, the incidence of wrong component will be low. A general overview of procedure:

1.- take out the old reel and scan in a own program where you specify product, device and scan part number. program have component device locations for every product. the same program gives you the kanban where component is located.

2.- Take the same reel and give to inspector from the end of the line so she/he can verify that is the same reel (to avoid scan the same reel twice)

3.- Back operator go to kanban location and pickup the reel, then go to computer an scan the new reel, if for some reason he pick another reel, computer will tell him that reel is wrong, if it's ok then he load it into machine and mark the board.

4.- Once the marked board leaves the oven, inspector had to have component identified on board so he can compare it to first article (in case of wrong labeled component), so she can release transaction on the program.

Is not a bad system, BUT you can bypass all the procedure and just load the new reel and let the machine continue, allowing the possibility of a wrong component. I Know that personel ownership, training and discipline is the best way to solve this, but from a egoist engineering standpoint is hard to fight against all the situations involved and I prefer to look for alternatives.

Also, if somehow I can add to the actual software that we have the feature of "force" to the operator to follow the procedure in order to allow machine continue running, i will sell the application to other companies with the same problem (LOL), nah I'm just joking.

We have a product with 489 placements, 106 reels, 1 tray component (QFP of 256 leads, 0.5 mm of pitch) some QFN, a bunch of 0402, appart of a bunch of other "normal" components, we have scheduled about of 125% of the machine capacity, and anyway have to ship on time. so you can imagine the sweetish of the matter.

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Scotceltic

#48938

Fuji parts out Signal for poka-yoke component replenishment | 10 April, 2007

I agree. We use Bartector. It is a very cost-effective solution to do what you need. It can hook up to all Fuji equipment including the new NXT.

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#48978

Fuji parts out Signal for poka-yoke component replenishment | 11 April, 2007

Excellent reply. You have my sympathies. Good luck!

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#48979

Fuji parts out Signal for poka-yoke component replenishment | 11 April, 2007

Seems to be easy and effective, I will ask for further information with them...

Regards

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#48986

Fuji parts out Signal for poka-yoke component replenishment | 12 April, 2007

you might wanna look at the Valor (Trace Expert) program they support also the old Fuji's but it might be a "over kill" in this case

http://www.valor.com/en/Products/Manufacturing%20Execution.aspx

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