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HOW TO REDUCE MACHINE SET-UP TIME???

Just wondering if anyone else out there has been able to red... - Jun 09, 2005 by

james

#34841

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

Just wondering if anyone else out there has been able to reduce Set-up time on SMT Machines. We are a contract manufacturer and run several different models in one day on 4 different machines. We currently have 40-50% downtime due to set-up time. It would be nice to have a feeder for every part but we all know feeders are quite expensive. If anyone else has solved this issue, I would love to hear from you.

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#34842

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

when we run a pilot run it usually takes a lot of time because it needs to be properly adjusted so that on production time everything could be set up easily and run smoothly. on a no feeder situation, components for the next model should be already labeled by numbers so that if the model being run is finished you can exchange feeders with the next model, you say you have 4 lines and if one line dont have any schedule of production yet you can use the feeders on that line. for faster output components should be prepared and double checked first.....

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#34857

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

James, I have worked at a couple of different companies and both have reduced their changeover times significantly. What type of placement machines do you have? Do you use customer part numbers or do you have your own internal part number for components?

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#34858

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

If your boss can't figure-out that buying feeders is cheaper than having a machine idle, then it's good that he has time available to torment you on why you're not developing other solutions.

On the other hand, if you don't have enough work to load the machine, it doesn't matter how many feeders you have.

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#34859

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

Do you have any parts dedicated on the machine? 100n 0603 or 0805 is probably used on almost everything you build. So why take it off and put it on the machine several times a day. Even if you dedicate only 20 parts to never come off the machine, that should help a bit. Where I was we had over 200 parts that never came off the line. It does slow down the machine a little but done properly it isn't even close to being significant when compared to 4 or 5 changeovers a day on each line.

Another major thing is preloads. As much as possible have the feeders for the next run ready

And don't overlook making sure everything and I mean everything is as close to perfect before SMT even hears about a job.

Some people think the manufacturing process starts at SMT but I say it is the halfway point.

I visited a CM on a one day tour. They were running one job, had the next loaded and were loading the one after. I think it is the only place that looked pre-SMT for issues that everyone else just assumes is SMT. Any complete solution to SMT changeover times will look at pre-SMT as much as they look at SMT.

enough of my rant, remember we are all in this together and keep your stick on the ice.

Steve

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james

#34863

HOW TO REDUCE MACHINE SET-UP TIME??? | 9 June, 2005

I would love to buy enough feeders, just for the common parts but unless I find somewhere cheap to buy them it can very expensive. We use our own internal part numbers with using smart feeding stations. Also we are going to try to leave all the common parts in feeders and store them that way on the shelf. The other problem is trying to locate parts. They do not order enough reels to run 4 jobs at a time. And alot of operators do not like cutting the reels, because of having to make a leader.

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#34870

HOW TO REDUCE MACHINE SET-UP TIME??? | 10 June, 2005

This sounds like exactly what I am going through here. If you come up with a nice solution please post it. One of the things I have done is make top and bottom programs similar as possible. No I didn't say all programs the same overall just each job has its own similarity. It says about 20 feeders for changeover sometimes but others it might be less than 5. With contract manufacturing there is no real easy way to do this. Just curious what programming platform you use and type of machines?

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#34876

HOW TO REDUCE MACHINE SET-UP TIME??? | 10 June, 2005

Once upon a time I worked for an equipment rebuilder. While employed there I installed many SMT machines. By far the best solution I ever experienced was more feeders preloaded with the next job. The next best solution I experienced was some custom planning/optimization software that examined the day's build, made programs (just changed the feeder location on an existing program) and schedules to minimize feeder changes. They would set-up for job #1 and run. To set-up for job #2 they just had to add a few feeders. This went on until there was no space left to add feeders. At that time the software had them remove all of the feeders and start the process all over. This customer was a large company and had in house programmers to create and maintain this software. I was told it took them a year to work out all of the bugs.

Jerry

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jbrower

#34878

HOW TO REDUCE MACHINE SET-UP TIME??? | 10 June, 2005

Hi James, As my companys process/manufacturing engineer, I set up a program that dramaticly reduced machine down time. Some base numbers; we went from an average of 4-6 hrs set up on our Mydata to setups of under 15 minutes on average and some below 9 minutes. Specifically, we set up the next job while the current one is still running. We don't allways use all of our magazines so the ones that aren't being used are pulled for our off line set up. Additionally we have a fixed magazine with common parts. Keep in mind that we are an OEM, but with more than 70 SMT assemblies of varied complexity. This process works well in a Contract Manufacturing setting also, My last gig was with a CM. Currently I am working on identifing like assemblies to group them into process families so we can run like assemblies with less set up. We set up the next job as much as possible while the machine is running. In Lean speak this process is called Single minute exchange of dies, (SMED. If I can be of further assistance please feel free to email me. Best regards, Jay

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#34880

HOW TO REDUCE MACHINE SET-UP TIME??? | 10 June, 2005

Steve,

We're not so sure that we've had enough of your rant. You say "I think it is the only place that looked pre-SMT for issues that everyone else just assumes is SMT. Any complete solution to SMT changeover times will look at pre-SMT as much as they look at SMT."

Please give more detail in your thinking. For instance: * What do you mean by "pre-SMT"? * What is "SMT" [baring the obvious]? * What "pre-SMT" items affect change-over? * What things can be done with "pre-SMT" items improve change-over?

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#34886

HOW TO REDUCE MACHINE SET-UP TIME??? | 10 June, 2005

James,

It's good that you have internal part numbers. Some CMs use customer part numbers which makes dedicated setups much more difficult.

Your materials group can tell you the quantities of part numbers they buy, and that can tell you which parts you can leave setup on your feeders.

What kind of equipment do you use? How much feeder space do you have left over on your setups? If you use turret-style chipshooters and can afford the feeder space, consider taking your top 20 or 50 part numbers and leaving them setup on the machine at all times. Then you'll have to regenerate your programs to match the new setup. It will have a minimal impact on your throughput if you do it correctly. Also with turret-style chipshooters, you can have often have a job running on one carriage and a second job being setup on the second carriage. I'm guessing you don't have that kind of equipment since you say your feeders are expensive. The feeders for HSPs and Panasonic MVs are relatively inexpensive, from what I've seen. I'm not familiar with other chipshooters. Even with other equipment, you should be able to utilize a dedicated setup, where the parts you almost always use never move. You are already planning to have parts set up on feeders, why not take the next step and leave them on the machine? Then, as others have said, you need to have the remaining parts for the next job set up on feeders and ready to be loaded on the machine at changeover time.

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Adnahn

#34906

HOW TO REDUCE MACHINE SET-UP TIME??? | 13 June, 2005

Is your machine programs gang picking? Work out a machine set-up for commonly used components to have a fix location on the machine ( preferably on the side the operator spends the least time ).Most of your change overs take place on the front of the machine.

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peter ng

#34932

HOW TO REDUCE MACHINE SET-UP TIME??? | 13 June, 2005

Dear James 1)Standby the part for next model. 2)during the convention period,replaced the part for the machines. 3)All the programme are following the CAD data.It's help to reduced the situation. 4)All the feeder must be in the good condition. 5)The value confirmation by QA must be in the shortest period. 6)Using the same reference offset at machine,such as stopper offset,PCB layout offset.....

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james

#35138

HOW TO REDUCE MACHINE SET-UP TIME??? | 23 June, 2005

The ideas so far are good, but yet remember, we are running 4 different lines with "1" set of parts that are never removed from the feeders. We can not get purchasing to buy extra reels of the of the most used parts, and these parts travel from line to line so leaving them on the machine is not an option at this time. Also, we are strapped for room, so using removable feeder banks is also no an option. The best so far is having jobs preloaded on the feeders, but on off shifts where there is no support, operators are left loading feeders rather then running the jobs.

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#35139

HOW TO REDUCE MACHINE SET-UP TIME??? | 23 June, 2005

It's interesting that your company was willing to buy enough machines to complete 4 lines, but isn't willing to buy enough parts for them to operate. That sort of reduces your 2-4 lines to a role of emergency spares locations, doesn't it?

We experienced something similar at my last job when we knew we were going to be outsourced and they didn't want any excess (more parts than schedule called for) material on the floor. That was with 3 high speed lines. Now at my new job (a tiny little CM) we get orders for 25 boards, and the customers give us 25 SOT-23's on two 1/2 inches of 8mm tape.

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#35141

HOW TO REDUCE MACHINE SET-UP TIME??? | 23 June, 2005

James,

Take all of this good information that's been given to you. Develope a plan that will reduce set-up time. Present it to the "powers that be". If they do nothing it's not your problem anymore. In most cases to make a large gain in productivity it will cost money up front. Show them how they can spend some money now and save money for the rest of the companies life.

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james

#35144

HOW TO REDUCE MACHINE SET-UP TIME??? | 23 June, 2005

After a year of making up part lists that we need duplicates for, and having nothing more happen, and yet be asked to decrease the change over times, you can only bang your head against the wall so many times.

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james

#35145

HOW TO REDUCE MACHINE SET-UP TIME??? | 23 June, 2005

The majority of the time, all 4 lines are running 24/7, but it is a big juggling act with the parts. What�s clean, what can be move to another line etc.

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#35289

HOW TO REDUCE MACHINE SET-UP TIME??? | 4 July, 2005

James, sounds like you need one of these:

Feeder Arrangement Feeder arrangement problem concerns assigning components to the feeder slots

Placement Sequence Placement sequencing (or insertion order) problem concerns determining the sequence in which the components are printed on the board

Nozzle assignment Nozzle assignment problem concerns the tool changes for the placement head

Component retrieval Component retrieval problem concerns determining from which feeder slop the component is retrieved if it has been assigned to more than one slop.

check out at http://www.asprosoft.ca you might find info there very and very useful, especially with free trial account.

Cheers

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#40010

HOW TO REDUCE MACHINE SET-UP TIME??? | 24 February, 2006

All the opinion and recommendation given here is so useful, but there is not an optima solution for your specific problem. I recommend you to use some useful techniques of lean manufacturing like smed, kaizen , etc. it helps to get a solution for your deficient setup and apply all the tips and solutions given here adapt them to your case. We spend almost 100,000 usd to improve technology in our obsolete feeder and equipment, and now we are trying to improve the new setup process

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