2 Traceability Case Study AOI Component Traceability Project PC Manufacturer <-> Orbotech Electronics Assembly PC Manufacturer named CMf in this presentation September 2006
3 Orbotech AOI Executive Summary In July 2006 Orbotech successfully supported a collaborative pilot project for improved CMf customer experience The project focus for Orbotech was on AOI innovation for visibility and traceability at part level to improve quality metrics With the proven Orbotech solution, CMf can ensure better tracking of parts and products Implementing Orbotech AOI traceability at CMf EMS partners will help to reduce excursion breadth leading to cost savings and improved customer experience
4 Pilot Scope, Objectives, and Benefits Benefits 1:1 traceability for reduced excursion breadth Flexibility for different high value products Cost savings by limiting the number of resources and time when tracking defective products Improved customer experience
5 Pilot Goals Server Motherboard To read the 2D barcode on an individual chipset the alpha numeric marking on an LOM chip (LAN On Motherboard) Motherboard PPID during the SMT process Graphics Card Read the alpha numeric marking on the memory chips, the GPU, and the motherboard PPID (Parent Process Identification Number) For both products create a data association between the components and graphics card assembly.
6 Why AOI? AOI systems are an excellent match for the process for the following reasons: They can read and translate 2D barcodes (Intel chipsets) AOI has Optical Character Recognition (LAN on Motherboard (LOM) devices, graphics memory, and GPUs) Orbotech AOI systems were already in place at Foxconn on both Server and Graphics Card PCBA lines AOI equipment is programmable which makes it a flexible and scalable solution
8 Graphics Card Hynix Memory & Graphics Card PPID ATI GPU *Nvidia was used for the pilot
9 The AOI Requirements Capture different sets of data with barcode reading tools and OCR Read and translate 1D barcodes (PPID) on board Read and translate 2D barcodes on chipset Recognize chipset manufacturer logos Read and translate chipset part numbers and date codes
10 Pilot Phase 1 Data Flow CMf FTP:// Shared Website Traceability data pushed via Internet to CMf AOI REPAIR AOI Server Orbotech R&D Germany
11 Pilot Phase 2 Data Flow FTP:// Shared Website Required data pushed after each board test to shared website AOI Server AOI REPAIR SMT Production Line
12 Project Data Flow GPU Supplier Web Database Pilot Focus Area Data Pulled from Shared Website for Trending and Isolated Containment Planning in the Event of a Quality Issue GFX Memory Supplier Web Database LOM Chip Supplier Web Database Chipset Supplier Web Database Shared Website with Controlled Access Points. The site contains : Motherboard /GFX Card PPID Supplier Name Component Type Part Number Lot Code (Not Intel ) Date Code (Not Intel ) Unique ID (Intel Only ) Machine Number Data Pulled from Shared Website and Matched to CMf System Tag Information in the Event of a Quality Issue Chipset Supplier Database Chipset (Intel) Fab-Test-Packaging Data Pushed from Foxconn AOI System to Shared Website CMf Assembly Plant Database LOM Chip Supplier Database LOM Chip (Broadcom) Fab-Test-Packaging PCBA Plant (Foxconn) CMf Assembly Plant GFX Memory Supplier Database Graphics Card Memory (Hynix) Fab-Test-Packaging GPU Supplier Database Graphics Processing Unit (Nvidia) Fab-Test-Packaging PCBA Supplier Database
13 Data Flow CMf Global Access Vendor Vaults with Secured Access Chipset Vendor Assembly : Motherboard Component : Chipset Marking : 2D Barcode Data Acquisition : Orbotech AOI Access : Chipset vendor (Intel) LOM Chip Vendor Assembly : Motherboard Component : LOM Chip Marking: Alpha Numeric Characters Data Acquisition : Orbotech AOI Access : LOM vendor (Broadcom ) GPU Vendor Assembly: Graphics Card Component : Graphics Card GPU Marking: Alpha Numeric Characters Data Acquisition : Orbotech AOI Access : GPU Vendor (Nvidia) Graphics Memory Vendor Assembly : Graphics Card Component : Graphics Memory Marking : Alpha Numeric Characters Data Acquisition : Orbotech AOI Access: Graphics Memory Vendor (Hynix) Vendor Vaults with Secured Access Data Pushed from Orbotech AOI System and Foxconn Server Foxconn Data Acquired and Stored During Assembly Process
14 Pilot Timeline CMf CMf Dell High Value ASIC Traceability Pilot Timeline Evaluate the Pilot Server/Graphics Pilot at Foxconn Proof of Concept at Orbotech Web Development / Testing Prepare the Pilot Create the Pilot Plan Define the Pilot Group Define Pilot Scope / Objectives 5/15/2006 5/22/2006 5/29/2006 6/5/2006 6/12/2006 6/19/2006 6/26/2006 7/3/2006 7/10/2006 7/17/2006 7/24/2006 7/31/2006 Start Date Duration Finish Task (Days) Date Define Pilot Scope / Objectives 5/15/ /14/2006 Define the Pilot Group 5/15/ /30/2006 Create the Pilot Plan 6/14/ /7/2006 Prepare the Pilot 6/30/ /10/2006 Web Development / Testing 6/30/ /21/2006 Proof of Concept at Orbotech 7/10/ /17/2006 Server/Graphics Pilot at Foxconn 7/21/ /28/2006 Evaluate the Pilot 7/14/ /31/2006
15 Motherboard Solution Laser etched LOM 2D On chip barcode 1D barcodes (PPID) on board
16 Cross Reference Output Data
17 Chipset 2D Barcode Solution AOI Directed light is key to success
18 The AOI Solution Orbotech Vantage S22 features 3D optics with high intensity white light technology for high-contrast OCR reading Fixed 3D Optics High Contrast White Light
19 Direct White Light Diffuse Top Steep Flat Total Xenon Flashes Illumination Directions Camera Views + 18 Light Sources = 90 images of each component
20 Direct Light Removes Optical Noise Weak, combined Illumination Direct white light Direct light creates strong shadows to remove background noise
26 Sample Data Output Orbotech has a flexible solution for writing product data to different vendor vaults Via FTP To enterprise web server via TCP/IP Configurable data content & structure Different formats: XML, ASCII etc.
27 Read Rate Results 20,000 reads during project 60,000 reads during project
28 Conclusion Orbotech AOI is proven to deliver accurate data for the traceability of components on CMf assemblies The Orbotech solution already meets CMf s requirements It can read and translate 2D barcodes It has OCR for LOM devices, graphics memory and GPUs Orbotech AOI systems are already in place on both CMf server and graphics card PCBA lines AOI equipment is programmable which makes it a flexible and scalable solution for future projects
29 Vielen Dank für Ihre Aufmerksamkeit Die Unterlagen zu dieser Präsentation wurden von Orbotech Europa zur Verfügung gestellt.
30 Instant Process Control
31 Instant Process Control AOI Without Measurement And Immediate Action Is Like A Team With A Goalie And No Attack No more historical SPC what if s! A problem will be identified Direct the operator to the exact cause Then after adjustment Confirm and monitor production.
32 CIMCIS Computer Integrated Manufacturing Control & Information System This Error Measurement, Inspection and Feedback system collects data from boards in process and lets operators take corrective action when any segment of their line performance drops below a pre-set limit.
33 Manufacturers Needs. Maximum Return on Capital Expenditure Maximized Throughput. Minimal Scrap Minimal Non Value Added (e.g. Test.) Minimal Rework. Minimal Loss of Opportunity.
34 How can this be Facilitated? There are 2 obvious options to increase the Units per Direct Labour productivity metric. - Reduce the Operators. > - Increase the output. >
35 The CIMCIS Solution
36 Equipment Utilization. Process States Model * Non Scheduled Time Equipment Downtime Equipment Uptime Manufacturing Time Unscheduled Downtime Scheduled Downtime Engineering Time Standby Time Productive Time Total Time Operations Time *Copyright, 1996 SEMI E10 96.
37 What is our Goal? Maximize Productive Time! Equipment Downtime Equipment Uptime Non Scheduled Time Unscheduled Downtime Scheduled Downtime Engineering Time Standby Time Total Time Manufacturing Time Maximize Productive Time Operations Time Copyright, 1996 SEMI E10 96.
38 What's the Problem? - Standard root cause analysis using time & motion of historical data shows only - 20% attributable to Major Stoppages 80% Loss of opportunity due to many intangible issues. 100% 80% 60% 40% 20% 0% 20 80
39 Where are we loosing time? 1st Pick & Place 100 Placements per cycle Best Cycle 60 Secs In a perfect world we produce 60 units per hour
40 Where are we loosing time? Material Replenishment Required Part Used 10 off per cycle Machine Stops & Alarms Part Replaced with a different Feeder Machine Starts Feeder Faulty & Begins to cause errors
41 Where are we loosing time? Machine has auto recovery mode Auto Recovery set at 1 Machine will stop when more than 1 CONSECUTIVE error occurs But Error is intermittent! Only causes error every other pick Machine DOES NOT STOP. Each recovered error adds 1/100th to the cycle time
42 Where are we loosing time? Cycle time increased by 10% We now only produce 54 units per hour in our perfect world. 10% down and only 1 hour into the shift. Each Unit produced adds $100 value to the Company In 1 hours we have lost a minimum of 6 units or $600
43 Where are we loosing time? 50% of the errors caused a part to be rejected/scrapped The part is worth $ 0.50 We have rejected 540 parts One faulty feeder has just cost you another $ 270 per hour
44 Where are we loosing time? Performance analysis run every 8 hours Assuming no other errors we will have lost 4320 parts at a cost of $2160 We have also lost 48 units with a value of $4800 One faulty feeder has just cost you another $6,960 The reel only has 5000 parts on it Oh - it was the last reel. Your stopped for material 5 hours into the shift & lost 3 hours
45 What is CIMCIS? Sächsischer Arbeitskreis Elektronik Technologie? Fully Scaleable Off the Shelf Manufacturing Management System. Modular Design allows functionality to be added as and when required.
47 How Does It Work? Machine Manager Works with Operator Line Controller Exchanges Data with outside world
48 Peripherals CIMCIS COMPONENTS Non Intrusive Data Tap Fixed Barcode Scanner CIMCIS Patch Box CIMCIS DATA TAP Handheld Barcode Scanners AUX4 AUX3 AUX2 AUX1 PWR HOST HOST Real World Interface CIMCIS MINI PATCH EXPANSION PORT
49 CIMCIS Architecture 1 Equipment Level (FUJI Example ) Unplug FUJI Comms Plug In Bridge Cable Connect to Mini Patch CIMCIS TERMINAL GADGET Draw a custom shape. Size this shape to match the size of your shape. Copy your shape. Open this group and paste your shape inside. Send text block at bottom to front. Close group. Enter Clear F1 F2 Power Outlet Connect to Gadget Power from Machine FUJI MCS16/30 Real World Interface or Mini Patch CIMCIS Bridge Cable FUJI CP X
50 CIMCIS Architecture 2 Line Level To Network Equipment CIMCIS TERMINAL GADGET Draw a custom shape. Size this shape to match the size of your shape. Copy your shape. Open this group and paste your shape inside. Send text block at bottom to front. Close group. CIMCIS TERMINAL GADGET Draw a custom shape. Size this shape to match the size of your shape. Copy your shape. Open this group and paste your shape inside. Send text block at bottom to front. Close group. CIMCIS TERMINAL GADGET Draw a custom shape. Size this shape to match the size of your shape. Copy your shape. Open this group and paste your shape inside. Send text block at bottom to front. Close group. Enter Clear F1 F2 Enter Clear F1 F2 Enter Clear F1 F2 Daisychain Mini Patches Mini Patch Mini Patch Mini Patch Connect to Cell Controller Line/Cell Controller FUJI CP X FUJI CP X FUJI IP X
51 CIMCIS Architecture 3 Factory Level To Network Lines Network Line/Cell Controllers Factory Ethernet 10 base T Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Connect to Factory Network Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Add Other Lines as Required Factory Server Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2
52 System Functionality Line/Cell Controller CIMCIS Terminal & Machine Controller HUB Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Enter Clear F1F2 Links Line With Outside World Localised data storage Line/Cell Controller Provides Standard Interface to Line Regardless of Equipment To Network 10 base T or RS 232
53 Process Control Screens Control Screen Out of Control Warning Screen Allocation Screens Down Time OUT OF CONTROL Condition RUN 00:00:00 Power: Local Current: 000 MACHINE IN CONTROL... ( ) Limit: 000 Panels: 000 Minutes: 000 PREV **** **** **** TOT* **** SUMM NEXT
54 CIMCIS Factory View Factory Level To Network Lines. Network Line/Cell Controllers. Connect to Local Network Factory Ethernet 10/100 base T Local Ethernet 10 base T Connect to Factory Network Add Other Lines as Required CIMCIS Server
55 CIMCIS WEB Browser Data Accessibility Tool Uses Any Web Browser as container for database queries and displays in Simple pictorial format CIMCIS CIMCIS Analyzer Simple Charting of Data
56 CIMCIS Analyser. Enhanced Charting Identifies areas of Best Value Add
57 CIMCIS has been installed on SMT lines with the following equipment Pick & Place FUJI Philips Siemens UNIVERSAL GSM PANASONIC AOI MACHINE VISION PRODUCTS (MVP) REFLOW OVENS (USING KIC PROPHET SYSTEM) Screen Printers MPM DEK
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