TAL17 - Alois Mahr, Zollner Elektronik AG

SOLUTIONS FOR YOUR IDEAS
Networked Manufacturing Process in Electronics
Production
TAL Pilsen 2017
Alois Mahr
Director Global Engineering
Zollner Elektronik AG

 brief presentation of Zollner Elektronik AG
 traceability for continuous material- and process data
acquisition
 current customer requirements and realized projects
 future requirements towards Industry 4.0
 conclusion and future prospects
Agenda
15.09.2017 • Zollner Elektronik AG • A. Mahr • Networked Manufacturing Process in Electronics Production2 •

acquisition
Agenda

Solutions for a Common Future

Locations
Founded in 1965
17 Plants
285.614 m² Production area
7 Countries
Over 10.500 Employees

acquisition
Agenda

What Does Holistic Traceability Mean?
Ensures continuous traceability of:
COMPLETE SYSTEMS DEVICES MODULES PCB
Regarding the production of:
COMPLETE ORDERS SINGLE ORDER LOTS SINGLE PCB`S MOUNTING LEVEL

What Does Holistic Traceability Mean?
unique labeling (RFID, Barcode, DMC;)
of material & auxiliary materials, as well as products

MES / Traceabilitysystem
 no MES  no production
 Hotline
 on standby 7x24h
7 data bases productive
23 data bases in 3 testing systems
approx. 6.600 User-Accounts
approx. 123.000 LOCATIONS (machinery,
storage, shuttle ta bles,…)
Ca. 158.000.000 marked UNITS (assembly
units, modules, equipment)
Ca. 1.620.000.000 assembly unit movements
Ca. 5.200.000.000 batch-consumption postings
Key Data

Costa Rica
USA
China
DE
RO
HU
MASTER
Reporting
Server
WWW
MFT/SFTP
Traceabilty System-Pattern

Repair
Traceability Server
Traceability Database
Mar-
king
Siplace Test Island
AOXI
Traceabilty System-Pattern

 common challenges
 complete traceability
 clear labeling
Requirements for a Holistic Traceability
supplier
manufacturer
distributor
…
production
EMS
OEM
…
customer/
customer of
the customer
…
information process
product development process

Requirements for a Holistic Traceability
manual
workstations
material
auxiliary and
operating
materials
test systems
room
temperature,
humidity
…
repair data
production
plants
Traceability
System
Labeling– Interfaces- Data Security

The Zollner 5-Stage model
STAGE 5 process optimization
STAGE 4 process interlocking
STAGE 3 Process - Traceability
 process data:
screen printer, adhesive, placement module,
reflow soldering, wave soldering, selective soldering,
assembly, shipment, surrounding conditions
STAGE 2 Test - Traceability
 Test Data
 Optical
(AOI, X-Ray, Man. opt. inspections,…)
 Electrical
(ICT, FAT, HV-Test, Flying Probe,
Boundary Scan Test, Run in Test, Burn in Test)
STAGE 1 Material- Traceability
 modules
 auxiliary and operating materials

Reporting
elaboration, transfer, processing and storage of information about the company and its
surroundings with reports
 Defining standardized reports
(KPIs)
 Interpretation of figures
 Using reports as tools
 Online-Monitoring
 …

acquisition
Agenda

System Environment
SHOP-FLOOR
SAP
masterdata/orderdata
ProductionBackflush

Industry 4.0 “Soldering Paste Printing“ & „Closed loop“
Soldering Paste Printing is the
basis for good quality.
Inspection of soldering paste print
ERP
MES
process- &
control level

Closed Loop Paste Printing / -Inspection
SHOP FLOOR
MES
ERP1
- Communication with XML interface
- Paste printer transmits latest configurations to SPI
- SPI inspects printed PCB
- Measuring the X- and Y-mismatch
- Measuring height and volume of the paste
- Monitoring the soiling of the stencil
- Report results to the MES
- Response of SPI to the paste printer with the corrective configurations
 quick and exact setup of the stencil position at the printer
 Constant corrections of the stencil position
 Mismatch at the stencil printer and subsequently downtimes at
the SPI decrease
 Cleaning the stencil if necessary
 Savings in auxiliary production materials
 Higher throughput
- Validation of product, order, BoM, LP-batch
- Request: assembly unit serial number
- Feedback: marking results
- Validation of Batches
- Feedback of material consumption and
rejects
- Feedback: placement result
5
- Validation of order,
assembly unit, BoM,
solder paste, squeegee,
stencil  request at MES
- Load program
- Feedback: print result
and process data
- Validation of assembly unit
- Load program
- Feedback test result
2
4
3

Traceability “Today” and “Tomorrow”
yesterday today tomorrow
RISK MINIMIZATION
 Traceability of
 material batches
 test- and repair data
 process data
 locking of processes
(zero-defects principle)
 transparency in processes
 profound root cause analysis
 from traceability to MES
SYSTEMATICAL PROCESSOPTIMIZING

Test Records Debug Records
Traceability Data
to some extent every 4 hours
during production
at least once a day
at least once a day or according to
production schedule
Header File Component File Attribute File
 manufacturer
 Serial & parts-nr.
 location
 Product family
 Business Group
 …
 Date Code
 Lot Code
 Quantity
 Type
 Commodity Code
 …
 Differentiation assembly
unit or module
 e.g.: MAC-address
(e0:cb:4e:9f:fc:d3)
 for ALL tests at every
unit:
 test step
 test station
 test-slot
 test-period
 test status
 errors, TTF
 executing person
All reports have to be created and transferred automatically in the
future
 for every test, marked as
FAIL:
 error description
 defective part
 actions taken? What,
When, Where, Who?
 Information for
replacement
Which Data is required by our customer in the future?
The transparent
company

acquisition
Agenda

 Smart („fast“ and „clever“)
Data is the crude oil of the 21st century

react  regulate  foresee  recognize
Smarter Analytics maturity model
predict/determine the best that can happen?
Different views of: “What will happen next?”
What if this trend continues?
Why did it happen?
optimization
predictive analysis
forecast
statistical analysis
Ad Hoc Reports
Dash / KPI
Necessary measures?
Main cause and ID of the problem?
How many, how often, who & where?
What did just happen and why?
CompetitiveAdvantage
Smarter Analytics
AnalyticsAccess&
Reporting
alarms
Drill down queries

What is Predictive Analysis
Predictive Analytics
Generated from data of operative actions, by drawing reliable conclusions to the current
situation and to future events (Detect & Forecast)
Customer Analysis Process Analysis Risk- / Hazard
Analysis
 gain
 grow
 retain
 manage
 wait
 maximize
 monitor
 detect
 control

Application Areas of Predictive Analysis in PLZ
 Analysis of test
data
 Identification of related problems,
causes and measures
 Use of telemetric data for early
identification of errors
 Automated analysis of
texts
 Production optimization
and -monitoring
 Reduction of rejects
 Predictive maintenance and
warehousing Determination of customer requirements through
segmentation
 Automated surveys and
direct analysis of the
answers
 Product recommendations at
the Point of Sales
 Prevention of repeated
repairs
 Analysis of merchant statements and
subsequent measures
 Forecasting service intervals
Development
Early Production
Series
Production
Logistics
Marketing
Sales
After Sales
guarantee

IT-Processes
IT-
PROCESSES
Data Quantity
Availability
Rapidity
Support
Archiving
Growth: 50 – 70% per year
of the system (24/7)
when processing the data
(cycle time in production)
resp. Service-Hotline
of the data

acquisition
Agenda

Vision of Digital Networking
customer supplier
distributor
Purchase
order
Inspection data
…
Test data
Process data
Material data
Repair data
Placement data Order
Forecast
Quality data
Delivery note
Delivered
quantity
Delivery
date
Product
Customer SNo
Assembly unit SNo

Vision of a SMART Factory
TODAY FUTURE VISION
Automation of
production
processes
Optimization of
production
processes by
innovative
software systems
and technologies
Self-optimization
of entire
production by
cyber-physical
systems
IMPLEMENTATION OF INDUSTRY 4.0
Self-optimizing production process

Target of a SMART Factory
CUSTOMER TARGET: Master the complex process to improve yield, output,
efficiency, turnover factor, etc.
OUR SMART MOVE TO INDUSTRY 4.0
Optimization of production processes by innovative software systems and
technologies
TODAY: INDUSTRY
3.X
Automation of production
processes
VISION:
INDUSTRY 4.0
Self-optimization of
entire production
network
Process
Control
Throughput Inventory
Quality

The SMART FACTORY VISION
PROCESS CONTROL
EQUIPMENT
QUALITY
THROUGHPUT
Manual Process
Automation/Machines
Controlled Closed
Loop Systems
Expert systems
Single Cyber-physical Systems
SMART Factory

It is not our task to predict the future, but to be well
prepared for it.
Pericles, approx. 500-429 v. Chr.

15.09.2017
Zollner Elektronik AG • A. Mahr • Networked Manufacturing Process in
Electronics Production
38

SOLUTIONS FOR YOUR IDEAS
Thank you very much for your interest in the Zollner company group.
A. Mahr
Director Tel.: +49 9944 201-588
Global Engineering (GE) Fax: +49 9944 201-9343
Zollner Elektronik AG A._mahr@zollner.de

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