vManage Control System
The vManage Control System provides production overview and improvement issues on machine and feeder performance. It also includes the Report Generator for detailed production information and standard reports.
The vManage Control System is the basic module of the Valor iMES (Integrated Manufacturing Execution Solutions) suite and is always included with the application. All production information is shown in easy-to-understand windows, and data is collected from the programs and the machines in the solution Database.
Machine Performance
At the left hand side of the vManage application, a window shows the performance data of the SMD machine as well as basic information such as current program name, cycle time, etc.
Using the production performance data of SMD machines it is possible to identify bottlenecks based on the time elapsed in the different modes. Balancing the line will increase productivity.
Current efficiency (length of bar)
The current machine's efficiency and production performance history are shown in a vertical bar chart. A time scale (user defined) is displayed on the x-axis, and machine performance, measured as a percentage, is displayed on the y-axis.
Working mode (green)
The green fraction of the bar shows the time elapsed in working mode.
Waiting mode (yellow)
The two yellow colors shows the time elapsed in waiting mode. The dark yellow color corresponds to the time elapsed waiting for the next machine in the SMD line “Wait Next” while light yellow corresponds to the time elapsed waiting for the next board “Wait Board”.
Stop mode (gray gap)
The gap that may appear between the top of the bar and the 100% point on the y-axis indicates the time elapsed in any other machine status or user defined mode (the machine is stopped).
In the status box at the top of the performance window, it is possible for the operator to choose among a number of user-defined statuses to increase the detailed information level.
The “fixed user status” can be used for e.g. prototype production, to indicate lack of components and for machine maintenance. The “future user status” can be used, e.g., when the operators leave the area for a meeting. If a “machine stop” occurs, it will be reported correctly as “Meeting” instead of “Error Stop”.
Feeder Performance
The current feeder error level is shown in a bar chart. This provides information for the operator or supervisor about the feeders - if any - that need replacement or repair in order for efficiency to be increased.
The specific feeder table and slot number is identified for each feeder. A scroll bar to the right enables the user to scroll down to see additional feeder error rates.
Current error rate (length of bar)
The feeders with the most errors are shown at the top of the window. The horizontal length of the bar indicates the specific feeder's current error rate.
Error rate trend (color of bar)
The bars' color codes indicate the trend of the error rate for a specific feeder. A red bar means that the error rate is increasing; a yellow bar means that the error rate is constant, and a green bar means that the error rate is decreasing.
Error type and statistics
The actual error list with recent errors will pop up when a feeder error bar is double-clicked.
Global Performance Monitor
The Global Performance Monitor provides a performance overview of all SMD machines and production, which makes it a unique tool for production management and planning.
Detailed information can be used to balance production line and increase output.
Line Performance
The Line Performance graph displays the actual line performance compared to the possible performance. This is done in real-time for a period selected by the user. It is even possible to specify user-defined production line overviews.
The line performance is calculated as the performance of the bottleneck machine, since the bottleneck machine is the machine that limits line throughput. The bottleneck machine is continuously recalculated to reflect the actual situation in the line.
Two types of bottleneck machines are displayed to the operator:
The current bottleneck machine calculated from the cycle time only (the machine that is the bottleneck if all machine are running without error stops)
The current bottleneck machine calculated from the cycle time and stop time (the one that is the real bottleneck because it often stops with errors)
The current status (working, error, wait next and wait previous) is shown for all machines in the line.
The Real-time Feeder check
The Real-time Feeder check module ensures that the correct components are loaded and used on the machine.
This improves quality as well as productivity.
Ensures use of the right components
When a pick-up occurs on the SMD machine, the feeder b arcode is scanned and the slot position is determined. vManage verifies that the part number connected to the feeder corresponds to the part number specified in the program.
The real-time feeder check option is used
on SMD machines where the feeder is moved to the pick-up position. On other SMD machines, the feeder check takes place when the feeder is placed on the machine.
Improves quality and production
The kitting station is used to connect a tape reel to a feeder. When a feeder is placed in the kitting station, the barcode is automatically scanned, and the feeder is considered to be empty. It cannot be used in production until the feeder is connected to a tape reel.
When the operator scans the barcode on the tape reel, the color will turn green and information on the reel connected to the feeder is shown.
On-line help
If an error is detected, vManage stops the machine, and the button “Click for help” will appear. When the operator clicks on this button, a help text will be displayed to provide a more detailed description of the reason for the machine stopping and of the actions the operator needs to perform in order to solve the problem.
All necessary program information is automatically collected by the system and saved in the shared database.
Component verification
Feeder Validation
The Feeder Validation option is used when specific part numbers are only allowed on specific feeder types.
Operator Validation
This option provides verification of operators and full documentation for customers – e.g. in medical production when specific operator skills are requested.
The kitting station is used for operator login. Production can be stopped if an approved operator is not logged in. All kitting station actions are traced to the operator who is logged on.
Stock Control System
The Stock Control System enables amounts and locations of each component reel (oven, stock etc.) to be traced and to carry out automatic inventory and stocktaking. Position and numbers of components on each reel are continuously updated .
It is possible to provide data for ERP systems (SAP, BAAN etc.), which makes component ordering efficient.
This module requires reel IDs on the tape reel and that the amount of components on each reel is known.
Advanced Feeder Check
Advanced Feeder Check automatically checks that the correct components have been loaded on placement machines with fixed feeder stations.
Ensures right components
The system verifies the set-up in real-time and stops the placement machine when an incorrect component is placed on the machine. The set-up is already verified when the feeder is loaded and prevents the operator from starting the machine. This saves production time and reduces product change-over time.
Useable for many machine types
Digital cameras monitor the feeder set-up, and advanced software identifies the feeders and components placed on the machines. This makes it possible to ensure that all components are mounted in the correct slot.
Advanced Feeder Check uses the same concept as Real-Time Feeder Check: feeders are labeled with individual labels and components are connected to the feeder in a kitting station.
Improved feeder performance
During production, picked components and errors on each feeder are registered and continuously updated in the database. When a feeder runs empty on a machine, an automatic check is carried out to determine whether maintenance is due. If so, this is indicated to the operator.
Maintenance schedules
The maintenance interval can be defined as a “time period” and a “number of picked components”. When the date or number of pick-ups is exceeded, the operator will be cautioned by the appearance of a red bar “maintenance”.
If the operator attempts to connect a feeder and a reel in the kitting station, the kitting window will inform the operator that the feeder should be sent away for maintenance.
When a feeder is due for maintenance, the operator can still choose to use the feeder in production. This solution is available so that production can continue even if some of the feeders should to be sent away for maintenance.
Detailed Maintenance Information
The feeder maintenance database keeps track of the following feeder information:
1. The number of pick-ups since the feeder was last maintained
2. The number of errors since the feeder was last maintained
3. The date of the last maintenance
4. Days between maintenance
5. The total number of pick-ups before last maintenance on this feeder
6. The total number of errors before last maintenance on this feeder
7. Maintenance actions and history
The “Feeder Maintenance” application is a management tool intended for the technicians who perform feeder maintenance. This application supports feeder searches and provides updated feeder data.
vManage supports different types of Automatic Program Change according to the hardware involved. The best solution is to place scanners in front of all machines which reduces the risk of error when the operator removes or inserts PCBs into the line while also ensuring the best data for traceability.
If there are no scanners in the line, Automatic Program Change is performed through the handheld download scanner in front of the line. (The records in the Traceability data cannot contain any identification of the boards if this solution is chosen.)
Traceability
Traceability equates with production insurance - identify products affected by sub-standard components right from the outset. Locate PCBs to be checked or modified - remedy the problem - reduce your costs - increase your customer satisfaction.
Simplify your component usage identification processes, product recall planning, or your component supplier quality monitoring. vManage's Traceability range efficiently identifies components used on each product produced on your production lines - saving you time, and money.
Product recalling
vManage's Traceability solutions remove the guesswork from component usage identification. Quickly identify the PCBs with sub-standard components that have been delivered by your component vendors, along with those yet to leave your premises - improving your customer satisfaction levels.
Sub-standard component suppliers
Keep informed of the quality of components you receive. Accurate component usage and supplier statistics provide you with the information you need to make quality improvement decisions. Linked with end product recall statistics, you can rationalize your component suppliers, resulting in increased quality.
Information at hand
Each vManage Traceability solution comes supplied with the flexible Report Generator application - providing meaningful reports via a flexible and easy to use interface.
Basic Trace
Basic Trace is vManage's basic level tracing application - providing tracing functionality for products produced within a user-defined time period or with a common lot number. vManage stores data relating to each PCB Panel, such as the feeders and component reels used, associated lot numbers, along with the operator responsible for their use in production.
Advanced Trace
The Advanced Trace application extends the functionality of vManage's base Traceability application with the ability to trace PCB Panels and associated PCB Boards/Blocks on which a component has been used. This is achieved through use of each PCB’s barcode being read and stored in the vManage database.
Exact Trace
vManage's premier tracing application - providing full tracing functionality to the most detailed level. Component usage is traced to the exact placement position on each PCB Block/Board, meaning that when multi-block PCB Panels are produced, only the PCB Blocks/Boards containing a defective component need to be recalled. Exact Trace is especially suited for SMD machines with backup-table
The Low Level Warning
The Low Level Warning module provides an overview of the feeders that are running low on components.
In this way, the operator increases uptime by preparing feeders before the machine stops.
Alerts before machine stop
The Low Level Warning module calculates the remaining number of PCBs that can be produced before the feeders run out of components. In the vManage operation screen, the operator can view the feeders that will next run out of components.
When a new program is used on the SMD machine, the calculation of the remaining PCBs begins, based on the new program.
Feeder information (text on bar)
The slot number of the specific feeder is identified on each bar. When a feeder contains components for less than 50 PCBs, the part number will be displayed immediately after the bar.
Number of PCBs left (length of bar)
The length of the bar indicates the number of PCBs that can be produced before a specific feeder (marked with a slot number) runs out of components.
Feeder preparation status (color codes)
The color codes of the bars indicate whether a feeder has been prepared for placement on the SMD machine (green) or not (yellow). The operator can easily see which feeders are ready to be placed on the machine and which demand further preparation.
If the component reels are marked with an ID (serial number) barcode, the remaining amount will be tracked, and the Low Level Warning will work even if the same reel has been used on different feeders and machines.
Dry Component Administration
The Dry Component Administration module alerts the operator before open time for a dry component expires. Moisture-sensitive devices can be prepared and used correctly to
improve quality and
production.
This option displays the remaining time a dry part can be used in production. The machine will stop if the open time has expired and the operator has to replace the component before the production can continue.
Dry Component Administration keeps track of the time dry components have been opened, of the time elapsed in dry storage, and the time elapsed in a drying oven. This is done by scanning the reel serial number every time the component enters/leaves a dry area or a drying oven.
Defining dry components
Parts defined as moisture-sensitive are registered and listed in the vManage system. The following parameters are defined per part number: open time, dry-out time and max. number of dry-outs.
If a part is defined as moisture-sensitive, then the remaining open time is automatically displayed to the operator when the part is used on the machine or placed in storage or in the oven.
Each reel has to be marked with an ID barcode, so that the reels can be traced throughout the factory. This can be done with the vManage Inspector module.
Documentation
The machine will be stopped every 5 minutes if the operator forgets to remove the component from the machine. Each event is logged in the vManage database as documentation.
Note that this option consists of three individual applications: the Dry Component Option for the main vManage application, one application for each oven, and one application for each dry storage.
Kitting Area Optimization
Kitting Area Optimization ensures that all the parts needed for the next production program are prepared beforehand. This reduces change-over time and costs.
Kitting Area Optimization is a tool for preparing the next production orders and to simplify feeder handling. When a machine and a program are chosen, the application will select feeders with the needed parts and identify their correct location.
Kitting Optimization is used to create feeder set-ups for SMD programs. This reduces the search time for feeders with parts needed in the set-up.
The selection of feeders for a set-up ensures feeder rotation to reduce the risk of reels being forgotten and becoming too old.
The feeder set-up can be prepared according to the vManage data:
Feeder/reel relationship
Feeder data
Program information
Feeder position
The feeder/reel relationship is saved in the database each time a feeder is kitted in the kitting station. This is a vital part of the feeder verification in vManage.
Program information is collected in different ways depending on the machine type concerned.
The feeder location is updated each time a feeder is read at the SMD machine, at a kitting station, or from the Kitting Area Optimization when a feeder is placed and scanned in the storage area. The position must also be scanned if a chaotic storage system is used.
Incoming Material Registration
Incoming Material Registration is a tool for labeling components and registering the data in the vManage database.
This option provides required information on components and improves quality and control.
Correct component labeling
Incoming Material Registration is used in the incoming area before the components enter the production area. All relevant data is registered for each component, and a new serial number can be printed to connect each reel with the stored data.
As all data is stored in the vManage database, operators only have to scan one barcode when the reel is used in the production area.
Ensures needed information
The system has an advanced configuration system that makes it possible to automatically detect the different labels and to specify which data needs to be registered for different component types. This reduces the amount of work and the risk of registering incorrect data.
Inspector makes it easy to register information such as: part number, quantity, manufacturer, supplier, lot-number.
A world wide patent application is being processed for this system.