Current situation of material management in traditional SMT industry
Personnel: Traditional SMT industry requires a large number of personnel to carry out warehousing and logistics operations such as receiving, shelving, sorting, distribution and stocktaking of materials. There are problems such as difficult to find materials, easy to make mistakes, high strength, low efficiency, untimely update of inventory quantity, inconsistent accounting and so on.
Machine: The material storage is based on ordinary shelves, the space utilization rate is insufficient, and the storage environment cannot be effectively controlled. Materials with high temperature and humidity requirements are stored in drying cabinets. Material handling is based on wheelbarrow, and the logistics process is not traceable.
Materials: electronic manufacturing enterprises of raw materials, finished product models and specifications are numerous, order changes frequently, complete management complex, strict production process requirements, easy to produce dull materials, material management is difficult.
Method: The warehousing and logistics operation is mainly manual, the material preparation information of the work order is transmitted through paper documents, and the status, completion and target achievement of the operation process lack timely control, which can not effectively prevent the error and stay, and the traceability of the whole process is poor.
Environment: The electronics industry has high requirements on the storage environment, which requires strict standards of anti-static, moisture-proof and safety.
- Traditional SMT industry material management
The importance of intelligent SMT warehouse logistics
1. Reduce logistics costs and improve logistics efficiency
Logistics as the "third profit source", its intelligentization will effectively reduce logistics costs, improve logistics efficiency, increase profit sources. The construction of three-dimensional warehouse improves the utilization rate of space and reduces the floor area. Intelligent warehousing and logistics system combines hardware and software, liberates labor force with intelligent warehouse, robot, AGV and other equipment, carries out automatic data collection for each operation link, prevents stay and mistakes, manages the whole logistics process in a unified way, improves working efficiency, ensures working accuracy and traceability, and realizes efficient operation.
2. Data linkage helps enterprises manage efficiently
The intelligent storage system realizes the collection, processing and analysis of the information of various logistics links, and interacts with ERP, MES and other systems to break the information island and realize the sharing and connectivity of data. Warehousing and logistics information can be updated to each decision-making level in real time, providing data basis for enterprise market decision-making and production plan, and data support for business process improvement, organizational structure optimization and refined operation.
3. An important part of industrial upgrading
Chinese manufacturing industry is in the critical period of industrial upgrading. In the era of Industry 4.0, the flexible production characterized by customization, variety, small batch and multiple batches will replace the traditional large-scale production mode of a single product, which puts forward more refined, more timely and more flexible requirements for logistics. Only by making all "things" in the production process intelligently linked and keeping up with the rhythm of production, can the customized needs be met efficiently. Therefore, intelligent logistics is an important part of intelligent manufacturing upgrade.
SMT intelligent warehousing logistics solutions
With the progress of technology, the performance of logistics equipment such as storage equipment, loading and unloading equipment and packaging equipment has been enhanced day by day. For SMT material management, a variety of special equipment has been developed, such as intelligent warehouse, solder paste refrigeration and reheating equipment, X-Ray charging machine, etc. Based on these intelligent production logistics technology and equipment, SMT intelligent warehousing and logistics solution can provide the intelligent management of the whole material and the whole process of material logistics, from the large warehouse, the side warehouse to the production line, from raw materials, tooling, solder paste to semi-finished products and finished products, from receiving, warehousing, warehousing, sorting and distribution turnover. Through the integration of intelligent storage system with ERP, MES and other systems, the work order materials can be accurately distributed according to station information, and the automatic and intelligent integrated warehousing and logistics management can be realized.
- electronic workshop intelligent warehousing logistics solutions
1. Intelligent storage system
1) SMT Intelligent warehouse Intelligent warehouse is the core equipment of workshop warehousing logistics solutions. The material box type intelligent warehouse is a general automatic storage equipment, which can be used to store large size coil material, Tray tray material, tube material, unpacked humidity sensitive components and other raw materials, semi-finished products, finished products, etc. SMT tray intelligent warehouse is dedicated to SMT tray storage and management of automatic equipment, mainly composed of three-dimensional shelves, warehouse handling system and client management system. Closed, three-dimensional shelf storage, theft prevention and loss prevention, internal temperature and humidity monitoring, electrostatic elimination processing, optional constant temperature and humidity, nitrogen filling module to realize the control of storage environment. Automatic code scanning, shelving, real-time inventory, out of the warehouse according to the defined priority (half plate material, expiration date, warehousing time and other standards) in response to the needs of the work order automatically out of the warehouse complete set, automatic labeling machine can also be optional to realize automatic Posting of station information. When returning to the storage, the data of the tail plate can be automatically updated according to the data of the X-ray spotter or the patch machine.
2) Intelligent shelf is a more economical storage scheme for super size Tray material, tray tray material, tube material, unpacked humidity sensitive components and other materials and steel mesh and other tools. The intelligent lighting system is installed on the shelf and storage space, which can provide accurate and rapid instructions for the picking personnel through the system control of lighting, effectively improve the working efficiency and reduce the error rate.
3) SMT point feeder X-Ray point feeder is used to fully count the remaining materials of SMT production line, and connect with the WMS system to update the product quantity information associated with the unique identification code of the returned materials. The fastest point feeder takes 10 seconds, the point accuracy is above 99.9%, and four 7-inch plates can be counted at the same time.
4) Intelligent solder paste management equipment Intelligent solder paste management equipment realizes the integrated management of cold storage, intelligent temperature return, intelligent stirring, self-service collection of solder paste, the whole process of automation, supports the online reservation return and warm return timeout alarm function. All data can be queried in real time and transparently. With bar code control, it can effectively eliminate abnormal control of solder paste return temperature time caused by personnel or equipment.
2. Intelligent logistics system
1) Robot
Intelligent robot and intelligent warehouse linkage, to realize the automatic taking and placing of materials in and out of the warehouse, and according to the production plan sort into the turnover vehicle, to achieve the selection of unmanned, in the logistics link to further reduce staff efficiency.
2) AGV car
Agvs, as flexible logistics equipment, are the first choice for workshop logistics automation. The automatic distribution of electronic materials generally uses the roller type or fork type AGVs. AGV is directly connected with the intelligent warehouse and the production line docking station to complete automatic distribution according to the system instructions, realizing the intelligent and unmanned logistics transportation of components, PCB material frame, semi-finished products and finished products, such as on-line, turnover and warehousing.
3) Air intelligent logistics car
Many logistics channels in electronic workshop are narrow. Intelligent logistics car in the air is a lightweight material handling scheme to replace AGV on the ground. Intelligent logistics car in the air is a monorail automatic transport system walking under the roof. The track is hung below the main beam of the building, which effectively uses the upper space of the building, so as to give more ground space to production facilities, and other logistics equipment. The system mainly consists of carriage, track system, spreader, docking platform, dispatching system and so on.
3. Intelligent warehouse management system
1) The intelligent warehouse management system combines automatic identification technology to carry out intelligent management of warehousing links such as receiving, warehousing, warehousing, collection and inventory, so as to realize detailed management and control of material tracking, warehousing, cargo flow, inventory counting and warehousing distribution, and integrate with ERP, MES and other systems. Realize automatic data upload, electronic work order, intelligent access material, tail material destocking, material shortage warning and other functions.
2) Establish a standard warehouse management system to strictly control all aspects of the warehouse business.
3) The whole process of barcoding operation, automatic data collection instead of manual operation, improve efficiency, improve the timeliness and accuracy of data.
4) Establish a visual warehouse management system to collect and monitor the execution data, sorting progress, inventory, containers, abnormal conditions and other information in the warehousing process in real time.
5) From raw materials and semi-finished products to finished products, realize the whole life cycle management of materials and material traceability in the production process.
6) Establish a timely, accurate and scientific statement system to provide accurate data support for management decisions.
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