Electronics Production Digitize Production Planning And Setup Processes to Save Time

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Digital planning tools can optimize setup processes in electronics production, ensure material availability and make production processes more efficient. A practical example from partners Lacon Electronic and Multi Components shows the possible effects.

In electronics production, the number of variants and deadline pressure are constantly increasing. At the same time, batch sizes are decreasing, while material availability and supply chains are becoming more complex. It is therefore becoming increasingly important for EMS companies to control setup processes, production planning and material flows transparently. A user example at Lacon Electronic shows how digital planning tools can achieve concrete efficiency gains. The latest version of the T-Solution software from component manufacturer Hanwha Semitech was used, which was implemented by German sales partner Multi Components.

Initial Situation: High Complexity in Production

As an electronics manufacturer with a wide range of customers, Lacon processes a large number of different assemblies and variants. Production planning therefore had to be regularly adapted to changing requirements. At the same time, set-up processes and material provision caused considerable organizational effort, as many processes only had limited digital support. The aim was to increase the transparency of production processes, reduce set-up times and be able to make planning decisions more quickly.

As part of the optimization process, the company introduced the T-Solution software solution for production planning and material control. Among other things, this enables digital and centralized management of component data, a synchronized material inventory overview and functions for line planning and setup optimization.

A central element is the integration of storage and placement systems. This allows material movements to be recorded automatically and planning processes to be supported in real time. At the same time, the software facilitates the preparation of production orders and reduces manual coordination processes.

Improvements in Set-Up Time And Planning

After the introduction, a measurable effect was seen particularly in setup planning. According to the company, the time required in this area was reduced by around 10 to 20 percent. "In addition, initial samples can be loaded and decisions for the start of production are also made more quickly," they say. At the same time, transparency regarding material availability and production status has improved, enabling more stable scheduling. Changes at short notice can also be implemented more quickly, as the relevant information is available centrally.

The newly introduced functions of the current software version of T-Solution address central challenges of electronics production, primarily the optimization of line utilization and ensuring material availability in production environments with many variants.

Line balancing

• Algorithm-supported distribution of production orders to SMT lines and individual systems, taking into account capacities, setup statuses and availabilities
• Dynamic optimization of line capacity utilization to avoid bottlenecks and waiting times
• Improved synchronization of production processes across multiple machines
• Reduction of idle times and increase in overall equipment effectiveness (OEE)
• More stable material and production flow thanks to continuous plant utilization

Live inventory and material transparency

• Real-time inventory of all components across storage towers, component counters, placement machines and feeders
• Automated synchronization of material data along the entire SMT process chain
• Permanent transparency regarding material availability and consumption statuses
• Early identification of critical component stocks before production release
• Avoidance of line stops through proactive material planning and preparatory measures

Significance for EMS Companies

Digital planning systems can make a significant contribution to increasing efficiency, especially for EMS manufacturers with a large number of variants. In addition to reducing set-up times, factors such as material transparency, line utilization and planning flexibility also play an important role. With the increasing complexity of electronics production, integrated software solutions are therefore becoming increasingly important in order to ensure efficient production processes. (sb)

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