More Transparency and Effciency on the Shop Floor
We are your competent partner when it comes to your smart factory. We cover more than two thirds of the equipment of an SMT production line with our broad product range. In addition, we offer customized and turnkey material logistics solutions for different levels of automation. We offer the largest product portfolio and the most experience on the market when it comes to the automation of material logistics in SMT production. Here we bundle the know-how and experience of ASYS automation systems, as well as our subsidiaries like Totech and motives.
We follow a comprehensive approach. In the first consulting meetings, we look at any process linkages in the factory to be able to design them in a coordinated and autonomous manner. Individual, scalable concepts form the agenda. Thanks to a modular approach, we are able to implement material logistics solutions in various degrees of automation. In this way, existing factories with their prevailing conditions are adapted step by step to the specific requirements of our customers.
The Highlights of the Overall Solution
The Smart Factory consists of the five central processes - material inbound, storage, line setting, line support and transport. For this purpose ASYS offers complete solutions in the field of MATERIAL LOGISTICS, starting with incoming goods, through individual production processes up to outgoing goods, which cover the different requirements on the shop floor.
MATERIAL LOGISTICS Product Areas
Discover our unique products in the fields of Transport, Storage, Material Inbound and Software.
Material Flows in the Smart Factory
In order to ensure automated transport, standardized and automatically manageable containers are necessary. We offer equipment and solution concepts for different materials from component reels, magazines, printed circuit boards, consumables, KLT boxes, trays, waste containers and more.
Space Saving
Eliminate the many local storage locations in your production and create central storage locations for component rolls, KLT boxes and magazines that can be automatically approached. The Dry Tower and Material Warehouse use the maximum hall heights for storage and can be easily expanded thanks to their modular design. In the S10 select, consumables such as solder paste or glues can be stored in conformity with the product and close to production.
Keeping an Eye on the Material
We support different solutions, which enable you to keep an eye on your material stock. The automatic counting of component rolls, the allocation of labels with a unique ID, the reading and evaluation of RFID tags and, last but not least, smart software for material monitoring, management and calculation of requirements.
PULSE PRO - Material Software Solutions
The quantities and states of all materials on the entire shop floor are clearly documented in the PULSE PRO module „Material“. All component reels, trays and PCBs are managed on the basis of Unique ID (UID) and the replenishment of material is controlled autonomously, which reduces the operator‘s workload. Furthermore, the floor life time of moisture-sensitive components is monitored. Based on the order planning, full or empty magazines are autonomously controlled within the entire shop floor between lines and storage locations. Therefore all modules are integrated and connected for autonomous transport.
Component Manager
With the „Component Manager“, the material flow of the components is calculated in advance and controlled either manually and/or with AIVs, depending on the degree of automation of the production. In this way, the material is brought to the line in real time according to demand and the high storage costs caused by intermediate storage on the line are eliminated.
Material Locator
The „Material Locator“ app ensures that all material movements and quantity/condition changes are recorded in real time and can be called up directly. Necessary for this material tracking is the unique ID on all materials, such as component reels, PCBs or magazines. The simple, always up-to-date overview in the Material Locator sustainably relieves the operator and helps to reduce downtime.
Use cases
The broad product portfolio of the ASYS Group offers solutions for a wide variety of applications and use cases. From the connection of inbound goods to multi-level storage concepts, line supply with PCB magazines or the separation of frontend and backend by using flexible storage systems.
The materials are delivered in a bag, usually padded in cardboard boxes. The packaging is removed and the material (e.g. component reels) is fed into the booking process. This can be done directly at this cell, or alternatively stacked in a component reel container and transported to this cell by automated guided vehicle, an AIV. This is useful if the unpacking station is physically distant from the cell, e.g. between logistics and the shop floor.
The scan and label cell is the central element in material inbound. With this system, component reels in particular are received fully automatically without manual intervention, booked in the higher-level system and then labeled with a unique ID. Due to the modularity of this system, we have the possibility to integrate different material inbound systems.
A component counting station is a recommended extension. Here, the number of individual components on a component reel is checked and the stock in the database is corrected if necessary. This applies to new component reels, but also to partially used reels that come back from the line and are stored again. With our open interfaces we are able to integrate different partners in the field of component counting into our solutions.
During running production, e.g. the SMD lines, must always be replenished with material. As soon as the fill levels of the placement machines drop below the set limit values, the corresponding component reels must be replenished. The demand is registered with the controlling software PULSEP RO via our standardized interface, also of the partner systems, such as the pick-and-place machines of various manufacturers.
Filling takes place in the reel magazine loader by feeding the individual component reels coming from the DryTower via a cross pusher from the reel section of the line and, depending on the configuration of the reel magazine, placing them into this. In this case, up to two magazines can be placed on the line in parallel.
The material can be picked up manually or via autonomous transport systems, the ASYS AMRs, and transported to the M-station directly on the line. Thanks to different platforms, these can realize any material transport as required. An important task here is to deliver the material to the line „just-in-time“. The goal is to reduce line stops to a minimum and maximize process efficiency.
After the delivery of the magazine to the station at the placer, the RFID tag on the magazine is read again and the magazine is uniquely identified. Now, the reel which has to be replaced is uniquely identified via the booking process, i.e. scanning at the placer, and is queried at PULSE PRO. This identifies the exact position of the new reel in the reel magazine and visually signals the operator clearly the position of the correct reel. With random access to each reel, the operator has direct access to that reel and can replace it just-in-time with no search or travel time. In turn, the empty reel can be placed in the reel magazine. This eliminates reel waste on the line and means that the reel magazine, which ends up filled with empty component reels, can be cleaned out at a „dump“ location.
