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PULSE PRO

Material

Automate, Control, Trace all Material Flows & Types

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.

Overview of quantities and states of all materials in the entire shop floor

Autonomous magazine control and material replenishment for components and printed circuit boards

Monitoring the floor life time of moisture-sensitive components

Integration and connection of all modules for autonomous transport


Material – Functions


Material Locator

The „Material Locator“ function 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.

The information is detailed so that an operator can view the contents of a magazine down to slot level. A large number of additional filters enable a detailed view of the material stock. For example, only the stock of one storage facility (Drying Cabinet, Dry Tower or Material Warehouse) can be displayed.

Based on the information of the Material Locator and the order planning, different specialized material managers are offered.

  • Management of components (reels, trays) and printed circuit boards
  • Component management based on Unique ID
  • PCB management based on articles
  • Management of paste/ consumables/ stencil
  • Recording of storage/removal and remaining reel stock
  • Support of pre-fitting area
  • Magazine management on UID basis (2D/RFID)

Overview of quantities and states of all materials on the entire shop floor

Management and recording of all material flows and quantity changes

Hierarchical management of all storage types

Carrier Manager

With the „Carrier Manager“ the entire magazine flow is controlled. This offers the possibility of a completely autonomous magazine control for the production. 

Mobile Robot Manager

The „Mobile Robot Manager“ function receives and configures the travel orders from a superordinate system. 

Fleet Manager OMRON

The „Fleet Manager OMRON“ organizes and distributes the tasks of the AMR‘s taking into account the state of charge and current location. 

  • Moves empty / full magazines to the beginning of the line
  • Picks up empty / full magazines from the end of the line
  • Control based on work plan and order planning
  • Connection of M-Station and OMRON AMRs
  • Transfer of travel orders from a superordinate system
  • Configuration of static travel orders (routes)
  • Currently OMRON Fleetmanager connected
  • Planning of transport flows for optimized loading and unloading
  • Allocation of workstations, management of „skills“ and delegation of tasks to a suitably equipped AMR
  • Transmission of updates for the entire fleet

Autonomous magazine control

Integration and connection of all modules for autonomous transport

Optimal coordination of OMRON AIV fleets

Component Manager

With the „Component Manager“, the material flow of the components is calculated in advance and controlled either manually and/or with AMRs, 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.

Autonomous material replenishment for components

Operator support for manual material replenishment

  • Different outsourcing concepts
  • Demand-oriented replenishment (PUSH)
  • Pick up for complete order
  • Support PULL concept
  • Create picking list (automatic, manual)
  • Operator guided (picking list) and/or fully automatic material supply (AIV)
  • Checking the material availability

Advanced Component Manager

With the „Advanced Component Manager“ the material flow is controlled in two stages between hierarchically arranged warehouse structures. The material remains in the main warehouse until it is needed. The flexibility within the production is maintained.

1. Stage
Central warehouse to production warehouse (e.g. Dry Tower, Material Warehouse) 

2. Stage
Production warehouse to the line

Multi-level material replenishment

MSL Manager

The „MSL Manager“ displays the MSL start/stop times and manages and monitors the floor life time of moisture-sensitive components.

  • Recording of MSL start/stop times
  • Administration in the DryTower 
  • Administration in a centralized system (e.g. iTAC) 
  • Management via different storage locations/drying cabinets/ovens 
  • Locking of parts

Monitoring the floor life time of moisture-sensitive components

Administration on different levels


PULSE PRO

Software-Modules

The PULSE PRO Smart Factory Manager consists of six modules, which contain various smart functions. These can refer to single machines, a whole line or the complete factory.

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