Our Shopfloor Solutions
Transparent, Connected, Efficient

With Order Control, you always maintain full visibility of all ongoing production orders. “Live” planning allows orders to be flexibly scheduled, unscheduled, or rescheduled at any time. The progress of each order is captured in real time, enabling efficient planning and control of SMD areas as well as machines and manual workstations in final assembly.

The Material Locator provides complete, transparent management of all materials and transport assets across the entire shop floor. Operators always have a clear overview of the location, quantity, and status of all components—from parts and PCBs to consumables, as well as stencils, grippers, magazines, and KLT boxes. Thanks to unique identification (2D code/RFID), material movements can be precisely tracked and recorded automatically or via scanner. Intelligent filtering functions ensure that relevant information is quickly accessible, while storage prioritization enables optimal retrieval strategies.

The Carrier Manager coordinates the supply of the entire production environment with all required carriers—fully automated and always just in time. It manages all carriers across the shop floor, creates dynamic routes, and controls targeted transports via the Mobile Robot Manager to the Material Warehouse, Smart Buffers, production lines, and Dry Tower. This ensures that material flow remains efficient, reliable, and demand-driven at all times.

The workstation in the Setup Preparation Area supports the efficient and error-free preparation of setup processes. By selecting the relevant setups from current orders and performing automatic material availability checks, all required components are quickly identified. Sorted picking lists and the targeted distribution of materials to different delivery points ensure an optimally organized pre-setup process.

The Board Stack Manager enables efficient management of PCB batches throughout the entire production process. By assigning board batches to specific magazine slots, operators always maintain full visibility of the position, status, and sequence of PCB stacks to be processed. Operation is simple and reliable using a supported barcode scanner in combination with SynapticaOS Mobile software.

The Component Manager ensures fast, demand-driven, and optimized material replenishment at the production line. Various provisioning strategies—from PUSH and PULL/KANBAN to full order picking—provide maximum flexibility. Material flow is calculated proactively and executed either manually or fully automatically via AMRs, depending on the level of automation. This ensures that every component arrives at the line exactly when it is needed—without unnecessary intermediate storage and at minimal cost.

The MSL Manager monitors and documents the floor life (FLT) of moisture-sensitive components, ensuring maximum process reliability. Based on imported packaging data, the MSL level of each reel is known. By capturing start and stop times, the remaining FLT is calculated precisely and synchronized with connected systems such as Dry Tower or MES solutions. If the permitted FLT is exceeded, components are automatically blocked and marked for drying—ensuring a safe and compliant production process.

The MSL Manager Advanced extends standard MSL monitoring with intelligent automation capabilities. Based on precise sensor data from the DryTower, the system automatically calculates the required drying time and fully controls the movement of components between the normal storage area and the reset zone. After the drying process is completed, components are automatically returned—ensuring maximum process reliability with minimal manual intervention.

The Material Dashboard provides a clear, centralized overview of all material flow components. It visualizes the current status of systems such as the Component Manager, DryTower, AMRs, and M‑Stations, presenting all relevant real-time information in a compact format. Picking progress, active transport orders, and key statistical metrics are immediately visible—ensuring maximum transparency across the entire material management process.

The Task Manager revolutionizes the operation of production systems by effectively supporting your workforce. It reduces walking distances and helps prevent predictable line stoppages through early notifications. Remaining runtimes are automatically calculated by all machines and transmitted in real time—e.g., directly to operators’ smartwatches. The result: increased OEE and noticeable relief for employees.

The Smart Messenger is a versatile chat application that significantly simplifies communication between employees in production. By enabling fast message transmission to smartwatches and PCs, tasks can be distributed more efficiently and immediate support can be requested when needed. Walking distances are reduced, responsibilities are clearly defined, and all message histories are securely stored.

The Dash Cam feature enables operators to monitor critical machine processes in real time. Thanks to a freely positionable camera and configurable triggers, live video streams can be accessed on tablets or PCs. In the event of disruptions, recorded video footage helps quickly and accurately identify root causes.

Product Change supports planners and operators in the fast, reliable, and fully automated changeover of products across the entire production line. With a single click, all relevant parameters are transferred to every machine and centrally stored in a global database. This significantly reduces setup times and accelerates NPI (New Product Introduction) processes—enabling new products to be introduced into production faster, error-free, and consistently. Product Change integrates both ASYS Group machines and third-party systems, ensuring uniform and seamless product management.

The ASYS HERMES Assistant simplifies the use of the HERMES standard through centralized, offline-based program management. Thanks to integrated interfaces for HERMES machine communication, the tool enables fast and straightforward line changeovers without the need for complex individual programming of each machine. Third-party equipment can be integrated without additional licensing costs, while a central database ensures optimal transparency and control.

The ASYS Performance Monitor is the ideal analysis tool for monitoring the performance of your SMD line in real time. By automatically calculating and displaying OEE (Overall Equipment Effectiveness) based on performance, availability, and quality, you always have a comprehensive overview of your production—including bottlenecks and first-pass yield. This saves time and increases efficiency across the shop floor.

With Shopfloor Statistics, you gain a clear, data-driven view of all relevant performance indicators in your production. Machine data is automatically calculated according to standardized frameworks such as SEMI E10 or OEE, structured systematically, and presented visually. From standard KPIs and machine-specific analyses to custom reports, all information is transparently available—helping you optimize processes, reduce costs, and sustainably increase productivity.

Product Trace enables complete traceability of all materials used on a printed circuit board at a specific point in time. All traceability data is captured, stored, filtered, and clearly visualized—both at the order level and at the individual PCB level. Forward and backward traceability, along with integrated process interlocks, ensure maximum quality assurance. Supported hardware such as ASYS printers, SIPLACE, Fuji, or Panasonic integrates seamlessly into the process.

Process Trace captures and stores all relevant process data generated during the production of a printed circuit board. The applied process parameters are clearly displayed, enabling full traceability of manufacturing conditions. This creates maximum transparency—ideal for quality assurance, analysis, and traceability.