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FUJI Smart Factory

Preparation

Create accurate production programs in a short time using the automatic part shape data generator and a powerful optimization engine.
Then, use the scheduling function to achieve production without wasted time or materials.

Material preparation

Picking work is made more efficient through part location management. Because the part shelf life can also be managed, parts that may have deteriorated are not used by mistake.
Setup work can be performed without error by employing a system that provides guidance for loading positions in the offline changeover area.

Production

By connecting SMT processes through M2M communication, the machines work together so that the required actions are performed automatically. This connectivity also enables visualization of the entire production line.
Work that is performed manually such as part supply is made easier with guidance systems and automation units that enable error-free work processes.

Maintenance

To maintain quality production, it is necessary to keep the feeders, nozzles, and heads that are used in production and thus directly affect the outcome, in top condition.
This requires a method for automating maintenance work so that it can be performed at the same level by all operators. For this, our automated maintenance units that manage unit condition based on set values are highly effective. This is an important step in realizing a smart factory.

Performance management and analysis

Traceability data can be acquired from multiple conditions when errors occur. The cause and extent of the error's impact can be determined quickly through provision of data that includes information from external units such as the inspection image from SPI and AOI machines.
Production results that include the operation status are provided in an easy to read report.

System link

SMT processes are linked seamlessly to the user host system to deliver traceability data.

Factory improvements

Preventing defective pickup and placement

To keep the productivity high, factors that cause defects must be detected and eliminated through accurate recognition of the part state in a series of processes from pickup to placement.
The following introduces checks on part states for pickup and placement.

Placing parts with high accuracy

In addition to the advancement of smaller electronic parts and more complex electronic circuit designs, growing needs for finer pitch placement is making filletless soldering more popular. A small amount of solder is applied when performing fine pitch placement using very small sized chip parts, which makes it difficult to expect such parts to be applicable for self-alignment effects. Instead, producing accurate part placement to put parts in a definitive place is required.
The following introduces positioning techniques for achieving highly accurate placement.

Controlling placement load

To be able to maintain quality when placing electronic parts that are increasingly smaller, thinner, and lighter, it is necessary to have a high level of stopping accuracy as well as low load on the parts when placing them. Low impact placement is a prerequisite for controlling the load on parts and solder.
The following introduces mechanical features of our products to deliver low impact placement and also sensing technologies for placing parts at an appropriate height while securing stable tackiness with the panel in mind.

Excluding future defects attributed to parts

Highly accurate and functional placement machines do not always result in defect free production if the part to be placed is the source of the problem. To maintain high quality, it is very important to control production so that defective parts are not used, just as it is important to ensure good pickup and placement processes.
The following introduces applications to reliably detect defective parts and incorrect parts, and eliminate their usage.

Preventing drops in machine performance

Pickup errors and contact issues may occur in association with adherence of solder paste and dust from the panels and carrier tape. To avoid any loss of production from these factors, it is necessary to keep the feeders, nozzles, and heads that are directly related to picking up and placing parts in top condition. The following introduces functions and units to cover this objective.

Industry-based solutions

Automotive

Safety and reliability are extremely important for automotive products. In addition, there are a wide variety of models even for the same automobile type.

SiP and module parts

As electronics become smaller with greater functionality and along with demand driving shorter development times, there is an increased demand for package parts such as SiP and module parts. There are many different configurations of package parts that can be found in the market, but the common threads in the manufacturing process of these parts; multi-layering and thinner structures in the Z direction, and higher density in the XY direction, are being used in combination and continue to evolve. For these kinds of cutting-edge processes, Fuji is on hand to talk directly with factories to talk shop and provide an array of solutions.

Placement solutions for panels used in communication infrastructure

5G operations are now in full swing all around the world, and production of 5G base stations is proceeding at a rapid pace.
Stability and improvements in processing capability are sought from 5G base stations and servers so that large data loads can be processed without delay. The electronic panels and electronic parts used in data processing are becoming larger and heavier in order to support the high-speed processing of large volumes of data and higher performance, and the SMT process must be able to respond to these changes.
Here we will introduce placement solutions that are necessary for the production of 5G base station and server boards.

Mobile devices

Mobile devices are evolving to be smaller and more advanced. Along with the spread of mobile devices worldwide and the increase in their production volume, more efficient production of mobile devices is necessary.
Fuji is continuing to develop and provide machines, functions, and systems to satisfy customer needs in every aspect including quality, productivity, and advanced placement technology.

LED placement

LEDs, which are energy-saving, compact, and highly durable, have been widely used in various products. Along with that, LEDs with different sizes and shapes are now available to support various products. To handle such a diversified range of LEDs, we provide nozzles and functions to achieve accurate and efficient production.

Consumer electronics

In line with the spread of IoT, which has led to the evolution of household electronics, the control panels for household electronics have become complicated. On the other hand, relatively large parts related to power supply and leaded parts still need to be placed. Fuji mounters support a wide variety of parts, which is one of our advantages.

Medical devices

Quality is vital for medical devices. Product reliability is cultivated in our production processes. Fuji has equipment and systems to eliminate defects and their causes to support high quality production. It is possible to efficiently produce while maintaining high quality even when producing just the required quantities of many different types of products.

Proposals for specific issues

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Maintaining and improving quality

"We are wanting to improve quality, but are not seeing any results." "We have put measures in place, but productivity dropped." Is your production site facing any such quality-related problems? Fuji provides solutions for maintaining and improving quality without sacrificing productivity.