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Packetized Offline Changeover

This is a changeover operation for the NXTR A model, a pick and place machine equipped with an automatic feeder exchange system. The key point for packetized offline changeover is "optimal role separation between robots, systems, and people". Both improved productivity and labor savings can be achieved without difficulty by having robots and systems take on work that are prone to human error or take a long time to do in the series of preparation work from offline changeover to changeover.

Solutions to dilemmas arising from solving challenges in the printing process

The annual amount of data generated by the world's IoT devices is increasing every year. In recent years, the increase pace has been accelerating, driven by the rapid spread of generative AI. The power consumption required for data storage is thus projected to reach approximately 15% of the world's total power generation by 2030.

Minimize Changeover Time and Increase Productivity for High-mix Production with Multi Job Line Balancer

This tool groups together programs with a high degree of commonality to create feeder setups, and automatically adjusts the production order to ensure the fewest changeovers possible. It can be used for both when changing out feeders individually, and when performing batch changeover using a feeder cart.

Nexim part management solutions for efficient setup for production

Nexim part management solutions are used to track the movement of parts by scanning the ID codes that are affixed to parts and units. The Integrated Production System - Nexim collects, organizes, and updates scan data in real time, creating a state in which information is matched up with its physical counterpart, helping to ensure that there is no waste, unevenness, or needless work while preparing for production.

Check Parts After Placement Directly Inside the Placement Machine! Introducing the MPI Function

It is possible to check for missing and deviated parts on the panel by using the mark camera in the pick and place machine being used in production.

The ideal solution for high-speed placement of chip parts and LEDs – NXTR S model high-speed placement package

By combining the newly developed 2RV module with RH28 heads, W08t feeders, and MFU-63 feeder carts, the NXTR delivers a top-in-class throughput of 120,000 cph. This is a 39% improvement when compared with the NXT III. It is highly effective for part placement on panels such as for mobile devices and notebook computers that have many small parts and LEDs. 2RV modules can be loaded on the same base as 2R modules or 1R modules, enabling production line configurations that can cater to a wide range of panel types.

Never overlook line errors ever again!
FSF Mobile Conductor

FSF Mobile Conductor is a support tool for operators, that lets them know when an error or warning has occurred at a machine within the SMT line by sending a notification to their mobile devices, so that they can respond quickly.

Automatic nozzle quality management for improving OEE

We introduce various management functions that utilize individual nozzle ID management technology, focusing on reducing equipment-related losses (availability losses, performance losses, and quality losses) that lower OEE.

Road to automating insertion processes – Key points to success and Fuji solutions –

We aim to provide companies that are looking to introduce automatic insertion machines and individuals who would like to know more about the automation of manual insertion processes with information concerning the latest robotics and current trends for insertion machines. We also provide check points from the point of view of a robotics manufacturer that should be covered when looking to select the right automatic insertion equipment.

Learn fast, act quickly – Factory improvement solution, IPQC Expert

We introduce one of our productivity improvement solutions, IPQC Expert, which collects data from pick and place machine (chip mounter) production data, analyzes change points, and issues optimum guidance to respond to events that occurred.

Starting small in automating insertion processes using SCARA robots Panel Assembly Robot Cell – SmartWing BA

SmartWing BA is part of the Fuji SmartWing series of small articulated robots that make it possible to automate various processes in a factory. SmartWing BA is a Robot Cell package solution that includes the functions required for panel assembly processes.

Preventing incorrect parts from being placed – LCR check

This is used to check whether the correct parts are set by measuring the LCR value of the first part in specified reels that have been newly set or replaced, or reels for which parts have been replenished by replacing the feeders or splicing tape.

New model ramp-up time reduced by 57% Printing support system

Ramping up a new model involves a time-consuming process of determining the right printing conditions to use, which largely depends on individual operator skills. Furthermore, the fact that the result cannot be known until actual printing makes it even more difficult. Even after trial production with the right printing conditions is successfully performed and it comes time to go into full production, the printing conditions may need to be fine-tuned if the first pass yield at the SPI is poor and the quality is not stable, resulting in additional time spent. Fuji has a solution to this challenge with its printing support system, making it more efficient to set printing conditions, which currently depends on operator skills. With the printing support system, recommend parameters based on the accumulated data and quality data calculated from the first pass yield are presented, simply by entering printing conditions. In addition, inspection results are automatically accumulated through SPI linkage. The more that gets registered to the system, the more it will evolve into a database that matches your needs, and more practical printing conditions can be provided. Through this, printing conditions (parameters) can be determined while comparing quality data and cycle times, without relying on the operator's intuition. When performed under conditions at Fuji, this system reduced the startup time by 57%.

Solutions for issues in high density placement – Introducing the placement height adjustment function

The annual amount of data generated by the world's IoT devices is increasing every year, and the accompanying electricity consumption for data storage is expected to reach about 15% of the world's total electricity generation by 2030. Meanwhile, energy saving is an important issue for achieving SDGs and carbon neutrality and there is demand for smaller and higher-density panels that are used in all electronic devices, from mobile devices to automotive electronics, communication infrastructure, and servers. To achieve this, stable placement quality must be maintained in production using panels designed for space saving and economical wiring. This article introduces the placement height adjustment function, one of the solutions available for resolving issues in high density placement.

Reduce the time operators are tied up in changeover work to zero – NXTR PM Smart Changer

The process of changing product models from the current production to the next production involves a number of manual processes such as solder collection, mask replacement, and replacement of panel backup blocks and backup pins. It takes a lot of time and effort on the part of operators to perform these tasks. Fuji has already employed automation at its machines in the form of non-stop solder and cleaning paper supply during production, and automatically changing conveyor widths and backup pins. In addition to these, NXTR PM also allows for automatic exchange of screen masks using the PM Smart Changer, making it possible to reduce the time operators are tied up in changeover work to zero. All operators need to do is have the masks and backup blocks needed for next production ready in the Smart Changer rack, which they can do at a time of their own choosing, and load the Smart Changer rack into the NXTR PM. When a command to change product models is issued from the upper system, solder collection, mask exchange, backup block and backup pin change, conveyor width change, and solder supply are all performed automatically.

Large part placement solutions

The handling of large parts such as the high-functionality devices and connectors, the challenges posed in placing these in the SMT process, and Fuji's solutions to these issues.

Placement Technology Trends for 2021 and Latest SMT Solutions

We will cover the placement technology trends for 2021 and then introduce our efforts for digital twin solutions.

Easily create reliable vision processing data in a short time – Auto Shape Generator

When creating production programs on placement machines, approximately 80% of the work is related to creating vision processing data. Creating data for package parts with multiple leads and bumps is a very difficult and time-consuming task. If vision processing data is not properly set, it can cause losses such as misalignment and machine stoppage due to part recognition errors, so this work is extremely important for ensuring quality. However, the volume of new programs is on the rise as the number of products to be produced increases due to the diversification of market needs. In addition, in order to shorten the lead time to ramping up production there is a need to reduce the time required to create programs, and the workload is becoming heavier and heavier. We are pleased to introduce Auto Shape Generator, an application that solves the problems associated with creating such vision processing data.

Automate Nozzle Cleaning, Inspection, and Setting – Smart Nozzle Cleaner

We are introducing Smart Nozzle Cleaner as a tool that allows operators to be free from such maintenance work and time while effectively using the required quantity of nozzles in a timely manner.

Smart Setup Station makes changeover work quick and easy

As market needs diversify, mass customization that achieves QCD at the same level as mass production is being required of manufacturing sites. However, in the field of high-mix production in which products are frequently changed, decreases in production efficiency caused by increases in changeover frequency is a major issue. At many production sites the feeder setup work is being moved offline in order to shorten the setup changeover time, and a batch changeover method using feeder exchange units has become popular. However, offline changeover work is very detailed and time-consuming, as it involves a lot of work from checking out parts to setting up feeders, as well as having to perform all the required checks. In addition, this is a process that is difficult to run based on a schedule because it is highly dependent on people which means that work times vary depending on the skills of the workers.

Placement Solutions for Packages Including SiP and Other Module Parts

Fuji provides an array of solutions for manufacturing SiP and other module parts. We will be looking at solutions for higher density placements and thinner structures using Fuji functions and units.

Using Top View Recognition to Prevent Part Setting Mistakes

There are times when an operator may set the wrong part type or set parts in the incorrect supply direction when supplying parts to the machine. For example, when setting trays to a tray drawer there can be cases in which the incorrect parts are set or the supply direction may be wrong such as when a tray is set in the wrong direction or if someone has returned parts that have come out back into the tray by hand.

Smarter Factories with Digital Twin

Automation and digitization to attain digital twin with a focus on enabling production in which there is no difference (zero gaps) between the "virtual" and the "real".

Improving Placement Quality on Flexible Printed Circuits | Introducing Target On Paste (TOP) Placement

Fuji’s target on paste (TOP) placement solution that utilizes the effects of self-alignment, and is effective for preventing defective placements on FPC caused by the aforementioned positioning deviations.

Place interposers at high-speed with a high-powered vaccum – H01V head

To achieve four times the part retention power in comparison to the previously often-used H01 head. By using this head together with a dedicated design nozzle, interposers can be placed at high speed.

Tray Supply Tips to Improve Production Efficiency

Resupplying and performing changeover for tray parts is prone to high error rates, and reducing work time can be hard, but by selecting the operation method that works best for your factory's needs it is possible to reduce production stop time and prevent short stops and defects that are caused by setting mistakes.

sFAB-D Tool Kit for Flexible Handling of New Parts

Tool kits are formulated to include claws and locators that are most used based on past shipments, to be able to flexibly respond to part additions and changes.

Introducing the new Laser-type Lead Check Unit

High cost performance and focuses on checking leaded parts that are easily warped by external influences such as SOPs, QFPs, and connectors.

Maintaining High Quality amid Changes in SMT for Increasingly Complex Electronic Panels

This article will cover three areas that are important to improving quality in SMT processes and maintaining a high level of QCD, "Sure-fire pickup and placement", "Eliminating defective materials", and "Proper maintenance" with supporting data.

Solutions for handling large parts using sFAB-D

There are many cases of automotive boards such as ECUs having large connectors that exceed 100 mm in length. We suspect that the usage of such parts is going to increase in future. However, the packaging for such parts is very large and it was required to place these parts in a smaller tray to use them with conventional supply units. In addition, there was the issue in which the part supply cycles would increase because the quantity of parts supplied per tray was small.

Supporting automatic supply of parts from a cut length of tape

Fuji has developed part supply solutions using feeders and tray feeders for automating part supply using shorter tape.

Supply tray parts directly inside the machine -Inner tray stage-

Up until now Fuji has developed and delivered many different tray part supply units that meet various needs, such as the tray unit-LT, and the stacked tray feeder.

Part placement and glue application using one head

Fuji’s Revolutionary Dynamic head – DynaHead (DX) has become even more powerful with the glue tool newly added to its lineup of freely exchangeable tools.

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