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Home > Useful Information > Reducing line stop time due to changeover – Solutions for high-mix low-volume production

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Reducing line stop time due to changeover – Solutions for high-mix low-volume production

Have you ever had the following issues?

- The line often stops due to changeover or material exchange and the operation rate does not increase.
- Many short stops occur due to delays in supplying parts and in dealing with errors.
- Workloads remain high due to a shortage of personnel.

Fuji provides highly effective solutions to prevent drops in production efficiency and quality risks in high-mix low-volume production.

Major solutions for high-mix low-volume production are summarized in this document.
We hope you will check it out.

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Related information

NXTR A model

Fuji is paving the way to the future of Smart Factories with NXTR.

The accompanying Smart Loader frees operators from changeover and supply work, with additional features that strengthen the ability to maintain high-quality and productivity.

NXTR S model

NXTR offers a truly modular design for the optimal line configuration that caters to your production.
Real-time sensing placement, optimized placement actions, and part handling checks after placement are just a few examples. This high end model machine supports new functions that preserve a high level of QCD performance.

NXTR is the next stage toward the smart factory of the future.

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AIMEXR

This high end model machine supports the latest functions that support various production types flexibly on an advanced platform.

This machine is strong in flexible production such as NPI support for starting new production quickly and immediate support for production type change with batch changeover.
It inherits versatility which is a feature of the AIMEX series and features high productivity including high quality and mass production with new sensing functions.

NXTR PM

NXTR PM is a printer that embodies the NXTR concept of reducing line size, high area productivity, front operation, and ease of use.
It is built to support wide panel and frame sizes, and has the capability to print delicate solder patterns.
By creating optimum production schedules using the Fuji system, and linking with other machines in the line, it is possible to achieve stable production.
Various data is collected within the machine, which can then be used to maintain quality and the state of the machine.

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Useful Information

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.

Useful Information

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.

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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.

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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.

Useful Information

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.

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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.