ASM Case Study Field test of ASM ProcessExpert at TQ-Systems in Seefeld (Gut Delling) New excitement about the process Lean production concepts, Industry 4.0 and smart factory ideas are backed by the fervent wish of all manufacturers to make their production more organic and efficient. New technologies make this possible. All that s missing is the will to try out new things. TQ-Systems develops and manufactures products at six German and two international locations for the manufacturing, aerospace and medical technology industries, to name just a few. The company has grown steadily for more than 23 years to 1,400 employees today. No wonder that the SMT factory at TQ-Systems headquarters in Gut Delling near Seefeld in Bavaria nearly never stands still. The four production lines run in two or even three shifts. Despite the tightly packed schedule, the employees take time to analyze and optimize their operation. In addition to running their regular business, they continuously work to improve their processes and introduce new technologies. One reason for this level of enthusiasm is a new expert at TQ-Systems. Although still being field-tested, the ASM ProcessExpert has already become firmly established, because it enables TQ- Systems to further improve its printing operations and the entire SMT production process. Superlatives are a thing of the past While the field test being conducted jointly by TQ-Systems and ASM Assembly Systems is unusual, it is also symptomatic of a current trend in the industry. The hype around ever faster machines processing ever smaller components has abated. High-quality, state-of-the-art equipment remains at the heart of modern electronics production, but the focus has shifted to more intelligent connectivity, shorter control loops and improved process control. This is made possible by networking, automation, predictive maintenance and big data Industry 4.0 buzzwords that everyone is talking about. TQ-Systems has realized that the SMT printing process is critical for making improvements along the line. You can always upgrade your SMT production by installing ever-faster placement machines. But to optimize the whole system, you must also advance all other processes along the production line. This means having a stable printing process and preventing any deviations from the process parameters automatically and proactively. Ever thinner stencils and the mix of ever smaller and large components don t make this any
easier. For a high-mix production like ours with big variations in lot sizes and frequent NPIs, having a stable printing process is a major prerequisite for the high level of quality we are known for. We had long noticed the lack of reasonable printing process support in the equipment market, summarizes Matthias Voigt, SMT production manager at TQ-Systems in Gut Delling. More than standard The way TQ-Systems decided to face this challenge was not typical. In late 2015, the company was considering the purchase of an inspection system when ASM Assembly Systems introduced the ASM ProcessExpert at the Productronica trade show in Munich. The idea to conduct a joint field test was therefore not far-fetched. Anja Heitmeir, TQ-Systems long-term account manager at ASM: We purposely picked TQ- Systems as a field test partner. The company's high level of technological expertise and the diversity of production jobs provided an ideal starting point. For TQ-Systems in turn, the ASM ProcessExpert was what they had been looking for: ASM's approach to not just analyze printing parameters but to collect the data, process it and suggest improvements with the option to eventually let the system control the printer on its own was exactly what we had imagined, says Voigt. The parties quickly came to terms. After all, they have worked together for years. Getting better by trying out new things The ASM ProcessExpert system arrived at TQ-Systems Gut Delling plant in early 2016. The first tests were conducted offline, because the ASM ProcessExpert had to eventually fit seamless into the company's highrunner line, on which roughly 20,000 PCB are produced each week in lot sizes ranging from 1 to several thousand. Any production stop was therefore unacceptable. After TQ s operators and ASM's technicians had become accustomed to the new SPI technology and the ASM ProcessExpert as a whole, the system was integrated into the line initially with the ASM ProcessLens, a highly accurate 5D inspection system. The efficiency improvements became noticeable very quickly. SMT production and process expert Benedikt Stark remembers a concrete example: On one of our products we had trouble with a particular solder point for years. Our AOI system was unable to recognize it properly because of excessive solder paste and issued false error messages, which an operator then had to skip manually. Trivial, but annoying and time-consuming. The ASM ProcessLens recognized precisely this problem right away and recommended a simple modification of our parameters and the stencil. By adjusting the printing process accordingly, we eliminated a trouble spot and saved on labor, almost half a full-time equivalent, because the system uses the data from our equipment more effectively. The ASM ProcessLens supports our production philosophy of repeatedly analyzing even established processes. We took a fresh look at everything and made improvements based on the data and recommendations available to us. The parameters are better now, the printing process is more stable, and the printing results are more repeatable.
First-pass yield, positioning accuracy, solder quantities we sense improvements in efficiency and quality everywhere. Next step: Smart integration The ASM ProcessLens turned out to be a complete success for TQ-Systems while it was still undergoing a long and intensive field test. The next step has already been taken. The ASM ProcessEngine, the powerful software that uses collected data to run advance simulations and make recommendations for printing materials and parameters, went into operation a short while ago. The result: improved transfer efficiency, which cuts down on solder paste waste. In addition, the ASM ProcessExpert issues recommendations for appropriate cleaning cycles. TQ-Systems expectations were high: In the beginning, we had people on the factory floor who were not convinced of the need for an SPI system. Today, the ASM solution provides valuable help when we encounter problems during the printing process. That s when people often ask What does the ASM ProcessExpert say about this? We expect the ASM ProcessExpert to be especially helpful when it comes to our frequent new product introductions, says Matthias Voigt. Technology leaders who learn from each other Another important success factor is the fruitful relationship between ASM and TQ-Systems during the field test. Benedikt Stark: We definitely feel that ASM truly welcomes our feedback and that we inspire each other to make the ASM ProcessExpert even better. For example, we recently found out through testing that the ASM ProcessExpert is also able to measure and analyze adhesive points. That was something we developed internally and conveyed to ASM's project manager as part of the field test. For ASM, being able to try out the ASM ProcessExpert in a real production environment is invaluable. No test scenario anywhere in the world could be more instructive. And the use of the ASM ProcessExpert is just one of many improvements being made in Gut Delling. SMT production manager Matthias Voigt describes it like this: Industry 4.0, automation and connectivity are natural paths to improved efficiency for us. This is something every electronics manufacturer strives for, no matter how large or small the company is. We recognize quite naturally what our production is capable of, and then we look for the right technology and process improvements that help us get there.
TQ-Systems TQ - your partner for the whole world of electronics The companies of the TQ-Group develop and manufacture in-house and customer products for the manufacturing, aerospace and medical technology industries, to name just a few, at six German and two international locations (Switzerland and China). For 23 years, the company and its 1,400 employees have focused on customer proximity, innovative technology, and top quality. TQ-Systems is among the top ten contract manufacturers in Germany with total sales of 214 million euros in fiscal 2015/2016. The company's employees account for a large part of its success, because they enable TQ-Systems to master all challenges with in-house expertise. Because of its success and steady growth, the TQ-Group is constantly looking for competent additions to its team.
For 23 years, the company and its 1,400 employees have focused on customer proximity, innovative technology, and top quality. The company field-tested the ASM ProcessExpert at its Gut Delling location. TQ-Group companies develop and manufacture in-house and customer products for the manufacturing, aerospace and medical technology industries, to name just a few.
SMT production and process expert Benedikt Start (center) and his colleagues are excited about the SMT process, while the ability to test the ASM ProcessExpert in a real production environment is invaluable for ASM. The ASM ProcessLens is a success for TQ-Systems: The parameters are better now, the printing process is more stable, and the printing results are more repeatable. First-pass yield, positioning accuracy, solder quantities we sense improvements in efficiency and quality everywhere.