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首页> 外文会议>SMTA international conference >REDUCING LABOR CONTENT AS A STRATEGY TO IMPROVE COMPETITIVENESS - AN ANALYSIS THAT ADDRESSES THE VALUE OF DESIGNING FOR AUTOMATION AND AN EMPIRICAL ANALYSIS THAT EXPLOITS THE AUTOMATION USING META PROCESS CONTROL
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REDUCING LABOR CONTENT AS A STRATEGY TO IMPROVE COMPETITIVENESS - AN ANALYSIS THAT ADDRESSES THE VALUE OF DESIGNING FOR AUTOMATION AND AN EMPIRICAL ANALYSIS THAT EXPLOITS THE AUTOMATION USING META PROCESS CONTROL

机译：降低劳动力含量作为提高竞争力的策略-一种分析，说明自动化设计的价值，以及一项通过元过程控制来探索自动化的实证分析

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Reducing the labor CONTENT of an electronic product assembly has been shown to be an effective strategy to reduce labor cost. In many cases it permits production operations in high labor rate markets to successfully compete with operations that have available sources of local low cost labor. There have been a number of papers written to support and justify this strategy. Automating assembly processes that are traditionally manual is the basis of a tactical plan that potentially allows the strategic objective of reducing labor content to be met. The word potentially is used with purpose. Investing in hundreds of thousands of dollars of leading-edge automation equipment does not an automated factory necessarily make. If the automated processes require constant human monitoring and intervention, or electrical test yields are low and rework labor high, the objective of the automation (and the capital investment) is defeated - we say instead of automating, we faux automate. The objectives of this paper are to: 1. Provide examples of real world automation opportunities for future conversion from high to low labor content and, 2. Address the key elements that are needed to exploit this automation - not simply faux automate. Specifically: a. Designing a product for automated assembly. b. A factory infrastructure that has proactive process control built in and, ideally, automated proactive process control that self-corrects process issues, i.e., Meta Process Control. c. A skilled workforce that can develop and maintain the automated processes organized in a way to minimize cost. To achieve these objectives the work that this paper documents was divided into two distinct parts: 1. A case study undertaken to identify and analyze two opportunities that can use automation to reduce the labor cost of a product, i.e., reduce the labor content by converting to or initially designing for assembly automation. 2. An initial experiment that establishes the process window associated with printing solder paste for extremely small components (01005 English / 0402 Metric), i.e., establish the need to proactively monitor process parameters and ideally to auto-correct, i.e., Meta Process Control (MPC), to fully exploit the value of automating for a process with an extremely small process window. The results verify that: 1. Designing for automation can be an effective tool in eliminating the competitive advantage that low labor rate operations provide. In the opportunities identified, the total labor cost of a product assembled in a high labor rate region can be dramatically reduced by automating labor intensive hand soldering operations. Further, if the product is initially designed by combining the added automation with existing process assembly automation equipment, payback on investment will be accelerated. The paper predicts that based on a real world production model, automating two labor intensive assembly processes would result in a reduced labor cost of about 45% with a return on capital investment of about 14 months for the one process (11 months if a product redesign is not required). The coax soldering ROI is TBD. The results of actually automating these opportunities will be documented in a future paper. 2. Achieving low yield loss from any automated process involved in the assembly of the product (including electrical test false positives) is essential. The experiment that was designed used a component with a narrow process window to demonstrate the futility and increased cost in automating without an accompanying capable and controllable process. Further, simply identifying a process that has violated its process window is not enough. This has traditionally been the case with failures found at In-circuit test (ICT). By this time, there are typically many circuit boards that require expensive troubleshooting, rework and retest in a high labor rate environment. The experiment demonstrated that true test yields above 95% are required to take full advantage of the automation. In addition, to ensure these yields it is required that automated, proactive, real-time process control, e.g., Meta Process Control or MPC, must be integrated into a production operation's infrastructure. Automatically placing 01005 components on the actual printed solder paste and not placed based on component pad board coordinates is used to demonstrate this requirement.
机译：减少电子产品组件的人工含量已被证明是降低人工成本的有效策略。在许多情况下，它允许高劳动力价格市场上的生产运营与具有本地低成本劳动力来源的运营成功竞争。有许多书面文章支持和证明该策略。自动化组装流程通常是手动的，这是战术计划的基础，该战术计划有可能实现减少劳力含量的战略目标。这个词可能是故意使用的。投资数十万美元的先进自动化设备不一定是自动化工厂就能做到的。如果自动化过程需要持续的人工监控和干预，或者电气测试产量低而返工劳动量高，那么自动化的目标（和资本投资）就无法实现-我们说不是自动化，而是要实现自动化。本文的目标是：1.提供现实的自动化机会的示例，以供将来从高劳动含量向低劳动含量的转换;以及2.解决利用这种自动化所需的关键要素-不仅仅是简单的自动化。具体来说：设计用于自动组装的产品。 b。一种工厂基础结构，内置了主动式过程控制，理想情况下具有自动主动式过程控制，可自动纠正过程问题，即元过程控制。 C。熟练的劳动力可以开发和维护以最小化成本的方式组织的自动化流程。为了实现这些目标，本文记录的工作分为两个不同的部分：1.进行了一项案例研究，以识别和分析两个可以利用自动化降低产品人工成本的机会，即通过转换来减少人工含量或最初为装配自动化而设计。 2.初步实验建立了与印刷极小的零件的焊膏相关的工艺窗口（01005英语/ 0402公制），即需要主动监控工艺参数并理想地进行自动校正，即元工艺控制（ MPC），以充分利用具有非常小的过程窗口的过程的自动化价值。结果证明：1.自动化设计可以成为消除低劳动力成本操作所提供的竞争优势的有效工具。在确定的机会中，可以通过使劳动强度大的手工焊接操作自动化来显着降低在高劳动率地区组装的产品的总劳动成本。此外，如果最初通过将增加的自动化功能与现有的过程装配自动化设备相结合来设计产品，则将加速投资回报。该论文预测，根据现实世界的生产模型，使两个劳动密集型装配过程自动化，将减少约45％的人工成本，并且一个过程的资本投资回报约为14个月（如果重新设计产品，则为11个月）不需要）。同轴焊接的投资回报率为TBD。实际使这些机会自动化的结果将在以后的文章中进行介绍。 2.必须通过产品组装中涉及的任何自动化过程（包括电气测试误报）实现低良率损失。设计的实验使用了一个具有狭窄过程窗口的组件，以证明在没有伴随的可控过程的情况下自动化的无用性和增加的成本。此外，仅仅识别违反其过程窗口的过程是不够的。传统上，这种情况是在线测试（ICT）发现故障的情况。到了这个时候，通常有许多电路板需要在高劳动率环境中进行昂贵的故障排除，返工和重新测试。实验表明，要充分利用自动化，必须达到95％以上的真实测试合格率。另外，为了确保这些产量，必须将自动化，主动，实时的过程控制，例如元过程控制或MPC，集成到生产运营的基础设施中。自动将01005组件放置在实际印刷的焊锡膏上，而不是根据组件垫板坐标放置，以演示该要求。

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