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LED BIN validation & traceability Figure 4. Product flow control (PFC) assures data integrity while preventing defects. to automatically detect and identify the feeder at each slot (Figure 5). In addition to defect prevention, the smart feeder system automatically collects accurate traceability data during machine setup and replenishment. The deployment of smart feeders also increased productivity by replacing manual validation of line setup. By automating what was previously a manual procedure, Methode shaved 12 minutes off the average line changeover time. With three changeovers typical over a 21-hour work day, this efficiency gain equates to 36 additional minutes of productive line runtime per day. Machine monitoring: low level alarms The TTC system is directly integrated with the placement machine’s software. This allows critical real-time production data to be shared between both systems yielding numerous benefits. For example, the machine will stop whenever there is a PN related setup error. Holding the machine in cycle stop until the fault is cleared. Figure 7. Automated calibration eliminates product variability. Figure 5. RFID smart feeders to poke yoke setup and reduce changeover time. Integration with the machine’s SW also allows the TTC system to accurately track component consumption, including all miss picks and rejected components, enabling proactive material management. The system issues an alarm when the remaining quantity of components on any reel becomes lower than a set threshold. When a low quantity alarm is issued for an LED, the PFC upstream from the placement machine prevents additional boards from entering the machine. The operator is prompted to choose between replacing the low reel immediately, or resuming production with the current setup: • If the operator chooses to resume production using the current setup, the Figure 6. Detailed traceability report including LED BIN code data for every reel. system allows one additional PCB to enter the machine. – This choice makes sense when there are enough LEDs remaining in the low reel for one more PCB, or if the operator has a replacement reel in hand that contains a compatible BIN to the one that is low. • The error will come back for each subsequent PCB, until the Low LED Qty alarm is cleared. • The Low LED Qty alarm is cleared when the low reel is removed from the machine and replaced with a new reel. If there are PCBs within the machine when a reel of LEDs is replaced, the system will confirm that the new reel’s BIN code is compatible to the one it replaced. If by accident the operator used an incompatible BIN, the TTC system will issue an error and trigger the machine’s cycle stop circuit. This makes it impossible for the machine to place any incompatible BINs onto partially populated PCBs. If there are no PCBs within the machine when a reel of LEDs is being replaced, the system will permit any allowable BIN for that product, provided of course that the PN is also correct. complete traceability For each PCB S/N, a traceability report (Figure 6) may be generated that includes the following information: • Time stamp for start and end of SMT placement process. • Operator ID • PN and LN for each reel used. • BIN for each LED reel used Conversely, for any given reel, a traceability report may be generated that lists all affected PCB S/N. automatic product calibration The system described above ensures that any particular product only contains correct PNs and compatible LED BINs. However, it alone could not make separate 22 – Global SMT & Packaging Southeast Asia – Winter 2010 www.globalsmtindia.in
production units identical in performance. For example a unit assembled using BIN code “A” will emit a different intensity than one assembled using BIN code “B”. To maximize customer satisfaction, Methode took additional steps to eliminate variability between product units. To achieve this, the functional test process was integrated with the traceability database (Figure 7) and equipped with algorithms for automatic product calibration based on the BIN placed on the serialized PCB assembly. When a PCB assembly is placed into the tester its S/N is immediately scanned. The test SW then harvests the traceability data for that specific production unit from the traceability database. The product is automatically calibrated based on the particular LED BINs used to assemble it. This results in identical lighting characteristics for every unit leaving the factory. conclusions Methode Electronics overcame the challenges associated with LED BIN validation and traceability on the factory floor, through the deployment of a tracktrace-control system. Observed benefits Printed electronics for flexible solid-state lighting— continued from page 18 this nascent stage, value chains and supply chains are undergoing rapid development. SMT assembly processes could offer much support to this growing industry. As distributed light sources, OLEDs will open up new lighting paradigms for the lighting designer, lighting engineer and architect. With widespread installation, they should reduce the energy required to light our society while providing new lighting sources to complement the traditional point source devices. references 1. http://www.nglia.org 2. Holonyak and Bevaqua, Applied Physics Letter, Volume 1, 1962, pp 82-83 3. US DOE Solid-State Lighting Research and Development: Multi-Year Program Plan, March 2010, p.23 4. US DOE Solid-State Lighting Research and Development: Multi-Year Program Plan, March 2010, p.29 5. C. W. Tang, S. A. VanSlyke, Organic electroluminescent diodes, Appl. Phys. Lett. 1987, 51, 913 6. LUXEON Rebel Board Design and Assembly Application Brief AB32 (10/08) www.globalsmtindia.in include: • Optimal pricing and availability of LEDs because they can source a wide range of BIN intensities for each LED PN. • Reduced inspection and rework costs through assurance that each product contains correct PNs and compatible LED BIN codes. • Error-proof and automated system performance through the use of RFID smart feeders and product flow controllers. • Faster set-up times resulting in 32 additional minutes of productive line runtime per day. • Traceability data reporting and archiving in compliance with automotive OEM requirements, and including LED BIN data for each product serial number. • Proactive material management such as low level alarms on the factory floor. • Elimination of product variability through automated calibration. The system has exceeded its intended purpose and customer satisfaction has been enhanced. 7. https://www.msu.edu/~nobleda3/ pages/How%20Oled%20Works.html 8. “Flexible Solid State Lighting: Technology, Manufacturing, and Market Assessment”, FlexTech Alliance Report, Released May 19, 2009 9. Eastman Kodak, SID Tech Symp 54-2 (2008) 10. Anil Duggal (GE Global Research), FlexTech Alliance Conference 2009 11. http://apps1.eere.energy.gov/ buildings/publications/pdfs/ssl/ clausen_vancouver09.pdf 12. Dr Jonathan Halls – “Polymer OLED Technology Fundamentals, Status & Prospects” CDT SID 2008, http:// www.cdtltd.co.uk/resources/279.asp 13. “Organic Light Emitting Devices for Solid-State Lighting”, Franky So, Junji Kido, and Paul Burrows, MRS Bulletin, July 2008, Vol. 33, No. 7, 14. http://www.oled-display.net/oledinkjet-printing 15. Dr Jonathan Halls – “Polymer OLED Technology Fundamentals, Status & Prospects” CDT SID 2008, http:// www.cdtltd.co.uk/resources/279.asp, 16. http://www.osram-os.com/osram_os/ EN/Press/Press_Releases/Organic_ LED/ORBEOS-OLED-light-source.jsp LED BIN validation & traceability references 1. LEDs Magazine (2009, December), Industry News: Cree EasyWhite bins simplify LED design, improve color consistency. 2. NEMA: National Electrical Manufacturers Association (2010, April), Standard SSL 3-2010 “High- Power White LED Binning for General Illumination.” 3. DeCaire, Mitch (2006, March) Traceability Data Integrity – Challenges and Solutions, SMT Magazine. Dan Hodgman is global manager for electronics assembly with Methode Electronics, Inc. (www. methode.com). Mr. Hodgman has over 17 years experience in electronics assembly and a B.S. in physics from Central Michigan University. He may be contacted at 24585 Evergreen Rd, Southfield Mi 48075; 248-603-2105; email: Daniel.Hodgman@Methode.com. 17. http://www.lighting.philips.com/ in_en/global_sites/led_lighting/ information/oled/index. php?main=gb_en&parent=1&id=in_ en_led_lighting&lang=en 18. http://www.lighting.philips.com/ in_en/global_sites/led_lighting/ information/oled_lumiblade. php?main=gb_en&parent=1&id=in_ en_led_lighting&lang=en 19. Anil Duggal (GE Global Research), FlexTech Alliance Conference 2009 20. http://www.grcblog.com/?cat=19 Global SMT & Packaging Southeast Asia – Winter 2010 – 23
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