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June 2002

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Subject:
From:
Phil Nutting <[log in to unmask]>
Reply To:
TechNet E-Mail Forum.
Date:
Fri, 14 Jun 2002 10:31:47 -0400
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We have successfully used the Contact Systems through-hole machines (we have 5 systems) for our circuit board production.  They cut out a huge amount of assembly time.  Our lack of errors are dependant on the person loading the right parts into the right bins and the person inserting the parts to, a) insert polarized components in the correct orientation (the machine "blinks" on polarized parts), b) pay attention to the "last part" light, beep and screen display so there are no carry-over parts from one part sequence to the next part sequence and of course the person who programmed the board.  These systems are semi-automatic in than they deliver the parts to the operator who inserts them into the boards.  There is other equipment on the market that are 100% machine inserted from a custom tape-and-reel setup.  Here the errors are from programming, tape-and-reel setup and correct parts in the correct stock locations.

Seems the common thread here is the humans that interact with the machines.  Can it ever be goof-proof?

Phil Nutting
Manufacturing Engineer
Kaiser Systems, Inc.

-----Original Message-----
From: Sauer, Steven T. [mailto:[log in to unmask]]
Sent: Friday, June 14, 2002 9:05 AM
To: [log in to unmask]
Subject: Re: [TN] Throughhole insertion


Good Morning Peter,
Depending on your budget constraints, there are several companies that have
machines with light shutters to point out the insertion location and a
carousel that opens the corresponding bin with the component to be inserted.
These systems can also perform lead cut and clinch after the component is
inserted into the board.  To name a few:  Blakell Europlacer, Royonics &
Contact Systems are the ones that I am familiar with and have used in the
past.
I would suggest doing some research on Poka Yoke, which means "mistake
proofing".  Some suggestions that I have used in the past would be the use
of mylar templates, work samples, color photographs, and color coded
drawings.  In parallel the component bins and tubes would be setup in
insertion order and color coded or numbered for visual management.
The other topic is to balance the line with respect to insertion time,
number of insertions and number of assemblers.  This is important when
establishing a "pull system" rathen than a "push system" using a standard
"slide line".
If you should need more detailed information, please do not hesitate to
contact me offline.

Steve Sauer
Mfg Engineer
Northrop Grumman, Xetron

-----Original Message-----
From: Peter Lee [mailto:[log in to unmask]]
Sent: Friday, June 14, 2002 3:05 AM
To: [log in to unmask]
Subject: [TN] Throughhole insertion

Can anyone provide some guidelines/ rule of thumb on planning out a
manual throughhole insertion line? For example, how would one go about
assigning components to individual insertion stations to minimize human
mistakes?

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