PCB production is a multistage process with complex instructions and specifications

This manufacturer makes single layer and multi–layer printed circuit boards. This case study shows the advantages of a realtime tracking system.

Process outline

1. Cut and coat the layers with copper.
2. Photo-etch the copper.
3. Laminate the layers into boards.
4. Drill the holes and through–solder.
5. Inspect.

The problem

1. Many jobs were in progress, with multiple operations on subcomponents throughout the plant.
2. It was impossible to keep track of the jobs without a computer–based tracking system.
3. The “green–screen” terminal–based system was obsolete.
4. Changes in customer requirements had to be accomodated.
5. A system to handle complex customer order entry tasks was need.
6. The system had to integrate with the accounting system.

Reasons for choosing BellHawk

• A tracking solution using barcode scanners attached to PCs.
• Ability to deliver a complete system.
• Significantly lower cost than competitors.

Application outline

1. Enter all the details of each order.
2. Automatically launch a set of jobs to produce all the sub–components.
3. Track the progress of each job through each operation.
4. Generate a job to assemble and finish multiple batches of the required boards.
5. Track assembly and print barcode labels for each batch.

Results

1. Supervisors are able to track the progress of all their jobs in real–time.
2. Supervisors can take corrective actions to ensure that customer orders get out on time.
3. Significant reductions in time spent finding and expediting orders.
4. Customer service can see order status of immediately, no need for someone to go–look around the factory.

Job documentation

A bonus was the capability of the tracking system to disseminate information to the work cells. Engineering are able to add instructions to the barcoded job travellers. The system provides electronic references to files containing documents, drawings and numerical control machine files. It presents information to the operator at each job step, avoiding mistakes.

Payback

The savings in expediting and customer service pads for the system in less than 6 months. The substantial cost of preparing and tracking an extensive set of documents for release to production was saved.