In the electronics industry, the topic of traceability is playing an ever increasing role. The ability to uniquely identify and trace any component is required by customers. This is because in any defects case traceability offers the only way to narrow down possible sources of error and trigger targeted product recalls. Leesys accepts the challenge and extends its established traceability system to a component traceability.
In order to ensure complete traceability of products, boards and modules, it is necessary to identify, to read and to store proprietary information about the devices from the component containers. On customer request any component can be declared as required for traceability, then the master data management at SAP level will be adjusted accordingly. The information required for components traceability are already captured during the goods receipt. In order to allow an assignment of the information to the component containers, each container is assigned an absolutely unique identification number, a unique ID. Leesys processes approximately 2,700 different electronic components, which are sourced from approximately 600 suppliers worldwide. The volume of processed component containers is approximately 350,000 per year.
So far there is no uniform labeling standard for representation of manufacturer-specific information about devices. This is precisely the challenge, says Andreas Tärre, the project manager for the introduction of the system.
Leesys based its process on the traceability guidelines of the Association of Electrical and Electronics Industry (ZVEI) and encourages its suppliers to label their component containers with the ZVEI Material Label defined there.
Until this identification, however, has become widely accepted, a flexible system is imperative, which can reliably detect and process the wide variety of labeling options.
To meet these demands, Leesys has taken Modi Optical Solutions as a partner. By investing in a goods receipt scanner Adodat 5000 from Modi Leesys lays the foundation for a continuous traceability chain down to the component level.
Traceability - the collecting data process
Each component package with traceability requiring material is placed to a 400x400mm large glass pane with the side on which the manufacturer's label is applied. After starting the recording process an overview camera creates a photo of the placed component container. In the next step using the latest image processing technologies will determine the exact position of the glued label on the component container. These positions moves to an Adomo mirror deflector. A detail camera oriented to the deflection unit can use the full resolution to focus on the label to be read. From the label to be read a photograph is also taken, which is then fed to a pattern recognition which recognizes existing bar code on the label and reads the data content of the bar code. The entire process is completed in a few seconds. Following the determined data of the unique identification number of the component container are assigned and stored along with the photos.
Traceability - Part of the Automated Materials Handling System
The entire recording process is seamlessly integrated into the automated material flow realized at the Leesys site. Via various interfaces that have been developed in cooperation with Modi Optical Solutions, interaction with the material flow system is possible. This means that traceability requiring materials for which no data has been collected, are rejected by the material handling system, until the data collection was carried out without interruption. This control mechanism acts to the automation level of the high bay warehouses.
"Thanks to the automated recording of all data necessary for traceability we have been able to implement an otherwise manual and time-consuming activity in an effective manner. Our staff at the incoming goods is able to extract all the data within a short time of the containers. It is not necessary to learn the complex material identification of different manufacturers. At the same time we meet at the beginning of the process chain of our responsibility to ensure our customers' requests for a traceability to the smallest product level. The automated data collection is a fast and reliable solution," says Denis Hempel, Head of Logistics incoming / outgoing goods.
Traceability - Connection to the Mounting Process
In the placement process the unique ID of each component container is transferred during the process of setup control to the Surface Mounted Device (SMD) – production lines. The serial numbers of the assembled printed circuit boards PCB(A) can be assigned to the processed Unique ID's of the components container. In the traceability system for assemblies these unique ID's are stored and referenced to the data stored in the component traceability system referring to the devices.
Using this combined data the origin of any finished product can be traced down to the individual component throughout the whole supply chain.
Here this traceability chain enables debugging in two directions:
- the final product back for troubleshooting (Forward Tracking)
- the error to the final product (Backward Tracking)
technical properties of the components traceability:
- goods receipt scanner Adodat 5000
- 5 megapixel camera overview
- 5 megapixel camera Detail
- Identify and read all 1D and 2D barcode types
- simultaneous detection of multiple labels on the component containers
- short cycle times, approximately 1 second per scan