Turning boards in hours instead of days: ready for improved communication, productivity and product quality? Try a Web-based data management system that links the production floor with other departments.

As a contract manufacturer with three production facilities, we compete in the mid-volume, high-part-count, turnkey printed circuit board (PCB) and integration assembly market. Accordingly, we must turn products, processes and engineering change orders quickly to remain competitive and grow our customer base. Maintaining a high level of customer satisfaction via controlled and rapid information flow is the key to our success and has been the driving force behind our computer-integrated manufacturing (CIM) initiative.

For many years, we used first-generation computer-aided manufacturing (CAM) software tools to develop documentation and machine programs from computer-aided design (CAD) and bill of materials (BOM) data. These tools were the most common when they were purchased, and they functioned up to the expectations of that day. However, as the industry matured, customer demand for responsiveness and product complexity increased. Our previous system--which was built on an inadequate data backbone, a difficult and unconventional user-interface and a 16-bit Borland platform--was not up to the task. Consequently, we decided to abandon our CAM/CIM system and adopt a Web-based, transcollaborative manufacturing (TCM) software system from Aegis Industrial Software Corp. (Horsham, PA).

The TCM system includes traditional CAD/CAM for manufacturing data preparation and process development, Web-based product data management and Web-based manufacturing execution. As a central portal to all manufacturing information, the system allows multiple people, departments and even external parties to act upon the same information simultaneously.

Unlike Web-enabled systems that display server-prepared data, such as static HTML outputs, the TCM system provides dynamic two-way interaction via Web browsers. Rather than shuttling data copies that may or may not be current, TCM offers all parties visibility to a common database. Because the data copies are never disconnected from the database, synchronization, data portability and management issues associated with exchange-based systems are eliminated.

From Days to Hours

We started with data preparation software. A modern user interface, open architecture and flexible factory definition system allowed us to develop processes, documentation and automated assembly machine programs more easily and rapidly than before (Figure 1). Support for clipboard, object linking and embedding (OLE) and modern drawing capabilities satisfied the documenters, while the machine programmers benefited from increased machine program generation efficiency. Being 32-bit Microsoft applications, these data preparation tools were easily deployed and readily accepted by our information technology (IT) department.

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Our engineers could now rapidly define factory flows of product, automatically create documentation for each flow point and generate machine programs off-line, freeing up assembly equipment on the factory floor. These tasks were achieved quickly and without error from basic BOM and CAD data.

As we improved our data preparation, we added product data management (PDM) capability. This enhancement introduced complete management of approved vendor lists (AVLs) and approved manufacturer lists (AMLs) and multi-project revision management of the electronic BOM and the process required to convert that BOM into a product. This tight organizational and revision control of both process and BOM data was complemented by advanced BOM importing and error cleaning.

The system became collaborative, allowing two engineers to work simultaneously on the same project. One prepares the BOM and the other prepares the process data, rather than the traditional sequential work required in our previous CIM system. This collaborative and fully revision-controlled approach allowed our documenting, machine programming and process engineering departments to increase their processing throughput and volume without losing control of the information. Subsequently, we retained our customers' satisfaction as we expanded.

Before the implementation of these new systems, our average product introduction time was approximately two to three days. Now, we prepare a product for production in two to 12 hours, depending on product and process complexity.

Touching the Factory Floor

Having solved the data preparation and revision control problems associated with an expanding contract assembly enterprise, we reviewed the inefficiencies and control problems of actually disseminating this information to the factory floor. We scaled our deployment to a Web-based manufacturing execution system, which extended our present system to the factory floor via Web browsers and introduced several new functions.

Data developed and used with the data preparation and PDM modules was now maintained in a single SQL server back-end. These already familiar engineering tools now functioned as portals to a central server. Files and file management disappeared. The information management of a three-shift, 12-engineer CIM team in one factory became totally coordinated by the software itself. Web-based electronic signatures and approval processes controlled the flow of all process and BOM data and eliminated the risk of down-rev information reaching the factory. The TCM system provides three approval levels: data preparation, preproduction and operator setup (Figure 2).

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Shortly after the TCM server was introduced, we began deploying browsers on the factory floor to eliminate all paper-based documentation (Figure 3). Key points in the process flow are fitted with terminals that:

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* launch the appropriate document view

* guide operators through assembly, inspection or pre-production setup operations

* provide several other useful functions.

For example, the laborious task of locating a specific reference designator on a board and then finding the approved vendor and manufacturer list (AVL/AML) information was previously paper based and time-consuming, with high risk for error. Now, the touch-screen-compatible browsers allow the operator to type a reference and simply hit a button. The system provides a view of the part, highlights the general region on the entire assembly to localize the component on the board, and instantly displays the part data, AVL and AML information. These browsers provide easy electronic access to video instructions, audio instructions, corporate quality manuals, machine manuals and other associated documents.

The Web-based nature of this TCM system also offers benefits for our IT department as compared to traditional client-application CIM systems. Initial deployment and client upgrades are fully automated simply by pointing to a specific URL through the browser. The system itself takes care of browser maintenance automatically.

We are now beginning to benefit from the work in process (WIP) tracking system, which enforces product routing and automates the launching of only appropriate documents at appropriate stations. Unlimited nested logical routings accommodate product flows from a PCB up to final assembly integration. Subsequently, the manufacturing process can be visible to our customers; we select specific product and production data for them to view via their Web browsers.

The final phase of our deployment will include the quality control improvement system, which will collect and analyze our quality information from the factory floor via the browser terminals. Additional solutions planned for deployment will extend to preventive maintenance tracking, employee training management and labor tracking. Also, our in-house software developers can access the software via the complete CIM architecture to develop their own interactive solutions, when we require specialized tools specific to our needs.

Conclusion

The deployment of the TCM software system assisted us in growing from one to three facilities, without the increased engineering support staff typically required during such an expansion. Our TCM system offers rapid data preparation, engineering changes and Web-based information distribution, while also ensuring total revision and document control.

The TCM software system has helped us to shorten turn times, improve product quality and increase customer satisfaction. We have removed much paper from our process, improved communications, increased product quality and enhanced productivity. By implementing this collaborative, Web-based CIM software, we will be able to grow our business in the highly competitive contract manufacturing and assembly market.

James Roche is manager of manufacturing engineering, MC Assembly, Melbourne, FL; e-mail: [e-mail].