China Topscom provide turnkey electronics contract manufacturing,pcb boards manufacturing fabrication and assembly sevice.
 
As a pillar industry of a country, the electronics industry is closely related to our lives, from LED light bulbs to high-speed railways and space shuttles, all of which are inseparable from electronic manufacturing, especially precision instruments, and have higher requirements for the manufacturing process and stability of electronic products. However, from the actual situation of the enterprises investigated by the author, except for individual enterprises, there is no lean production in the whole electronic manufacturing industry in our country, there is no coordination between planning and logistics, and the quality can not be traced back to the whole process. Equipment and process can not be seamlessly connected, resulting in serious production black hole, no transparency.


In the past two years, we have been talking about intelligent manufacturing and made in China 2025. In this environment, we still have a lot of room for improvement in the electronic manufacturing industry. From the understanding of the electronics industry for many years, combined with the visited electronic manufacturing industry, the author summarizes the common problems in the industry.
 
For the electronic manufacturing industry, the environmental pressure requires enterprises to achieve management breakthroughs as soon as possible:
 
The pressure of cost control caused by labor costs, rising raw material costs and continuous price reduction by customers continues to compress profit margins.
 
Customers have more and more stringent requirements for delivery, how to balance delivery and inventory?
 
Sensitive items in electronic components and environmental regulations and product recall regulations make brands require their suppliers to establish a complete quality and material traceability system.
 
The customer needs the manufacturer to provide a management execution system to ensure that the quality of the product can be carried out in accordance with the predetermined rules to avoid uncontrollable situations.
 
The upgrading and transformation of the intelligent factory is imminent, and the old management and operation mode of the original factory has been unable to meet the requirements of supply management, especially in the personalized needs of customers.
 
The problems faced by the manufacturers themselves.
 
Performance Analysis and continuous improvement.
 
The effective production time of the production line can not be accurately confirmed, and there is no rapid feedback on the shutdown and idling of the production equipment.
 
The main reasons affecting production are: equipment failure, planning and scheduling errors, untimely material supply, frequent changes in planning, unreasonable process indicators and product design.
 
Can we automatically carry out statistics and SPC analysis on the product quality inspection data, accurately distinguish the random fluctuation and abnormal fluctuation of product quality, and eliminate the hidden danger of product quality in the bud?
 
administration cost.
 
How to abolish manual reports, realize paperless office, and automatically count the production quantity, qualified rate and defect code of each process.
 
Reduce the dependence on unstable factors and reduce the impact of anomalies that may occur on the production site on the production line.
 
Quality traceability.
 
When there is a customer product complaint, how to trace all the production process information of this batch of products according to the product number, immediately identify its: raw material supplier, operating equipment, operator, process passed, production time and date, and key process parameters.
 
Process error prevention.
 
When the same production line needs to mix multiple types of products, how to automatically check and operation prompts to prevent workers from parts, assembly errors, product production, process errors, product mixing, misassembly errors, whether to automatically associate standardized SOP work instructions.
 
Transparency of production process information.
 
How to clearly understand the quantity of each product on the current warehouse and each process line, which customers they want to supply, and whether they can be delivered in time.
 
There is a big black box in manufacturing management.
 
From the issuance of work orders to the feeding of materials in the workshop, the information flow of the whole manufacturing process is not completely smooth. For workers, workshop planners, and factory decision-makers, the whole manufacturing process basically belongs to a black hole, and finally only knows the number of completed storage, and whether the specific implementation process is abnormal, which processes have been shut down for materials, how to hand over between processes, whether the quality inspection data is normal, equipment OEE index, and so on. The data can not be obtained in time, and we can only know through the statistical data that there is lag and untimeliness.
 
The overall solution of the electronics industry.
 
From the basic modeling of electronic manufacturing enterprises, advanced production scheduling, production process monitoring, process tracking of SMT production line, and the connection with logistics execution system and equipment, a closed-loop information flow system is formed, and green production and environmental energy monitoring are emphasized to help users of the electronics industry to achieve the goal of intelligent factories more quickly.
 
According to the rating of intelligent manufacturing by the Ministry of Industry and Information Technology, the implementation of the system can enable electronic enterprises to achieve horizontal and vertical integration, achieve the three levels of intelligent manufacturing, reduce costs, improve product quality, production efficiency and customer satisfaction, and seize the commanding heights of the industry.
 
Benefit Analysis of Intelligent Manufacturing.
 
Whole process traceability.
 
Positive traceability: trace back to analyze and deal with the records of materials, production line and equipment, operation staff, quality and so on.
 
Reverse traceability: according to the material batch, production time, etc., trace the use of the material of the product and in the warehouse, shipping information.
 
Real-time information and timely decision-making.
 
Real-time collection of logistics, production and quality information using bar code or RFID as carrier; real-time understanding of material receipt, IQC, storage, delivery, WIP and semi-finished product inventory information; real-time understanding of production order processing progress, production line output and WIP status; real-time understanding of yield, through rate, defect distribution and quality control chart, analysis and improvement of quality status.
 
Automatic error Prevention and Real-time Monitoring.
 
Process error prevention: prevention of jump war, leakage station, bad shipment, packaging error, shipment error, etc.; feeding error: SMT feeding error prevention, material preparation error prevention, material change error prevention, engineering change error prevention, etc.; packaging error prevention: packing list and accessory inspection.
 
Good customer value-added service.
 
Cloud platform for intelligent manufacturing industry: in the cloud platform, you can keep abreast of the operation status of equipment, manufacturing information of workshop, working status of personnel, logistics such as PCB board and electronic material tray, and with the foundation of transparent factory, customers can query order execution and quality status through Web at any time to create a perfect customer experience.