Production Control

Introduction

This page explores every detail of production setup, from setup procedures for different scenarios, production line handling, workstation handling, to picklist defining.

Production Setup Procedure

For different scenario, the production setup procedure may be different. Below are two common scenarios user may usually encounter:

Scenario 1.

Production Setup for a new (or previous built) product item on a new shop floor production line, suggested following the steps below in PTS:

1. Convert and upload SMT Picklist into PTS.	Refer to SOP-5-I-PTS0014-C
2. Create a New Production Line.	Refer to Create a New Production Line.
3. Create all required Workstation(S).	Refer to Create a New Workstation.
4. Add the Workstations into the Production Line by sequence.	Refer to Add a Workstation into a Production Line.
5.Define Workstation Process Sequence in a Production Line.	Refer to Move Up Process Sequence.
6.Define Workstation Parameters for each added Workstation(s).	Refer to Workstation Setup.
7.Define Picklist for each above added Workstation(s).	Refer to Define Picklist.
8.Location Mapping for PTS workstation. (Optional)	Refer to Location Mapping
9.Set Production Online.	Refer to Set Production On/Off-Line.

Scenario 2.

Production Setup for a previous built production item on where previous built shop floor production line, suggested to follow the steps below in PTS:

1.Convert and upload SMT Picklist into PTS.	Refer to SOP-5-I-PTS0014-C.
2.Define Picklist for each Workstation which corresponding to the associated Production Line.	Refer to Define Picklist.
3.Set Production Online.	Refer to Set Production On/Off-Line.

Note 1: The following content is a general training guide that is not to provide a standard shop floor production process flow for all individual plant or department.

Note 2: Please avoid setup a new assembly on any existing created production line in PTS. It is recommended to have a PTS production line naming setup for one specific assembly exclusively.

Production Line

This section will introduce how to create new line by PTS system.

Click Production Status > Production Setup

Create a New Production Line

Please refer the following example to create new production line!

Select and click Create a New Production Line as above figure marked.

1. Enter the new Production Line Name. (See following for naming format suggestion).
2. Click Create button to create new production line.

Suggested naming format for Production Line
By Shop Floor Location
Format:	Area Location + Production Zone - Production Part Number - Production Process - Production Side
Area Location	F (Floor), G (Ground)
Production Zone	Floor level or zone area in production either in alpha or number format.
Production Part Number	as named
Production Process	S (SMT), H (Hand Load)
Production Side	T (Top), B (Bottom)
Example	F2-ABC12345-S-T Production Line for product ABC12345 top side SMT production at 2nd floor
By Production Process
Format	Production Process + Production Zone – Production Part Number – Production Side
Production Process	S (SMT), H (Hand Load)
Production Zone	Floor level or zone area in production either in alpha or number format
Production Part Number	as named
Production Side	T (Top), B (Bottom)
Example	S2-ABC12345-T Production Line for product ABC12345 top side at SMT Line/Zone 2

Search a Production Line

Search the existing production line as follows example:

1. Enter the production line name or key words in the Search Line Name field.
2. Click Go
3. The related production line will be listed in Production Line Available text box.

Rename a Production Line

According to requirement to rename production line name.

1. Select the production line from the “Production Line Available” Menu.
2. Click Rename Production Line
3. Enter the New Name in “New Production Line”.
4. Click the Change button to rename the production line.

Note: Production line name can be changed only when the production line is in off-line mode. (See Set Production Off-Line)

Set Production On/Off line

This module allows user to

Set Production On-Line

Once you have production line and workstation ready, now we need to set production line to be On-Line mode for starting work order production. You can’t load material or scan board if the production line is off.

• Select the production line to be set on line from the Production Line Available Menu.
• Choose Set Production On/Off Line functional module.
• Enter a released Work Order number if known or Select the work order from the list by clicking Show button.

To be continued on the following page for showing the screen if you click Show

• Select the Work Order (you can view the BOM detail by clicking the BOM P/N).
• Click Check in the BOM/PL column to verify the BOM against the defined picklist and vice versa under two sessions if there is unmatched items:

To be continued on the following page for showing the error screen once you click Check and if there is any unmatched item

1. Items not exist in BOM
   To compare and validate all material placements in SMT placement program (i.e. PickList) not exist in Oracle BOM.

1. Items not exist in PickList
   To compare and validate all material placements in Oracle BOM not exist in SMT placement program (i.e. PickList).

• Fill the required Work Order with associated production ECN.
• Click On-Line button to set the production line online after confirmed the Work Order and ECN selection.

Note: If you have the situation that your selected work order BOM components unmatched the defined Picklist, you need to follow below confirmation and update accordingly:

1. Confirm on the Work Order you enter/select is associated with the latest ECN or not.
2. Confirm the Picklist you defined is correct or not.

Set Production Off-Line

Once the work order is completed on the production line, the production line needs to be set to Off-Line mode.

1. Select the production line to be set on line from the Production Line Available Menu.
2. Click Set Production On/Off Line functional module.
3. Click the Off-Line button.

Hide Production Line

This function can be used when one line is in offline status.

1. Select and click one off line.
2. Click OK button to hide this production line.

Recover Production Line

This module is used to recover the line that was hidden in Production Setup module.

1. Select and click Production Status >Recover Production Line from PTS main menu.
2. Select one line user wants to recover from Production Line Name drop down list.
3. Click Send button.

Workstation

Create a New Workstation

It is used by engineer to create new work station in PTS

Click Production Status > Production Setup from PTS main menu.

1. Click Create a New Workstation from the functional option menu. (See following section for naming format suggestion).
2. Workstation: Enter the workstation name
3. Workstation Type: select one workstation type.
4. Click Create button to create the new workstation.

Note:{color:#3366BB;} The workstation type should be added first in SMT Machine > Workstation Type module.

Suggested naming format for Workstation
By Shop Floor Location
Format	Area Location + Production Zone - Placement Machine
Example	F2-CP6B
Explanation	Fuji CP6B placement machine located at 2nd Floor
By Production Process
Format	Production Process + Line/Zone - Placement Machine
Example	S2-CP6A
Explanation	Fuji CP6A placement machine located at SMT Line 2
By Placement machine model with associated serial number
Format	Placement machine model – Placement machine serial number
Example	CP6-SN12345
Explanation	Fuji CP6 placement machine with its own unique machine serial number SN12345

Add or Remove Workstation

This module is used by engineer to add or remove workstation(s) for selected production line.

Click Production Status > Production Setup from PTS main menu.

Adding Workstation into a Production Line

Add workstation(s) to selected production line when production line is in offline status.

1. Select the production line from the Production Line Available menu.
2. Click Add or Remove Workstation from the functional option menu.
3. Select the workstation name from Workstation pull down list to add to the specific production line.
4. Click Add button to add the workstation.

Note: After created a new workstation, user needs to add new workstation to production line via this function.

Remove a Workstation from a Production Line

Remove workstation(s) from selected production line when production line is in offline status.

1. Select the production line from the Production Line Available menu.
2. Click Add or Remove Workstation from the functional option menu.
3. Select the workstation name from Workstation pull down list which is under In Use to delete workstation from the specific production line. (Such as above figure marked)
4. Click Delete button to add the workstation.

Rename or Delete Work Station

This function is used to change workstation name or delete workstation for offline production line.

Click Production Status > Production Setup from PTS main menu.

1. Select the production line from the Production Line Available menu.
2. Click Workstation Maintenance from the functional option menu.
3. New Workstation: input new workstation name to replace original name.
4. Workstation Type: re-select one type from dropdown list if needed.
5. Click Change button to change workstation name and save modified result.
6. Click Delete button to delete this workstation.

Note:

1. Workstation type must be added first in ‘SMT Machine > Workstation Type’ module.
2. If one workstation is assigned to 3 production lines, renamed workstations will affect at these 3 lines.
3. CAUTION: Please be noted that it is compulsory to remove workstation from all involved production line(s) before deleted the workstation. (See Remove a Workstation from a Production Line ) An error message “Workstation is now used by another production line!” resulted if the workstation is still under any existing offline/online production line.
4. If one workstation was deleted, user can’t reuse the same name again.

Move Up Process Sequence

Used by engineer to redefine the proper workstation sequence for the production line if the previous setup is incorrect. The selected workstation would move one step onward in the procession list. But the first workstation in the production line will not move.

Workstation Setup

This module is to setup the scanning behavior and scanning rules for each defined Workstation under associated Production Line.

Figure: Workstation Setup Parameters

Select the production line from the Production Line Available menu and select the workstation to be set up in the Work station Available Menu. Click Workstation Setup option as hightlighted above, a workstation setup page shows up on the right of the window:

• Barcode Regulation(Recommended): 

Fill in “Barcode Regulation” based on the serial number mask which applied on each PCB serial number barcode label. If blank, no serial number will be validated for all PCB serial scanning.(click  button to see the detailed regulation)

• Scanning Behavior(Mandatory): 

1. Scan By Later Workstation: All this workstation material placements can be recorded with the next Workstation(s).
2. Must Scan At this Workstation: All this workstation material placements are required to be recorded at this Workstation before reach and/or scan at next Workstation(s).
   
3. Scan for Previous Workstation: All this workstation material placements will be recorded with the previous Workstation placements.
   

• Scan Board/Panel(Mandatory): Select the Scan Board/Panel for both 1^st Side and 2^nd
  

1. Board: Each individual PCB board number.
   
2. Panel: Each PCB panel number.
   
3. Serial: Each PCB serial number.
   

• Scan Extra S/N(Mandatory): Define if required extra serial need to be scanned. If it is required to scan the PCB boards additional barcodes such as, the package label, select “Yes.” Default is “No”.

• S/N Regulation( Mandatory if Scan Extra S/N above is Yes): Define the serial number barcode regulation.

• Completed MSD( Mandatory if MSD control is needed): Default is “No”.

Note: MSD control is only applied to the workstation(s) prior reflowing process.

• Scan Side( Mandatory if Completed MSD above is Yes): Define which production side(s) needed to be scanned.

1. 1^st Side: First PCB production side or One PCB production side.
   i.e. Such as PCB’s TOP side production only which do only have material placements on one PCB side.
2. 2^nd Side: Second PCB production side.
   i.e. Such as TOP side can be called 2nd Side as it is the second production side after BOTTOM side placement finished.
   
3. 1^st & 2^nd Side: Top and Bottom
   i.e. Both production sides required to be scanned at the same Workstation.
   

• Scan Material(Mandatory) :
  

1. Select “Material Barcode” (For plant which used PTS format material label that included an unique printed PTS material barcode).
   
2. Select “Manufacturer P/N” (For plant which might used standard plant approved / developed material label that included printed SSCI Part Number barcode).
   
3. Select “SSCI P/N.” (For plant which might used manufacturer provided label that included printed manufacturer Part Number barcode)
   

• Material Run Out Stop (Recommended): Define if the system automatically stops machine when material runs out. Select Yes or No. Default option is No.

Note: If Material Run Out = Yes under System Setting page, system automatically stops the machine when material runs out regardless of which option is selected here; If Material Run Out = No, Yes should be selected here if user wants to set system to automatically stop machine.

• Dual Sled (Optional): Define if the station supports dual tables. Select Yes or No. Default option is No.

Note: If Yes is selected, there will be two tables showing up on the bottom of the Load Material and Prepare Material page, and there will be a Dual Sled option displayed on Scan Board Barcode allowing user to select Table 1 or Table 2.

• Request Material (Recommended): Define if the system automatically requests material from warehouse when material reaches a pre-configured quantity. Select Yes or No. Default option is No.
• Process(Mandatory):

1. SMT: For SMT Machine workstation
2. Hand Load: For Manual process workstation
   
3. AI: For Auto Insertion workstation
   

Note: Different setup option defines different material loading process. Refer to the Load Material work instruction for more detail.

• Check P/N In Picklist(Mandatory): Define whether or not to check part numbers in BOM with the ones in Picklist when production line is on-line. Select Yes. Default option is No.
• Allow To Change BOM P/N(Mandatory): Define whether or not to check BOM part number consistency of current scanning and previous scanning when the same board is scanned more than once. Select Yes. Default option is No.
•  Click on  button to set up the workstation or save changes to the workstation.
• Click on button to view the change history of a selected workstation.
• Click on button to go back to previous window without saving changes.
  

Define Pick List

This module is for assigning the early prepared/loaded SMT placement program into a Workstation under the specific Production Line.

• Select the production line from the Production Line Available Menu.
• Select the workstation from the Workstation Available Menu.
• Select the Define Picklist.
• Enter the Picklist name into Search textbox.
• Click “Go” to search Picklist name.
• Select the Picklist name to view material placements with reference designator listing(refer to below figure).
  

• Verify Picklist and submit

a. Verify and confirm the placements and corresponding reference designator, click Send to assign the selected picklist into the Workstation.
b. Click Cancel to return to the Select Picklist menu.

Note: For additional detailed Picklist information, refer to EZPickList Work Instruction SOP-5-I-PTS0014-C.

Location Mapping (optional)

This sub-module is designed to map PTS workstation with SFDC location, so that SFDC will forward serial number information to pre-mapped PTS workstation upon board scanning, which help to avoid duplicate board scanning and improve production efficiency.

To map a PTS workstation with a SFDC location, please select the workstation of a production line, and click on Location Mapping, refer to below figure:

1. Update an existing mapping, click on corresponding “Edit” button;
2. To configure a new mapping, click on the “Create” button and a window will pop up as below:
   

• MDS User ID(Mandatory): SFDC user ID at MDS. Select from the drop-down list.
• Location Name(Mandatory): Fill in SFDC location name that to be mapped with selected PTS workstation.
• Device ID(Optional): Fill in SFDC Device ID.
• Click on Send button to complete the mapping and Cancel takes you back to previous interface.