Dynamic material flow planning for SMT production

The initial plans and the actual needs on the line often diverge because of static material requirements planning. This leads either to material bottlenecks during production runs and ultimately to line stops or to the preventive accumulation of space-wasting “emergency stocks” directly at the SMT line.

A new application in the WORKS smart shopfloor management suite from market and technology specialist ASMPT effectively counteracts this. WORKS Material Demand Calculation dynamically calculates the material requirements for definable time intervals taking all incidents into account and continuously adjusts the material requirements. The goal is to always have the right material available at the right time in the right quantity in the right place and to create maximum transparency in warehouses and around the lines.

Always up to date

Many electronics manufacturers still calculate their material requirements in static processes prior to the start of production and use the results for the entire production cycle. Too tightly calculated material supplies or unexpected events can quickly lead to expensive line downtime.

If the calculations include overly large buffers, however, materials may back up at the line WORKS Material Demand Calculation (MDC) continuously analyses material consumption, cycle times and production progress and combines this data. In this way, it continuously computes actual material requirements and updates them dynamically.

Since no two factories are alike, the time intervals for the material requirements calculations can be defined individually. WORKS Material Demand Calculation thus turns rigid material planning and supply into a time-based and flexible closed-loop control system that dynamically computes even non-linear material consumption during setups and teardowns and compensates for disturbances such as increased scrap or non-scheduled maintenance cycles.

“This new solution optimally complements our proven applications in the WORKS smart shop floor management suite for the the ‘Logistics’ workflow. It enables us to offer our customers unprecedented added value by providing them a basis for their comprehensively automated material supply that is always adapted to current conditions,” says Erwin Beck, Head of Product Management Automation Solutions at ASMPT.

Valuable space on the shop floor

Like unscheduled line downtimes, unnecessary manual activities or travel times between lines and warehouses, wasted space on the shop floor is a disruptive factor that drives up costs. If “emergency stocks” no longer need to be stored at the line, the freed-up space can be used much more effectively for productive machines, special equipment or autonomous transport systems (AIVs).

Seamlessly integrated into ASMPT’s Open Automation concept

“Like all the applications in our WORKS suite, the Material Demand Calculation fits seamlessly into our modular Open Automation concept and paves the way for electronics manufacturers to implement their Integrated Smart Factory in stages,” says Erwin Beck.

WORKS Material Demand Calculation completely eliminates manual reordering processes and thus makes an important contribution to the automation and optimisation of internal logistics. AIV fleets can now take over the material supply completely and independently, whether according to the milk-run principle, with dedicated deliveries, or according to other criteria. In addition, employees get relief from unnecessary trips and are notified and instructed automatically and just in time regarding new material supply requests by WORKS Command Centre – via smartphone, tablet, or smartwatch.

WORKS Material Demand Calculation in the ‘Facts on Open Automation’ livestream

WORKS Material Demand Calculation is also a topic in ASMPT’s ‘Facts on Open Automation’ livestream on February 22, 2023, in which everything revolves around perfection in material management.

This ASMPT show format offers viewers each month a roughly half-hour English-language livestream around ASMPT’s Open Automation concept with live feeds from international SMT hot-spots, interviews with experts, practical examples from SMT productions, and much more.