Traceability is playing an increasingly important role in the electronics industry. The ability to uniquely identify and trace any device is increasingly required by customers. This is the only way to limit possible sources of error in the case of a defect and trigger targeted recall actions.
Leesys processes around 4,600 different electronic components, which are sourced from around 285 suppliers worldwide. The volume of processed component packages is around 350,000 a year. This extremely high number of component packages is necessary to realize the required material flow in the company. Each month, around one million finished products are delivered as an assembly or assembled system. This requires placement of up to 1.38 million components per hour.
To ensure complete traceability of products, assemblies and components, it is necessary to identify manufacturer-specific information about components, to read them from the component packages and to store them. If the customer wishes for complete traceability, the relevant components are declared as mandatory for the traceability in the master data storage, that is on the SAP level. In order to allow the information to be assigned to the component package, each material package is assigned an absolutely unique identification number, a unique ID.
Thus, the use of state-of-the-art laser systems for direct labeling of printed circuit boards with a Data Matrix Code (DMC) is indispensable in the implementation of seamless traceability. At only a few square millimeters, a large amount of data can be accommodated. The DMC can record 3116 numeric or 2335 alphanumeric characters, with a size of 144 by 144 rows and columns. Thus, this type of component direct marking fits even the smallest areas and can be placed between the increasingly narrowing tracks or electronic components. Circuit boards always carry all the relevant product data on the smallest surface, such as a birth certificate.
Leesys has been able to fulfill its customers' demands for module and component traceability even more comprehensively with regard to the labeling of PCBs. In the past months, it has replaced the existing lasers on five SMT lines with the ASYS Insignum 4000 laser systems.
“MAKE TWO OUT OF TWO"
The conversion of existing laser systems to the ASYS Group's Insignum 4000 laser systems brings a multitude of advantages.
Thus, the new systems have an integrated turning station, so that both sides of the circuit board can be laser-engraved and thus a reduction of the set-up times can be achieved with double-sided printed circuit boards. The new laser systems also have a much higher speed than the previous laser. The process step of lasing and scanning now takes place in one work step. Depending on the PCB, this leads to a 50 percent reduction in cycle time.
With the new connection to the existing Manufacturing Execution System (MES), Leesys will be able to respond even more flexibly to customer requirements in the future. This way, customer-specific serial numbers and codes can be lasered onto the PCB.
EVERYTHING AT A GLANCE
With the following functions, the laser systems increase productivity and support Leesys in the implementation of current and future customer requirements:
- Customer-specific serial number and code generation
- Logos and individual texts can be lasered
- Very compact design
- Highest accuracies
- Short cycle times
- Short transport times
- Minimum module sizes = 0.127 mm = 5 mil
- High accuracy placement by measuring each PCB
- Monitorial verification of readability
- Ensuring complete traceability in accordance with traceability requirements in regulated markets
From the point of view of the Leesys, the comprehensive investment in the new generation of laser marking systems was necessary to make the already existing, integrated system for traceability even more effective. Customers have the option of having their own labels inscribed on their circuit boards and can at any time learn about their manufacture, composition, storage and transport for their products. Leesys thus meets customers' demands for risk minimization and avoidance or limitation of losses. Continuous drive for component and module traceability is the basis for responding to the speed and unpredictability of today's market situation.