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CFX Presentation for Milpitas
Transcript of CFX Presentation for Milpitas
Marc PeoCFX‐Reflow SolderingDiscussion of the IPC CFX Standard as it relates to Reflow Ovens
The Digital Industry 4.0 Revolution
Internet of Manufacturing (IoM) – Smart factories, intelligent machines and networked processes bring us improvements in yield and the ultimate in production efficiency and traceability.
1800
1900
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For some companies Industry 4.0 implementation seems like a large
mountain to climb
There are so many questions, variables
and costs…
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Today we will answer questions and give clarity to Industry 4.0 as it
applies to Electronics Assembly and Reflow in particular
IPC – Connected Factory Exchange (CFX)
IPC – Connected Factory InitiativeAn electronics manufacturing industry developed standard
forming the foundation of Industry 4.0 Applications.
Simplifies and standardizes machine to machine communication while also facilitating machine to
business/business to machine solutions.
CFX was created to allow all different types of machines to communicate
with each other
CFX Allows for Plug and Play Data Content Definition
Communication Protocal
Defined Language Content
Data is Encoded using
IPC Connected Factory Exchange (CFX)Industry 4.0 Enabler:• IIoT “plug & play”• Open, consensus‐based, >300 participants• Machines, processes, systems & humans• No licensing, contract or dependencies• All discrete assembly manufacturing • Published April 2019
CFX DifferentiatorsFor the entire factory:• Same physical connections:
• Plug & Play connected• Reduced implementation cost and time
• Same data content definition:• Consistency and accuracy• Greater value of data
• No Dependencies:• On any 3rd party software, middleware,
hardware or licensing
• Easier to use:• In‐house adaptions / enhancements
(processes and IT solutions)
Easy CFX Adoption/IntegrationSoftware Development Kits:• Open‐source SDKs available free of charge from IPC
• Windows.Net, Linux, Labview, JAVA, etc.
• 100s of machines have demonstrated with native CFX
Business Enablement:• Achievement of Smart Industry 4.0 business goals• ROI fully scalable across sectors and tiers
CFX Real‐Time Monitoring Demo Headline Participants
CFX Live Data Generators:
CFX Manufacturers/Partners:
Two entire production lines were set up and running within 4 days!
The Visitor Experienceat APEX
• Visitors scan QR code to access data from all CFx‐enabled machines on the show floor (also through APEX App)
• Visitors scan vendor‐specific QR code in each booth to access those machines directly
The Visitor Experienceat APEX
Welcome to APEX“Scan QR Code to Experience the CFX Connected Factory Show floor”
“The World’s First Standards‐Based, Multi‐Vendor IoT Electronics Manufacturing Network”
Visitor enters CFX BoothWelcome to CFX Vendor B Booth
“Scan our QR Code to Monitor our Machines”
CFX Demonstration Flow:• Welcome visitor to watch the CFx site on their phone.
• Ask visitor to lift hood, or press E‐Stop• Site updates nearly instantly• Shows CFX live connection, data exits machine to the cloud, processed, then streamed to the handset
• World‐first of a real multi‐vendor IoT standard in actual use
What about Hermes?Hermes and CFX are complimentary!
The Hermes Standard:• SMEMA Replacement – simple, effective multi‐vendor line management
IPC CFX Standard:• IIoT Technology – comprehensive technology for smart production
The Hermes Standard & CFX Together:• The CFX – Hermes Bridge – both technologies
working together• Line to line build‐record transfer• Hermes Trace (execution data)
communication
Host Interfacing can provide:
• Central Control• Production Reporting ‐ # of boards
processed, up time, down time• MTBF / MTTA / MTTR• Energy Management and Control• Traceability of Product
Note: new IPC standard will use Connected Factory Exchange = CFX to mean Industry 4.0; however most customers might say “Industry 4.0”
Industry 4.0 CFX Connectivity
HC2 Linux Firmware
HC2 Windows O
CX
HC2-3 Firmware
HC3 PC C#
HellerInterface4.0
SECS/GEM ServerEIB GEM or
GWGEM
Log FilesRESTMQTTAMQP
Host
SECS/GEM
Host
Heller SECS/GEM
Bridge
App
Inte
rface
s
Note: OCX also communicates with 3rd party applications – e.g., KIC, ECD, etc..
Oven to Host Communication
CFX.Production Message Reference
R 1 2 3 Structures
Auto App
lication
Auto Assem
bly
Auto Inspection
Auto Solder
Auto Test
Man
ual A
pplication
Man
ual A
ssem
bly
Man
ual Inspe
ction
Man
ual Solde
r
Man
ual Test
SMT Re
flow
SMT Assem
bly
Solder Paste
THT Assem
bly
Tran
sactiona
l
Uniqu
e ID M
arker
CFX.Production:ActivateRecipeRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesActivateRecipeResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesActivitiesExecuted Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt OptBlockMaterialLocationsRequest Yes Yes Yes Yes Yes Yes Yes Yes YesBlockMaterialLocationsResponse Yes Yes Yes Yes Yes Yes Yes Yes YesGetActiveRecipeRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesGetActiveRecipeResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesGetRecipeRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesGetRecipeResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesGetRequiredSetupRequest Yes Yes Yes Yes Yes Yes Yes Yes YesGetRequiredSetupResponse Yes Yes Yes Yes Yes Yes Yes Yes YesLockStationRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesLockStationResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesOperatorActivated Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesOperatorDeactivated Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesReadingsRecorded Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt Opt OptRecipeActivated Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesRecipeModified Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesSetupRequirementsChanged Yes Yes Yes Yes Yes Yes Yes Yes YesToolsUsed Yes Yes Yes Yes Yes Yes AsAUnblockMaterialLocationsRequest Yes Yes Yes Yes Yes Yes Yes Yes YesUnblockMaterialLocationsResponse Yes Yes Yes Yes Yes Yes Yes Yes YesUnitsArrived Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUnitsDeparted Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUnitDisqualified Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUnitsInitialized Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUnlockStationRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUnlockStationResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesUpdateRecipeRequest Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesUpdateRecipeResponse Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesWorkCompleted Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes YesWorkStageCompleted Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesWorkStagePaused Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesWorkStageResumed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesWorkStageStarted Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes AsA YesWorkStarted Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
CFX.Production.Application:LabelAppliedMaterialsApplied Yes Yes Yes Yes YesMaterialsUnapplied Yes Yes
• CFX Messaging is Easy to Set Up
• User Friendly Messaging Guide streamlines implementation
Reflow Oven Main Overview Screen
Main overview screen has a tremendous amount of data –but nothing you can use!
Traceability Report Data
Barcode, Time Stamp, Belt Speed, 02 PPM, Zone Setpoints, Actual temperatures can be reported
Nitrogen and Power Consumption
Outlier Report Data View
Outlier report shows Zone 5 was out of spec for 2017‐01‐06
Daily Cpk Tracking
Daily 02ppm Max Tracking
Profile Parameters can be reported
‐‐ Soak Time (FAT)‐‐ Liquid Time (TAL)‐‐ Peak Temp‐‐ Ramp Rate‐‐ Cool Rate
Profiles: Baseline vs. Actual for each PCB
System uses baseline profile from KIC or other profiler and creates a calculated profile for each PCB based on actual temperatures for that
board’s trip through the oven
Baseline Profile Calculated Profile
CFX can Provide Throughput Optimization in Conjunction with Dual Lane / Dual Chamber
Configuration
‐‐Basically 2 Ovens in one frame‐‐Independent Tunnels can run temperatures up to 100 degrees different—2 different profiles in each lane‐‐Host can instruct one lane to run production while the other is preparing for the next run
Reducing Profile Changeover Time Using Cool Coils
• Cool Coils with circulating water can drop the temperature in heated zones quickly
• Temperature drops of 50‐60 degrees can be produced in 5‐10 minutes
Computer Controlled Valve System for Cool Coil System
• Host computer can instruct the system to engage
• Automatically adjusts based on desired zone setpoints
Energy Management
•Oven tells the host it has been idle for some time and host downloads the Energy Management Profile. This results in:
•~50% KW Reduction in Standby Mode•~60% N2 Reduction
Case Description Power (KW)
O2(PPM )
Nitrogen Flow Rate (SCFH)
1 Normal Operation 10 1000 650
2 Standby Mode(no boards in oven)
5 1000 240
Predictive Analytics(Eliminating Un‐Planned Downtime)
Component Failure Prediction
• Blower Motors Failure Prediction¬AC Current fundamental and harmonics¬Vibration Analysis
• Zone Heater Failure Prediction¬Temperature rate of rise and stability¬Current amplitude
• Conveyor Belt Motor Failure Prediction
¬Encoder determines speed¬DC Current amplitude
• Battery Backup Unit (BBU) Failure¬Monitor signal to determine health of unit
System Health Analysis
• Oxygen PPM Drift¬O2 Analyzer provides warnings/alarms when out‐of‐spec
• SMEMA Board Check¬System continually checks that Boards In == Boards Out¬Guard against lost (or dropped) boards
• Preventive Maintenance Prediction¬System tracks oven hours of operation – i.e., Uptime¬Notifies User when Preventive Maintenance is required based on Uptime
Closing the loop?CFX is GREAT for creating closed loop functions within the line to improve throughput and yields. (Screen
Print, P&P for example)There has been conversation about utilizing CFX for
closing the loop with Reflow.
At this time we do not recommend creating closed loop feedback and interactive changes with Reflow for the following reason:
• Reflow is a “mirror” of what it is given. If you give it something beautiful—it gives you beautiful in return.
• If you see a defect in an AOI or other downline system and try to institute a change in the reflow, you may be trying to fix a problem that didn’t come from the Reflow in the first place. (Screen print, P&P for example )
• As a result, changing Reflow parameters may only introduce NEW problems and defects.
• Further research and field study should be done to see where this loop can be closed.
But Maybe We Can Narrow the Loop?
• We have been working with AOI vendors to create a look up table that associates defects they see with potential root causes.
• In this way, the AOI or host can provide guidance to the operators as to where to look for the root causes and how to effectively close the loop.
Summary
• CFX unifies the Industry 4.0 landscape
• CFX provides the ability for all aspects of the factory to communicate to the host and to each other with virtually no cost
• CFX can be implemented quickly and without complicated software or middle ware.
• CFX is complimentary and works well with Hermes
• CFX provides many wonderful and immediate benefits to the production line. Including:‐‐Increased throughput
• Transition Optimization‐‐Improved Quality
• Traceability with failure analysis• Inclusion of Predictive Analytics
‐‐Traceability
Most of your vendors are already providing CFX or are
working on it.
Push them to bring you test versions or assist in set up!
Thank you for listeningQuestions?
Marc PeoPresident | Heller Industries Inc