THE ROI OF DIGITAL SUPPLY CHAINS Industry 4.0 beyond the factory walls Sanmina Corporation’s JAN/FEB 2019 | i40today.com Ongoing Journey with Smart Manufacturing

Connect your company with the Industry 4.0 market that is projected to reach $152 billion by 2020. For more information, visit www.i40today.com Welcome to Issue 4 of i4.0 Today i4.0 Today is a new platform dedicated to the concept, technology & future of Industry 4.0. We are not just another publication we are an interface for sharing all Industry 4.0 news, research and development within electronics manufacturing. Our mission is to Lead the industry 4.0 movement, and give an insight into the concept, technology and future of Industry 4.0 Leading the Industry 4.0 Movement In today’s fast paced and extremely competitive market, every second saved in the workplace saves not only time, but revenue. Using Industry 4.0 technologies to increase productivity and reduce risk is the number one priority emerging with every industry and sector. What to expect from us... • Opportunity to hear industry leading • Established quarterly publication speakers • Industry 4.0 technology events • Dedicated Industry 4.0 website around the world www.i40today.com • Sponsorship opportunities • Global digital campaign Magazine Contacts... Editorial & Advertising Enquiries To enquire about available advertising opportunities, please contact: [email protected] Website www.i40today.com NEXT ISSUE 5 Deadline for content: Apr/May 2019 27th March 2019 2 An insight into Industry 4.0 January/February 2019

Inside this issue... 4 The ROI of Digital Supply Chains – Industry 4.0 Beyond The Factory Walls Sanmina Corporation 8 Industry 4.0: Leading the Charge for Industry 4.0 KUKA Robotics 10 How Smart Do You Want To Be? SingEx Exhibitions 16 Combining Automated Advanced Process Control with Feedback to Revolutionize the Printed Circuit Board Assembly Process Koh Young Technology 22 From the Lab to the Shop Floor – Industrialisation of Additive Manufacturing Siemens 26 5G Is The Fourth Industrial Revolution Sitowise 28 IPC–CFX: A 2018 Reflective IPC CFX 30 Adaptive Acceleration Holds the Key to Bringing AI from the Cloud to the Edge Xilinx 34 Yamaha Pitches Advanced M2M connectivity Concept Yamaha Motor Europe 36 Convection Soldering Systems in the Age of Industry 4.0 Smart Reflow Permits Predictive Maintenance Rehm Thermal Systems GmbH 40 First i-Connect Forum Held In San Jose - Great Success! i4.0 Connect Forum Editorial director contacts All right reserved Wendy Tindle [email protected] SMT Today Ltd, 1 Dow Road, The content of i4.0 Today is protected Published by Prestwick International Aerospace Park, by copyright law, full details of which Prestwick, Ayrshire, UK, KA9 2TU are available from the publisher. While Electronics Beyond Content great care has been taken in the receipt Tel: +44(0)1292 834 009 and handling of material, production Email: [email protected] and accuracy of the content in this magazine, the publisher will not accept Wendy Tindle, Editor any responsibility for any errors, loss or Email: [email protected] omissions which may occur. Skype: wendy-smttoday Call: +44 1292 834009 Andrew Carpenter, Global Sales Email: [email protected] Call: +44 (0)7535 645205 ortal i40today.com 3

The ROI of Digital Supply Chains – Industry 4.0 Beyond The Factory Walls By Gelston Howell, Senior Vice President, Sanmina Corporation A year ago in i4.0 Today, Sanmina described some of the benefits of implementing Industry 4.0 and cloud technology in its manufacturing facilities. The company reached a major milestone when it surpassed 25,000 pieces of manufacturing equipment connected to its cloud manufacturing execution system (MES). Connecting its equipment to the cloud enabled real time, M2M (machine-to-machine) communication for a significant portion of Sanmina’s manufacturing equipment. This M2M communication, along with relatively simple real time analytics, deliver on the promises of Industry 4.0; tangible ROI, higher product quality and manufacturing efficiency in Sanmina’s factories. Perhaps more compelling though, the approach has delivered benefits well beyond the walls of a single factory. Supply chains for complex mission critical products are Sanmina is a tier one Electronics Manufacturing often global, with components, sub-assemblies and Services provider producing about 1 million sub- finished products manufactured in different locations assemblies and systems per day in 75 factories and countries. Even when SMT manufacturing, systems worldwide. In our manufacturing operations, we face assembly and test are co-located, they may take place complex challenges across a range of industries in different buildings. Delays and technical issues including the communications, computing, storage, encountered at the component or sub-assembly industrial applications, medical, automotive, defense level can have a ripple effect, negatively impacting and aerospace markets. In many cases Sanmina finished product quality and on-time delivery. The global manufactures components, sub-assemblies and systems distributed nature of supply chains for mission critical in different buildings, often located in different countries. systems poses two challenges: managing global supply There are examples where more than 10 of Sanmina’s chains with a high degree of complexity and ensuring worldwide facilities contribute to the manufacture of that sub-assemblies and systems are manufactured a single system. according to product design and manufacturing process Here are two examples of the benefits of digital supply specifications. chains beyond the walls of a single factory. In the first Sanmina has 75 factories and 25,000 pieces of manufacturing equipment connected to the cloud, giving executives real-time manufacturing and supply chain visibility, anywhere in the world. 4 An insight into Industry 4.0 January/February 2019

A forced quality framework implemented in cloud based virtual factories ensures process compliance in Sanmina’s facilities worldwide. example virtual factories are created in the cloud MES point just before the failure occurred. This practice replicating physical production flow. Validation rules ensures that each repaired sub-assembly and system and a forced quality framework ensure that each product passes the test it originally failed. Now think about is manufactured in accordance with the defined bill managing the flow of product through the defined of materials, approved manufacturer list and product manufacturing process at a rate of one PCBA per specifications. In the second example the availability second. That’s the requirement when the volume of real-time data from equipment and scanners in increases to more than 10 million units per year. The multiple factories allows more efficient management number of permutations of valid process paths that could of global supply chains. occur as a result of pass/fail results for an individual PCBA is enormous. Digital Factories, Process Compliance In our implementation of this high volume production and Forced Routings line, we connected bar code scanners, equipment and operator’s actions to our 42Q cloud-based MES Ensuring that each product is manufactured in system. The defined physical manufacturing and test compliance with the product design and manufacturing process flow is replicated in the cloud-based MES and specifications is a challenge when multiple factories pre-programmed rules validate all activity. At every step are involved. However, compliance is essential for of the manufacturing process, each product is scanned mission critical systems, particularly in highly regulated and the MES forces it through the defined process industries including medical, aerospace and automotive. flow, ensuring process compliance. Another result of Components are specified in a bill of materials and must this approach is a searchable database of thousands be purchased from manufacturers on the approved of electronic travelers, each having a complete record manufacturer list. Printed circuit boards (PCBs) are of every production operator (name, time, date) who manufactured according to a design specification worked on the product, hyperlinks to lot codes for all in one factory. PCBAs are produced by assembling components requiring traceability, and electronic upload components onto the PCBs in surface mount technology of critical optical inspection and electrical test data files. (SMT) manufacturing facilities. Other sub-assemblies This approach has been used in a number of Sanmina including cable systems, enclosures, RF and optical locations where PCBAs are manufactured in one building modules, are manufactured in specialist facilities. and the system is assembled and tested in another facility. The system not only ensures that the systems Think of a simple manufacturing process having 15 are manufactured in accordance with the product steps. Five may involve inspection or testing. If the design and manufacturing process specifications, it sub-assembly or system fails an inspection or a test, it also provides a complete traceability history of both is routed out of the main process flow and is repaired. Repaired assemblies are then reinserted in-line at the i40today.com 5

I can see in system and PCBA manufacturing records. delivery schedules in real time. MES data is converted real-time what Global Real-Time Data Visibility and Pro-Active by the system into visual signals that provide real-time Intervention status at product, workstation, production floor, plant, happens in Risk in managing global supply chains can be reduced if regional and global levels. production and I you have real time visibility throughout the supply chain. can optimize the WIP visibility can indicate whether sub-assembly and The system monitors yield, throughput, work-in-process product manufacturing have started on time. Yield data (WIP) ageing, labor efficiency and productivity against process. It’s a is a good indicator of component and sub-assembly predefined targets. If production or yields fall below complete game quality and whether there are any technical issues with target, the system sends real-time alerts to technicians. changer.” - Senior the manufacturing process. Knowing this information in If a problem is not solved within a defined time period, Vice President real-time is invaluable for Operations and Supply Chain automatic text and email escalation messages are of Operations Management. It prompts them to allocate resources to initiated. For example, one of our executives may resolve issues as they occur, maintaining quality and land after an extended flight, and he or she receives at a Fortune on-time delivery performance. Here is an example of notifications on their mobile device, alerting them of ‘out 500 telecoms how Industry 4.0 has been applied to provide real-time of control’ conditions for a specific factory or product visibility and control to complex, global supply chains. line based on how they programmed their alerts. This company. Sanmina employs 44,000 people who operate over cloud-based MES platform enables more efficient and 1,000 production lines in 75 factories worldwide. Many cost-effective management of complex manufacturing of these lines operate 24 hours a day. Managing and processes, with real-time data visibility from anywhere analyzing the high volume of data generated from in the world. facilities in different regions that are manufacturing hundreds of different products is extremely complex. These examples demonstrate the benefits that Industry In addition, our executives and plant managers travel 4.0 techniques and machine to IT communication can frequently to meet with customers and suppliers. We have beyond the walls of a single factory. Use of a cloud- needed a system to streamline the entire process and based MES platform can also be extended beyond a ensure that the right people had the data they needed manufacturer’s own operations to third party suppliers to proactively address issues or solve problems as they that agree to use it, providing insight into the status of occurred on our production lines. their operations and component availability. While still We use the same cloud-based MES described in in early stages at Sanmina, broadening the scope and the previous section to convert data into a virtual use of our cloud-based MES platform to more suppliers representation of the factory and production. This automates the flow of critical data to us in real time, provides supply chain managers and operations providing comprehensive global supply chain visibility executives with access to a virtual factory floor via that allows us to react and adjust to potential problems laptop, enabling them to view information on the status at suppliers. of component inventory, production problems and www.sanmina.com Some automated production lines at Sanmina employ real- time data analytics for better yields and product calibration. 6 An insight into Industry 4.0 January/February 2019

Sanmina is a Global Electronic Manufacturing Services Provider with 75 Locations Worldwide TIME TO MARKET. SUPPLY CHAIN SIMPLIFICATION. Sanmina’s advanced supply chain management systems, global footprint and complete services enable the worlds most innovative companies to launch, manufacture and get their high technology products to market faster. www.sanmina.com i40today.com 7

Industry 4.0: Leading the Charge for Industry 4.0 By Joe Gemma, Chief Regional Officer at KUKA Robotics Science fiction has long been obsessed with a future where humans are at the mercy of hyper-intelligent robots. While this explains some hesitance about the evolution of AI and other technologies, it’s about as likely to happen as flying cars. Here’s the reality of a future where the digital and real example, are designed to collaborate with their human worlds are seamlessly connected, known as Industry operators. Integrated sensors serve multiple purposes: 4.0: Humans and robots will need to work side-by- Allowing the robots to perform delicate tasks, pause or side in order for the innovation around automation work around an object in their way. Ideally, the robots and data exchange in manufacturing to reach its full serve as an assistant during workload peaks and potential. Smart factories, automated supply chains and resource bottlenecks. And soon, smart collaborative personalized production are just a few of the benefits robots will be able to learn a task simply by watching of this ever-improving wave of robotic technologies, a human perform it. which is already well under way. A safer, smarter workplace. Manufacturing robots are To thrive in Industry 4.0, manufacturers must identify the also stepping up to perform what’s perhaps their most key challenges they face and pursue integrating new important function: Tasks that are either impossible technologies that will help streamline their businesses. for or harmful to humans. KUKA’s KR 1000 Titan can Those goals can include reducing downtime, simplifying withstand temperatures of more than 2,500 degrees order processes and digitizing the customer experience Fahrenheit, and has a maximum payload of nearly — areas where KUKA’s cadre of robots, software and 2,900 pounds. Its operators no longer need to risk training is well equipped to help. exposure to scorching materials like liquid steel — in It’s time to either adapt footprints, processes fact, thanks to KUKA’s software, they don’t even need and workforces to align with Industry 4.0 or risk being to be in the same room. left behind. Staying ahead of a changing industry. Most electronic products have very short lifecycles, with new iterations What does it mean to operate an Industry 4.0-optimized pushed out to market as soon as the first version hits company? the shelf. But with a modular robot, manufacturers Industry 4.0 asks that we look for in a manufacturing and can repurpose machines for second, third and even sales landscape what was once beyond imagination. fourth lifecycles. From cloud computing and Big Data, to advanced It’s important to consider how robots can be recycled manufacturing and cybersecurity, Industry 4.0 touches and modified for future use cases to help maximize every corner and component of the workplace. ROI. But choosing the right partner is an equally key Manufacturing factor; not every robotics vendor carries solutions Where’d all the noise go? Loud, dangerous machinery representing an entire manufacturing portfolio. When that was once sequestered in cages is being replaced vetting robotics vendors, manufacturers should assess by collaborative robots, or cobots, that work fully side supplier alignment at both the robotics level and the by side with humans. KUKA Robotics’ LBR models, for systems integration level. Look for vendors that can support systems implementation and provide the technical know-how needed to ensure a seamless adoption. Robots that grow with your business. Just like the modern consumer, the modern manufacturer demands the ability to personalize and customize. And modern robotics are built with this desire in mind. Instead of replacing an entire robot investment, manufacturers can retrofit their existing fleet. KUKA’s add-ons include: ● End effectors: Add-ons that can serve as the “fingers” on a robotic arm for increased precision across a wide range of applications. ● KUKA_3D Perception sensor: A sensor and camera system that enables robots to sense the position and orientation of items in space. ● Robot energy supply systems: Units that power robots as efficiently as possible. 8 An insight into Industry 4.0 January/February 2019

Computing Manufacturers are looking to satisfy increased Strength behind the scenes. While the physical demand with a little help from robotics and automation appearances of these sleek, powerful robots may technology. As a result, robotics training is taking on be the most initially enthralling thing about them, it’s greater importance than ever before. But how do you their digital lives that will have the biggest effect on put it into action? business. From intricate software that allows them to It starts with educating future engineers and tech stars be programmed in nearly any way imaginable to the today. And when it comes to recruiting new hires, keep metrics and insights the robots produce simply by doing an eye out for candidates with strong engineering and/ their jobs, the computing side is just another example or computer science backgrounds in robotics. of the give-and-take relationship between robots and humans in Industry 4.0. Stanford University students specifically use KUKA Programming the robots of the future requires well-tuned robots in their classes. As a final project, students had software of today. KUKA’s to pick a task to teach the robots; choices included KUKA.SystemSoftware is loaded with a basic package ping-pong and serving as a drone landing pad. The of functions from path planning to I/O management, as company also has an official partnership with Greenville well as a host of customization options. These include: Technical College’s Center for Manufacturing Innovation. ● Cooperating robots, both with regard to the shared The South Carolina university received $700,000 worth workspace and in the form of load sharing between of KUKA robots to educate students throughout the several robots via KUKA.RoboTeam. duration of the partnership. ● TCP/IP data communication with KUKA.EthernetKRL. In exchange, KUKA was able to install one of the most ● Real-time sensor connection/communication via important igniters for Industry 4.0: Training. KUKA clients KUKA.RobotSensorInterface. like BMW have plants in the Greenville area, and an ● Protection of the controller against malware through onsite representative at the college will be able to train the KUKA.Ikarus antivirus solution or the KUKA.CPC clients with the robots. whitelisting procedure. But that’s not even the most in-depth educational ● Know-how protection of KUKA.SystemSoftware experience KUKA offers. With more than 25 locations through the encryption of function modules using worldwide, KUKA College offers an immersive KUKA.EncryptionTool. experience in all things robotics, from robot operation As an added bonus for the operator, KUKA’s software and programming to specific courses for Volkswagen runs on a touchpad controller, similar to the commercial employees. KUKA’s German locations even offer an tablets many people are already comfortable with in entire series of courses centered on Industry 4.0. their own homes. No matter how Industry 4.0 fits in to your company’s Testing, testing… Instead of simply assuming future, bolstering both technologies and training is the new systems will fit within an existing environment, first step to truly effective integration. manufacturers can leverage robot simulation software www.kuka.com to tackle potential issues well before installation. The more time you devote toward identifying potential process issues and design concerns, the better chance you have of reducing friction later on. Better yet, robot simulation software promises to advance virtual commissioning. By completely redesigning a process chain, virtual commissioning makes it easier than ever for new components to interact with one another — regardless of whether they come from a wide range of manufacturers. Businesses also can begin programming their new equipment before it even arrives. The result? Greater efficiency across the factory floor. In addition to testing ideas for a fraction of the cost, such software can also help you sidestep expensive problems later on. If, for example, an application is expected to have trouble collaborating with an existing system, you can make any necessary adjustments well ahead of time. Writing their own futures. With the capability to provide metrics around areas like efficiency and productivity of a work cell, error reporting, quality reporting and basic analysis, recommendations and adjustments can come at lightning speed. Industry 4.0 technologies also predict when maintenance will be necessary, cutting down on costly breakdowns and allowing parts to be ordered before they’re needed, but not so much so that they create a stockpile. The important question for manufacturing executives to consider: Do you have the personnel and resources in place to put these data insights into action? How can you get your employees — not just your technology — up to speed? i40today.com 9

How Smart Do You Want To Be? By James Boey, Executive Director, Industrial and Urban Solutions, SingEx Exhibitions Smart homes. Smart gadgets. Smart living with smart solutions. Technology is the modern-day balm to the soul and it nourishes the competitive spirit that compels us to be best-in-class in our professional lives. For individuals, it may just be an enabler of convenience. But for corporations, it is the nirvana of truth that paves the way for disruptive innovations and creates a new world of alternative realities. Smart homes. Smart gadgets. Smart living with smart physical systems pretty much like a sacred cash cow solutions. Technology is the modern-day balm to the of unlimited potential. soul and it nourishes the competitive spirit that compels With consumers getting smart and demanding us to be best-in-class in our professional lives. For sophistication in their products and services, individuals, it may just be an enabler of convenience. manufacturers too have to answer the call for But for corporations, it is the nirvana of truth that paves transformation with technological breakthroughs in the way for disruptive innovations and creates a new smart manufacturing that push the agenda for industrial world of alternative realities. IoT. It is easy to push out innovations that may be just The 4th Industrial Revolution is creating ripples of change the darling of the moment but have no more substance that is infinite in effect and resounding in impact. It is and economic impact than internet-connected toilets. like an omnipresent cloud of influence that transforms With this context, we take a look at the overriding trends business models and reinvents product lifecycles from influencing the industry. design to production. This blurring of realities has created a fusion of technologies that offers up cyber- Smart IoT solutions generate smart dialogue 10 An insight into Industry 4.0 January/February 2019

Industry leaders speaking at the ITAP 2018 Conference 1. Ever the twain with AI and HI With consumers getting Will it be a world of dystopia or utopia for mankind? smart and demanding As the onslaught of artificial intelligence continues to sophistication in their impact us in our lives, we all question the necessary products and services, evil of technology. Is it necessarily smarter? Is creativity our saving grace? According to Oliver Tian, immediate manufacturers too past president of the Singapore Industrial Automation have to answer the Association (SIAA), all’s not lost for humanity. call for transformation He had this to say at IoT Asia 2018 this year: “IoT sectors with technological which include artificial intelligence, robotics, machine breakthroughs in smart learning and big data analytics have already disrupted manufacturing that push our way of life, challenged established processes, and the agenda for industrial threatened conventional progression roadmaps… By IoT. It is easy to push out fostering a culture of openness, continued innovation, innovations that may be investment and commitment, our regional IoT ecosystem just the darling of the comprising communities and stakeholders will play a key moment but have no more role in shaping developments and spurring the global substance and economic environment to adapt and leverage on the profound impact than internet- economic changes to come.” connected toilets. Today, the impact of AI can be felt from healthcare to human resources. The 2018 Deloitte Human Capital Trends report revealed that the adoption of automation, robotics and artificial intelligence (AI) is accelerating dramatically. Forty-one percent of respondents rated this topic as very important. Almost half of the survey’s respondents said that their organisations are deeply involved in automation projects with 24% using AI and robotics to perform routine tasks, 16% to augment human skills and 7% to restructure work entirely. Chatbots may replace personal shoppers; AI assistants (Siri, Alexa) may put nannies out of their jobs; and self-driving technology could displace drivers. But it is important to remember that the most effective applications will still require a human touch. AI and HI may be trending topics today, but the star for this industry is industrial intelligence. HANNOVER MESSE 2019 is one of the platforms Industry – Industrial Intelligence. This refers to the that will be exploring the driving forces behind the digital networking of humans and machines in the age intelligent industry. The theme this year is: Integrated of artificial intelligence, which is an important theme i40today.com 11

CFeoanttuinreued... that interests manufacturers, brands and businesses Singapore makes a strong case. in Asia. The Asia Pacific market will benefit from AI and Senior Minister for Trade and Industry Koh Poh Koon machine learning at Industrial Transformation ASIA- stressed at ITAP 2018: “Workers have to be the ultimate PACIFIC 2019 - a Hannover Messe Event which will beneficiaries of industrial change.” According to him, be held in October 2019 in Singapore. “A successful Industry 4.0 in Singapore is only possible with worker 4.0.” In Asia, where the rate of IoT technology adoption is Singapore workers can look forward to numerous gaining velocity, it is crucial that key event platforms workforce development initiatives announced by are able to create the right connections for technology the minister at ITAP. One key initiative is SkillsFuture solution providers, enablers, end users and adopters. Singapore’s new continuing education and training In the 2019 edition of IoT Asia, to be held March 27 (CET) strategy for advanced manufacturing, aimed at to 28, we will be highlighting the application of IoT for attracting, retaining and developing talent in the field. the retail and logistics sectors. More importantly, the show will showcase two emerging technologies that In his speech, Mr Koh also touched on the importance are taking the world by storm – artificial intelligence of public-private partnerships to harness the potential and blockchain. The show programme will deep dive of manufacturing-related technological advances. into specific industry applications that will add value and enhance takeaways for all attendees. To that end, 17 companies, including automotive manufacturer Rolls-Royce and local firms, have 2. Not just about tech, but about people and begun collaborating with the Industrial Internet of partnerships Things platform developed by the Agency for Science, Bots still need their human masters, so we cannot rest Technology and Research (A*Star). The platform seeks on our laurels. to develop and accelerate the adoption of smart manufacturing technologies such as sensors, industrial 12 An insight into Industry 4.0 IoT Asia 2018 addressed the ambitions of the Smart City in the new 4.0 world. January/February 2019

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CFeoanttuinreued... data analytics and cyber security. Three research 3. Platform economy fuelling experimentation projects focusing on manufacturing technologies were With the Internet of Things (IoT) binding our physical also awarded a Singapore-Germany grant, which will and digital worlds together, we saw an opportunity also support research collaboration between the two to respond to the needs of today’s business event nations’ public and private institutes and organisations. participants at IoT Asia 2018. ITAP 2018, which is the region’s largest advanced Underscoring the integral role that the community plays manufacturing trade show, drew 15, 000 visitors in today’s digital and global world, SingEx launched across 55 countries and more than 260 companies The Interchange - a digital community platform to from global technology and solution providers. The bring different industry players and communities onto exhibition features four main display areas – Additive a common space, in order to address challenges or Manufacturing, Digital Factory, Industrial Automation, problem statements together as part of an expanded and Smart Logistics – as well as national pavilions ecosystem. Connecting various communities within from Germany, India, Japan, Malaysia, and Singapore. and beyond the current operating universe, the platform Fourteen industry-leading enterprises supported the enables members to seek out and adapt solutions to premiere, including Accenture, SAP, Schneider Electric serve each community’s unique needs. and Siemens as founding partners. While expecting to be engaged on multiple fronts, participants are most keen to build meaningful Seen & Heard at ITAP 2018 in Singapore relationships; learn from other industries; explore radical opportunities; and derive real business value “Singapore is the perfect location for Industrial out of their committed time. By being connected in Transformation Asia-Pacific thanks to its excellent new ways, both in the online sense as well as within infrastructure, advanced manufacturing capabilities and existing and new communities, this helps businesses a strong focus on engineering, R&D and innovation.” address industry challenges; seed and test-bed new - Dr. Jochen Köckler, Chief Executive Officer of Deutsche ideas; accelerate their time-to-market; and achieve Messe AG commercial success. The event is poised to 4. When the smart agenda crosses swords with social generate significant concerns economic benefits for As consumers and corporations get caught up with the Asia Pacific as it plays myriad of possibilities, it is easy to overlook IoT problems a role in catalysing which typically emerge during the implementation phase. With as many as 50 billion connected devices by 2020, deepened cross- we can expect a tsunami of problems to hit us. From industry collaboration, privacy infringement to data theft and physical security investments and trade issues, the list goes on as IoT services expands. What exchanges among players should we be aware of? Who should take responsibility? in the manufacturing, Government, the CIO, or a consumer body? manufacturing-related and digital communities of The IoT and the problems related to cyberattacks take our region; and enhancing a prominent position in the World Economic Forum’s Global Risks Report for 2018. Each year, researchers competitiveness. with the Global Risks Report work with experts and decision-makers across the world to identify and analyse the most pressing risks that the world faces. As the pace of change accelerates, and as risk interconnections deepen, this year’s report highlights the growing strain we are placing on many of the global systems we rely upon. Are hackers, phishers and stalkers having a field day in the IoT era? Has the proliferation of IoT devices made the human element more vulnerable? In addition to paying attention to tactics that increase security (e.g. strong cryptography, data loss prevention, web filtering technology) why not visit The Interchange for some answers, or raise this as a topic for discussion today? - Mr. Aloysius Arlando, Chief Executive Officer of At SingEx, we believe strongly in being a proponent SingEx Holdings of the learning journey in the 4th revolution and to create platforms that build value chains and connect “The rapid wave of transformation in manufacturing is smart cities with industrial IoT of economic value. We prompting our businesses and workers to rethink what organise owned and managed shows such as IoT Asia we need to do differently to stay ahead of competition… and Industrial Transformation Asia-Pacific that bring through the ITAP event, we look forward to working with together industry players to facilitate adoption rate, partners to build a robust community for collaboration improve business efficiency and increase bottom-line. and knowledge exchange to help Singapore and This translates into tangible business opportunities that countries in the region upgrade their manufacturing make sense for manufacturers. capabilities, and to further cement Singapore’s position While manufacturers are keen to fast track the production as a leading manufacturing hub.” of innovative products and solutions to capture a bigger - Mr Lim Kok Kiang, Assistant Managing Director, market share, it is also important to be cognizant of Singapore Economic Development Board the trends and opportunities that create important business leverage. www.internetofthingsasia.com www.industrial-transformation.com 14 An insight into Industry 4.0 January/February 2019

IPC APEX EXPO San Diego, USA January 26-31, 2019 Booth 2201 Collaborate Advise Formulate Invent Partner Test Research Tailored Solutions Refine Manufacture Our winning Approve Distribute formula for superior Comply electro-chemicals Support Globally When every connection counts, you can count on Electrolube’s electro-chemical expertise. With a 77-year pedigree, a growing presence in 55 countries and production in 3 global locations, we have the products, research facilities, resources and personal expertise to engineer solutions to your manufacturing challenges. Make contact and discover what makes Electrolube the solutions people for leading manufacturers worldwide. Tel: 888-501-9203 www.electrolube.com Electronic & General Conformal Encapsulation Thermal Management Contact Maintenance Purpose Cleaning Coatings Resins Solutions Lubricants & Service Aids i40today.com 15

Jenny Yuh, Marketing Assistant Combining Automated Koh Young Technology, Inc. Advanced Process Seoul, Korea Control Joseph Park, Senior Application Engineer, Koh with Feedback to Revolutionize Young Technology, Inc. the Printed Circuit Board Assembly Denis Kang, Senior Sales Process Manager, Koh Young Technology, Inc. With a shortage of highly-skilled employees for printed circuit board assembly, the Brent Fischthal, Sr. Manager, electronics industry faces a severe challenge, which is being complicated with a high Americas Marketing, Koh Young turnover rate as employees jump between companies or simply become misaligned with America, Inc. the organization. While leading industry organizations like IPC and SMTA are tackling the issue head-on with education and training programs, a need exists for equipment suppliers to cooperate with other industry leaders and organizations to adopt Machine- to-Machine (M2M) communication standards. Initiatives like the IPC Connected Factory Exchange (CFX) and the IPC-Hermes-9852 standard underpin the efforts within the industry, and many companies are working together to develop standards to create seamless production. Guided in part by Industry 4.0, these M2M communication create innovations. For example, Solder Paste Inspection standards are quickly altering the manufacturing process (SPI) has undergone a shift from 2D to 3D, because the by improving metrics like first pass yield and throughput 2D inspection technologies manufacturers traditionally by applying autonomous process adjustments. Far used to collect solder deposit images could not solve beyond an automatic line changeover, this bi-directional shadowing problems. Thus, companies developed communication allows equipment to automatically adjust 3D SPI to capture the printed solder paste height to production parameters to increase board quality and accurately measure the total volume of paste printed. lower costs by eliminating rework and scrap. Several years later, we see the same need for surface Building on our expertise and testing, this presentation mounted component inspection with AOI systems. will explore Industry 4.0, and then explore how Advanced As today’s board complexity is increasing with more Process Control (APC) can increase production yields components, more solder joints, higher density, and and reduce defects. Specifically, the presentation will shrinking package technologies such as 0402 metric discuss how APC improves process repeatability by (01005 imperial) and even 0201 metric (008004 imperial) automatically adjusting component placement to the microchips (Figure 1), 2D AOI technology using grey- paste, rather than to the pad location. Moreover, it will scale image analysis or angled camera view of color show how APC will identify a shift trend and implement images may no longer be a practical possibility. Most further position correction by using true 3D measurement decisions made are based on a “good-bad” comparison data from the Automatic Optical Inspection (AOI) of reference images, which can easily be affected by system. While a smart factory will help resolve the variables like component surface finish, board condition, skilled employee challenge, it will also revolutionize component proximity, and more. process optimization. Key words: 3D Measurement, Automatic Optical Inspection AOI, Artificial Intelligence AI, Advanced Process Control APC INDUSTRY 4.0 DISCUSSION Figure 1: Using a ballpoint pen for reference, the image Big Data is the foundation for Industry 4.0, so advanced compares 0201 metric (008004 imperial) component inspection systems must evolve from simply judging with an 0402 metric (01005 imperial) and  an 0603 “Pass/Fail” tools into highly intuitive, dynamic decision- metric (0201 imperial) component [image courtesy of making systems, which emphasizes the need for reliable, ASM Assembly Systems GmbH] traceable data. Artificial Intelligence (AI) engines can empower tools to help customers analyze and optimize the production process by managing process data from connected SPI and AOI systems. When we look at the optical inspection market growth trajectory, we can see how process challenges helped 16 An insight into Industry 4.0 January/February 2019

Although 2D AOI is still a major technology in the improve line maintenance with other tools for real- market, more manufacturers are adopting 3D AOI to time monitoring to instantly display relevant process increase board quality. The benefits are clear: putting parameters at remote locations for immediate analysis rock-solid faith in inspection tolerances and reducing and action. What’s more, combining multipoint views efforts to constantly debug inspection programs. from SPI, Pre-reflow AOI, and Post-reflow AOI with real Moreover, measurement data generated from 3D AOIs data management and monitoring allows operators to provides meaningful insights about the process and determine actionable insights to optimize the processes. helps eliminate the root causes of a defect. The 3D However, the adaptation of AI-powered process tools SPI, together with 3D AOI, enables manufacturers to takes optimization to a higher level. accurately control and monitor the solder printing and Converting all the data requires a simulation tool to component placement processes. review identified defects with accumulated historical data But with so much data, engineers are hard pressed from PCBA lines, while avoiding unnecessary downtime. to collect, process, and implement all the data using Software tools can reliably allow manufacturers to traditional techniques and software. Artificial intelligence predict the effects from fine-tuning without stopping and deep learning lay the foundation for machines to the line. Moving forward, an AI-powered platform can learn from the vast amounts of process data collected autonomously render complex process optimization by adjusting the output based on the data inputs and decisions typically reserved for dedicated process performing tasks to help engineers perform tasks engineers. Embracing the connectivity can create a smart more intelligently. The many examples we hear about factory. For instance, software modules can exercise like computers playing chess or autonomous (self- complex algorithms to develop closed-loop process driving) vehicles use deep learning  to achieve tasks recommendations. The Machine-to-Machine (M2M) by processing large amounts of data and recognizing connectivity drives the smart factory vision one step patterns in the data. further by enabling automatic SMT line maintenance. Finally, combining inspection with printers and mounters As today’s board can enable the network tools to connect and simplify complexity is increasing communication across the entire PCBA line. with more components, Defining the correct process parameters often requires more solder joints, higher a high degree of expertise, because of the various density, and shrinking environmental considerations affecting the process. package technologies... Using AI-powered systems and M2M connectivity, 2D AOI technology using manufacturers can link inline inspection systems with the grey-scale image analysis associated printer and mounters in the line to overcome or angled camera view the challenges. Figure 5 shows how automated machine of color images may no learning can already match the results from process experts, and this will only improve. longer be a practical ADVANCED PROCESS CONTROL METHODOLOGY possibility. Reliable AOI methods have become powerful, economical complements to traditional test strategies. This is ideal for volume PCB production and helps AOI can be used successfully as a process monitoring create a data set for a Smart Factory. From statistical tool for measuring printing, placement, and reflow process control to instant program refinements, AI- performance. Some advantages include: powered platforms can intelligently apply real-time • Detecting and correcting SMT defects during process data to improve production processes. Going beyond monitoring is less expensive than after final test and smart factory solutions, manufacturers can use the inspection, where repairs are typically 5 to 10 times same technology to optimize the process and adjust more costly process parameters by exercising complex machine- • Detect trends in process behavior, such as learning algorithms. placement drift or incorrect mounting, earlier in the Realizing a smart factory means taking a practical overall process. Without early inspection, more boards approach to process and systems, while examining with the same defect could be rejected during functional areas to improve productivity. Combining machine test and final inspection learning with 3D measurement data generated during • Identify missing, skewed, or misplaced components inspection helps manufacturers define inefficiencies and with incorrect polarity earlier in the assembly process boost line efficiency. Machine learning uses programmed when component placement is verified before reflowing algorithms that receive and analyze input data to predict Yet, a single inspection system has limitations, especially output values within an acceptable range. As new data when there is limited or no communication with the is fed to these algorithms, they learn and optimize balance of the line. In this setup, it simply cannot their operations to improve performance, developing optimize a printed circuit board assembly (PCBA) intelligence over time. process. Equipment suppliers must cooperate to For example, some tools allow manufacturers to achieve communication for a zero-defect future. M2M simultaneously deploy programs and inspection connectivity can optimize the process by exchanging conditions across multiple lines, which enhances real-time SPI and AOI measurement data with other productivity and, more importantly, data integrity machines in the production line. This real-time feedback with consistent performance. Operators can further includes measurement data such as offset, volume, height, area, and warnings to other systems, while analyzing trends to optimize the process and identify trends. The connected systems can automatically define correlations between the processes. For instance, the PCBA industry has many studies and documentation detailing how the solder reflow process can help position surface mount components normally on the pads, even if component placement is off pad. However, the trend to shrink components to 0.3mm bumps or 0201M microchips is opening doors i40today.com 17

to explore how process controls can improve yields in An enhanced APC solution, formed of interlinking high-density placements. software modules, can actively optimize the printing Enter Advanced Process Control (APC), a proven control process by combining real-time printing information and optimization technology delivering measurable and with SPI measurement data. More advanced software sustainable improvements in production yield. Most automatically performs Design of Experiment (DOE) engineers will agree that stabilizing control loops, with intended to complete a detailed SPI result analysis underutilized or ineffective process time and strong using advanced diagnostic algorithms and noise process interactions is exceedingly difficult.  APC has filtering models, and then recommends the ideal print become a standard solution for realizing stable control parameters. processes – and quite simply – APC is the added In the testing, the software conducted an automatic value upgrade to a process automation system. APC DOE by changing the screen printing parameters. When collects and analyzes solder and component location handling two parameters, it needed 11 prints. For three data from an inspection system, and then sends the parameters (Printing Speed, Printing Pressure, and recommendations across the line to printers or mounters Separation Speed), it would require 17 prints, as was for automatic implementation, as Figure 2 shows. used in the results shown in Figure 3. The software triggers the SPI to send the information to Figure 2: Theoretical SMT Line using Advanced Process the screen printer to automatically adjust the parameters. Control Active Feedback between solder paste printer, The Max and Min values for printing pressure, printing solder paste inspection (SPI), component mounter, and speed, and separation speed can be set when adjusting automated optical inspection (AOI) systems the printer parameters as shown in Figure 4. In this hyper-competitive world, manufacturers place Once the system defined the optimum values for ever-challenging demands on process solutions. the printer parameters, ten boards were printed and Manufacturers want to monitor and adapt the process analyzed. The volume histogram and the X-bar & to achieve zero defects by accessing all the data – sigma chart of 10 boards show that the screen printer anytime, anywhere. They must also cope with shorter quality between the engineer and the KPO module is life cycles, so inspection solutions should be able to almost identical. The blue colored histogram in Figure 5 collect and analyze a large amount of data to produce represents the optimization completed by an engineer traceable results. with 25 years of intensive print process expertise. The APC PRINTER green colored histogram in the same figure represents FEEDBACK RESULTS the optimization completed autonomously by the The continued demand for software. The results are virtually identical. smaller, lighter, and smarter Other software can use multiple anomaly-detection electronic devices has algorithms to actively optimize the print process and led to an increasing use further reduce false calls. Ideally, the software will of smaller components. evolve to autonomously generate optimized models These shrinking packages and fine-tune the process parameters in real-time using force smaller aperture actual results. While the software modules would each designs and finer solder provide standalone process benefits, the combined paste, which have made power of an AI-powered software suite would ensure stencil printing a highly- the highest process reliability and production flexibility sophisticated process with without dedicated resources and expertise. This will a tremendous impact on be validated with additional testing as the features production yields. In fact, evolve and mature. 70 percent of all PCB APC MOUNTER FEEDBACK RESULTS assembly defects are With the benefits of printers communicating with primarily due to problems solder paste inspection machines known, what about directly associated with the solder printing process. Manufacturers must ensure the optimal printing paraments are consistently applied during production. Figure 3: Three printer parameters (printing speed, squeegee pressure, and separation speed) were all considered in this test run of 17 PCBs 18 An insight into Industry 4.0 January/February 2019

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mounters and automatic optical inspection? Connecting Process Control-Mounter Feedback), improves process mounters with inspection and measurement solutions repeatability by automatically adjusting component provides obvious benefits, but when integrated with placement to the paste, rather than to the pad location APC (Advanced Process Control) systems it can improve (Figure 8). Moreover, APC-MFB will identify the shift trend yields, especially in high density boards. The mounters and conduct further position correction by using true use the received data to update the placement program; 3D measurement data from the AOI system. thereby, ensuring the components are placed onto the Figure 6: Traditional Chip Placement onto Pads (before solder deposits rather than onto the substrate pads. This and after reflow) [Images courtesy of Panasonic System approach to placing components on the printed solder Solutions Company of North America – Process uses the self-alignment principle to increase production Automation or PSSNA-PA] yields and reduce defects. As shown in Figure 6, when solder is off pad due to myriad reasons and components are placed to the pre-defined placement location in the program, self-alignment is not effective. During reflow, components will shift off pad or bridge with other pads; thereby, causing rework or scrap. Alternatively, APC-controlled placements will maximize the self-alignment principle. Using APC to mount microchips onto the solder instead of the pad will increase yields and quality. Figure 7 shows a set of test results. Using this advanced communication, the 3D AOI can feed corrected mounting position values to mounters, which ensures the pick and place machines mounts the components in the correct position. This improves process repeatability by automatically adjusting Figure 4: Automatic print process data analysis by SPI Figure 7: APC-controlled Chip Placement onto Solder machine with feedback to printer (before/after reflow) [Images courtesy of Panasonic System Solutions Company of North America – Process Automation or PSSNA-PA] Connecting inspection systems with mounters can help achieve complete line communication and further enhance the value of the inspection process. For example, M2M connectivity optimizes the process by exchanging real-time measurement data between printers, SPI, mounters and AOI systems. The systems feed offset and warning data to other systems, while analyzing trends for process optimization and traceability. Combined this process provides unsurpassed performance power. Communication between equipment will improve process repeatability by automatically adjusting component placement to the solder deposit, rather than to the pad location. This advanced process further Figure 5: Advanced APC test results comparing human ...Real-time feedback (blue) and software (green) printer optimization includes measurement placements and identifying trends to make further positional corrections. data such as offset, volume, height, area, Using real data from quantitative measurements, certain and warnings to other 3D AOI system can feed correct mounting position systems, while analyzing values to component mounters and ensure components trends to optimize the are mounted in the targeted position as intended. This process and identify type of feature, also known as APC-MFB (Advanced trends. The connected systems can automatically define correlations between the processes. 20 An insight into Industry 4.0 January/February 2019

Figure 8: Example of pre-reflow 3D inspection detecting part skew, which is fed back to mounter improves microchip mounting reliability. Figure 9 charts misalignment lead to high turnover, which further dramatic improvement across five different defect types compounds the challenge. The leading industry when a manufacturer uses advanced process control organizations like IPC and SMTA are tackling the issue in production compared to a conventional placement head-on with education programs and training initiatives, approach with no communication between systems. it is not enough. While the lack of skilled labor remains Networked intelligent systems that allow real-time results a challenge, Industry 4.0 and its associated benefits will to be correlated, calculated, and visualized will become help advance the industry. Equipment suppliers need even more essential in the Smart Factory. to work diligently to accelerate M2M communication standards to help the situation. Initiatives like the IPC Connected Factory Exchange (CFX) and IPC- Hermes-9852 underpin the efforts within the industry to develop standards and create a Smart Factory. Figure 9: Post-reflow Defect Reduction Effects in an These M2M communication SMT PCBA lines using Advanced Process Control standards, guided in part by Conclusion Industry 4.0, are quickly altering The electronics industry is facing a chronic skilled the manufacturing process by employee shortage. Job hopping and employee improving metrics like first pass yield and throughput by applying autonomous process adjustments. Far beyond an automatic line changeover, this two-way communication with suppliers will allow the equipment to automatically adjust production parameters to increase board quality and lower costs by eliminating rework and scrap. As part of this mission, advanced process control with interconnected PCBA equipment will revolutionize process optimization and lay the foundation for the smart factory. www.kohyoung.com i40today.com 21

From the Lab to the Shop Floor – Industrialisation of Additive Manufacturing By Phil Hatherley, General Manager, Materials Solutions – A Siemens Business In 2006 a man had a vision for how additive manufacturing could revolutionise traditional manufacturing processes. In December 2018, and with the backing of Siemens, this business, Materials Solutions, is doing just that – taking the AM process out of the laboratory and into a fully industrialised factory. Additive manufacturing, rapid prototyping, 3D printing super alloys, steels, titanium and aluminium. This means – it has many names, but it is set to change the way complex and challenging applications are the firms focus. parts are manufactured across many sectors. From “We are there to help customers solve high end complex replacing legacy parts and components to creating problems with additive manufacturing, continued parts designed specifically to be made using AM – the Hatherley. “For example, in the power or aerospace opportunities are endless. sector, we provide products which work in the turbine Siemens began exploring additive manufacturing and combustion areas where components experience in the 1990s. As it gained more importance across extreme conditions and require tight geometrical manufacturing sectors, it looked for partnerships, tolerances.” which led to Materials Solutions, a Worcester based AM Materials Solutions still produces the Siemens gas specialist. From initial talks, the two companies formed turbine burners of its initial partnership, but it also a partnership to develop a component and process for has a much wider customer base - from aerospace, a gas turbine burner. automotive, motorsport and power generation. And, “It was a very successful partnership but there was with the connection to Siemens, there is no other concern a competitor would acquire Materials Solutions, company which can boast significant experience of so we acted fast,” says Phil Hatherley, General Manager, running AM parts as well as offering dedicated AM Materials Solutions – a Siemens business, as it is known software solutions via Siemens digital factory and today, because in 2016, Siemens took a controlling manufacture high-performance AM metal components stake. Its founder, Carl Brancher remains an active from Materials Solutions. part of the business. This fiscal year, the business will use AM technology Expertise and opportunity from design to manufacture combustion components for the Materials Solutions’ expertise lies in the selective laser Siemens designed SGT5-9000HL combined cycle melting form of AM with knowledge of nickel based gas turbine which will be used for the first time by SSE, the firm developing the new Keadby 2 power station in Lincolnshire. l From starting out in space rented from the University of Birmingham, the company has recently moved into a large, purpose-built factory in Worcester. The factory, controlled by Siemens digital factory software, houses 19 AM printers, including two of the latest four laser machines – the Renishaw RenAM 500Q and the EOS M300-4. These printers use lasers to print patterns into fine metal powder, which melts within fractions of a second and welds itself to the solidified layer beneath it. Each layer is thinner than a human hair, meaning that printing large components can take several days, but it’s a process which can be quicker than using traditional manufacturing methods because no tooling is required. However, metals that must withstand temperatures far beyond 1,000°C in a gas turbine are very difficult to melt and weld with a laser process. In the 12 years working with these challenging materials, the Materials Solutions engineers have developed world leading expertise and 22 An insight into Industry 4.0 January/February 2019

knowledge in order to get the very best product from By using this innovative method and following this relatively new technology. completion of the digital twin, it took just five days to Moreover, even if planning has been extremely precise, ‘print’ the steering box as a robust, single piece prior to severe stresses can build up within complex components post processing – something which would have been during the build process. But here too, Materials unachievable using traditional manufacturing methods. Solutions’ experts have the answer, by understanding This reverse engineering procedure would also be the necessary support structures required and relieving suitable for industrial sectors that experience bottlenecks stresses by heating in a vacuum furnace. in the supply of spare parts for old machines whose Engineers also require detailed process know-how to design drawings can no longer be found. In this manner, ensure that cracks do not form in a material even after 3D printing can be used to manufacture spare parts years of use. whenever they’re required, which eliminates the need Speed up supply chains for expensive tooling, warehousing and logistics, and One of the main benefits of AM is the freedom to makes spare part management faster and more efficient.  design components which couldn’t be manufactured End to end service traditionally. This could potentially improve the Earlier this year, Siemens put £27 million (€30 million) performance of the product, it could allow a group into Materials Solutions – a Siemens business to expand of components to be produced as one or it could be and create a new state-of-the-art additive manufacturing a prototype where the cost and timing of tooling is factory, taking a traditionally experimental laboratory prohibitive. process and turning it into a valuable industrial practice. “Additive manufacturing can provide freedom in terms There is enormous capability in the business which of design and the speed that you can get a functional offers a true end to end service, from consulting and prototype part out of a machine without the need for materials expertise to parts production, post processing, any tooling – you would not be able to do it as quickly qualification and certification. Combined with Siemens’ using traditional methods,” said Hatherley. digital processes, it is one of only a handful of companies A good example of this, and the expertise of the company who have this know-how under one roof. is a recent reverse engineering project the firm took Siemens has also strongly supported the adaption of on. It has helped bring a 100-year-old vintage Ruston- additive manufacturing with a range of its software tools Hornsby car, back to life using reverse engineering and is active in making the technology more and more and high-efficiency metals additive manufacturing, capable for designers to embrace. to recreate the car’s steering box without any original “When designers fully embrace what can be achieved technical drawings. with additive manufacturing I can see the opportunities With no design drawings, the housing had to be scanned continuing to grow, said Hatherley. “Currently we get from all sides using cameras. Before the component customers coming to us with designs and tolerances could be scanned, broken-off pieces had to be digitally based on traditional manufacture, but I anticipate a reassembled. Missing areas were then filled into the 3D new generation of designers coming to us with designs model on a computer using Siemens NX CAD software. based on additive manufacturing.” i40today.com 23

The factory will still make prototypes for its customers, of the component prior to its delivery to our customer,” but as some sectors, such as aerospace and automotive said Hatherley. look to move their AM components into production and In the past year, the number of employees at the factory are looking for high quality AM suppliers I want them has also risen from 29 to 44 with a plan to employ up to think of Materials Solutions – A Siemens Business to 25 more as part of the expansion. as being their partner of choice. “The big goal for us now is it to really get behind the Industrialisation of AM industrialisation of additive manufacturing. AM is still A few years ago, if you visited an AM facility, you would cost intensive, but by employing industrial methods to have seen perhaps one or two machines in a clean scale-up production we will be able to bring down cost environment with engineers in white coats, doing lots by having the ability to manufacture parts repeatedly in of trials. Materials Solutions will change this image a robust, industrial environment,” continued Hatherley. at Worcester by adopting more of a true industrial Customers are encouraged to visit the factory, to see how approach, using production flow and robust quality they work. In some cases, there could be opportunities systems. to redesign a component or combine it with others which What you will see is a place that has a shop floor, multiple then make AM viable. But, the team work in partnership machines working parts through various processes, and to discuss whether a traditional manufacturing method engineers making sure parts are compliant. The factory is more appropriate. will see a place that employs typical manufacturing A tag line of the company is ‘If you can dream it, we can principles such as LEAN, visual factory, Kanban areas print it’ but the reality still looks a bit more challenging. and other production techniques to improve productivity “We advise our customers based on our long-time while ensuring highest quality of the product. experience in designing for additive manufacturing and “We’ll be taking advantage of some of the software- our material and process expertise to leverage the full based tools that Siemens has to offer to help us potential of their components, Hatherley says. “Together develop a complete end-to-end process, continues with our partners within Siemens we are constantly Hatherley. “This will allow us to maximise the potential enhancing our design, materials and printing capabilities of digitalisation and create a true digital factory. to guide our customers towards AM industrialisation.” Some of the software and systems which will be Industrial strategy in action used are: • Real-time location system to track capital equipment With the UK government’s emphasis on the industrial and inventory to establish the real-time location of strategy, this factory is a true representation of what the work in progress future of manufacturing will look like. Siemens UK Chief • MindSphere cloud applications to monitor our factory Executive Officer, Jurgen Maier sums up the investment environment and equipment “For many years I’ve been a big supporter of making sure • NX software to develop manufacturing methods and Britain invests more in advanced digital manufacturing. simulate the manufacturing process This is a key part of the national Industrial Strategy trying The factory currently has 19 printers, and the investment to create more industries like this. So how brilliant is it has the potential to increase current capacity to more that we are here showing the nation that we don’t just than 50 machines as well as increasing post-processing talk about it, we do it – we’re investing and we’re creating capabilities. “By doing this we’ll have better control over the fourth industrial revolution right here in Worcester.” lead-time, quality and cost throughout the supply chain www.siemens.co.uk/worcester www.materialssolutions.co.uk 24 An insight into Industry 4.0 January/February 2019

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5G Is The Fourth Industrial Revolution By Anssi Savisalo, Director, Sitowise looks at the fundamental challenges ahead of the 5G roll-out and calls for operators and municipalities to work hand-in-hand 5G is not just another G on the mobile technology evolution path. It is the fundamental platform for the fourth industrial revolution and will become an integral part of societies and civil infrastructures, just like roads, energy and transportation. 5G opens the era of virtual, purpose-made micro different planning and investment cycles. From that networks or slices, which organically adapt to perspective, operators will find network and capacity varying customer and application needs in real-time planning truly challenging. and on-demand. For network operators, 5G will become Today, network and capacity planning and site acquisition the ultimate platform for true business innovation and are solely operator driven processes based on their own new revenue streams. business parameters such as ARPU demographics, So, what makes 5G different and why does it become population density and historic consumption patterns. a paradigm shift, not just a rollout of another G? In the 5G era, the conventional operator business A key challenge for operators is that 5G requires a parameters are complemented with long term civil completely different approach to designing networks, and public development plans, routes for self-driving managing and measuring them and assuring the quality buses, set in different evolving urban areas with mixed of service they deliver. Network planning, implementation functions such as industry, manufacturing, residential and maintenance evolves from isolated to integrated, and cultural areas, all with their diversity of stakeholders. from vertically oriented to horizontally collaborative These public development plans have to be made and from technology-driven to service-driven platform from a very long perspective. If a city plans to switch solutions. 100,000 street lights to LED bulbs in 2020, the next As 5G becomes an integral component of civil time those poles are upgraded might be in 30 years infrastructure and a key digital society enabler rather time. So, if operators want to equip those light poles than an isolated operator driven service production with a backhaul fiber, suitable energy supplies and safe platform, 5G requires a completely different approach housing for the network nodes, an open and interactive to operators’ operational model and life-cycle thinking, collaboration with cities, municipalities, utilities and starting from network planning and site acquisition. other stake holders is needed early on. Today networks are deployed into data centers, small When different stake holders with very different managed regional hub containers and in various types backgrounds and objectives share the same 5G planning of cellular sites like towers, rooftops, basements and arena, it is clear that a digital collaboration platform is maintenance rooms, all of which are isolated “territories” needed to support the dialog and planning process controlled and owned (or leased) by the operators. between the operators, cities, utilities and more. Tomorrow, network units will be found anywhere, there The platform should provide contributors that do not will be more of them and they will be small. Cell sites and necessarily have a Master’s degree in cellular technology, core network nodes will be seamlessly integrated into an easy, non-techy way to model what kind of 5G surrounding infrastructure; they will be “hidden” into light services are needed and where. Different contributors poles, bus stops and billboards. Cities, municipalities should be able to visualize 5G services with easy drag- and-drop functions in a 3D Virtual Reality space that and utilities with planning simulate an actual urban environment. An open and and investment cycles collaborative platform would keep the planning process spanning decades are interactive and all participants up to date.  going to be in charge of this “site” infrastructure. If operators are to capture the full potential of the 5G These countless, small, promise, the 5G paradigm shift must begin right from ubiquitous sites will the outset of their operational model, network planning. of course require high The 5G era must become a seamless and open joint bandwidth backhaul effort between the operators themselves, and with (often fiber) and stable municipalities and cities and other similar stakeholders energy supplies hidden in society. within the infrastructure. www.sitowise.com/digi They will be shared with other private and public stakeholders with 26 An insight into Industry 4.0 January/February 2019

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IPC–CFX A 2018 Reflective By David W. Bergman, Vice President Standards & Training, IPC – Association Connecting Electronics Industries 2018 was an extremely eventful year for IPC’s Connected Factory Exchange (CFX) initiative (IPC – 2581). While the standard was still being written a significant effort was put in place to raise awareness and build industry support for IPC-CFX - the foundation of Industry 4.0. A comprehensive website was created to build industry Demos, demos and more demos…. awareness and highlight companies that are behind the CFX demos launched in February 2018 with the first of its CFX movement. Currently more than 70 equipment kind virtual demonstration. Equipment manufacturers on providers have indicated willingness to support CFX as the IPC Apex Expo show floor published CFX messages well as multiple software providers and manufacturing from equipment in their booths. These messages were partners. The website provides an application process directed to a cloud server and from there to attendees’ for joining IPC’s CFX committee as well as an opportunity mobile phones. Over 800,000 messages were published for companies to spotlight their support. For those and delivered during APEX Expo show week and individuals/companies that want to jump in deep, a companies as individuals got their first glimpse as to resources page provides a one-hour tutorial on how to how CFX could help create the future of smart factories. write CFX messages as well as promotional videos and In June 2018, the virtual demonstration moved to case studies on successful implementations of IPC-CFX. Nürnberg Germany as part of the SMT Hybrid show. Interest continued to build in CFX, and we saw more companies and more equipment for the European debut of CFX. Once again, the demonstration was nearly flawless as show attendees could monitor the activity of equipment on the show floor of SMT Nürnberg. By September, the CFX committee was ready to gamble on building a manufacturing line and manufacture product. The team goal was to build CFX assemblies at What’s New in Electronics Show September 2018 in Birmingham UK. A manufacturing line was constructed and PCBAs were built during the WNIE show. And finally, a full-size manufacturing line was built at the LEAP show in Shenzhen China in October. Again, CFX assemblies were built on the show floor and major crowds got to experience CFX. The demonstration was highly popular. So much so that the state news media spent time interviewing IPC staff and members on the benefits of IPC-CFX. A five-minute clip made the evening news that day in China. With all of the successes, of CFX it’s sometimes difficult to remember that the standard was still being written by the committee and messages still being created and implemented. Other collaborations IPC’s CFX committee actively solicited collaboration with other industry supported open-source standards. The first opportunity considered was with the Hermes Standards Initiative. The Hermes standard initiative is a machine vendor effort to create an open source standard for line control. The participants in the Hermes initiative consider the standard to be an upgrade of previously released SMEMA standards for line control. Discussions on cooperation started in Nürnberg in June and with positive reactions from both sides, IPC and the Hermes Standard initiative discussed releasing the Hermes standard as IPC-Hermes-9852. IPC-Hermes-9852 is out for final vote with release expected in January. CFX and Hermes are already working together cooperatively. In addition, IPC staff visited the PROTEC show and met with the chairman of the JARA-1014 committee to discuss opportunities for cooperation the 1014 28 An insight into Industry 4.0 January/February 2019

committee and CFX. The JARA-1014 chairman of the working seamlessly together to deliver SMT automation committee expressed openness to discuss collaboration value. The second line will feature the wider application and recommended further meetings and presentations of IPC CFX across multiple technologies of assembly take place following the release of the version 1.0 of CFX. production, including manual processes. Both lines We’ve got your SDK feature machines from different vendors, all speaking It is quite obvious that one of the major reasons for the same language, creating demonstrable value the positive traction seen in the adoption of IPC’s CFX from machine-to-machine communication, creating a standard was the creation, donation and free availability of simple to operate, practical, smart and fully connected a CFX Software Development Kit (SDK). The SDK lowered manufacturing environment. the barrier for companies to be able to communicate from The following companies will be participating in the their native format to CFX. Once previously would have show floor production lines: been weeks of programming time was now reduced to just a few hours. The ease of implementation that Aegis Software the SDK facilitated, allowed some companies join the ASM Assembly Systems tradeshow demonstrations last minute. The donated SDK Asys was developed in a Windows environment using .net Cogiscan format. This format was determined to be too expensive Creative Electron for some applications and innovation led to companies Flexlink exploring avenues to participate in CFX. OK International Fuji wanted to incorporate CFX output into their soldering Heller hand tools but found that using .net and Windows would Keysight be prohibitively expensive. They turned to Linux as an KIC operating system and managed to incorporate CFX in Koh Young the hand tool cartridges economically. As OKI achieved Kulicke & Soffa success using Linux, other companies expressed interest. Nutek Also, companies expressed interest in working an SDK in other languages/formats including LabVIEW, Python and Node JavaScript. IPC is encouraging the development of these additional SDKs and to help the process has created a series of networking lists to encourage individuals to work together create SDKs for these other formats: [email protected]; [email protected]; CFXLabview@ ipc.org; [email protected] Industry participants can send a subscribe message to the appropriate list or subscribe through IPC’s website. Next steps OK International Pemtron Saki Test Research Vayo IPC 2591 IPC CFX currently in final ballot ending mid- In addition to the show floor production lines, IPC will January. IPC-Hermes-9852 is also in ballot closing in host an Industry 4.0 Buzz Session, “How IPC-2581 December. It is anticipated that both standards will be Enables Industry 4.0” on Wednesday, January 30. approved and released in January. The Buzz Session will feature short presentations, a And not to be left out of the manufacturing business, IPC panel discussion and opportunities for attendees to APEX Expo will feature two production lines, at which ask questions. visitors can see and experience achievements made For more information on the IPC CFX Showcase or Buzz in digital standards development over the past year. Session on Industry 4.0, visit www.ipcapexexpo.org The first line will feature both the HERMES standard and for more information on the CFX standards, visit, (IPC-Hermes-9852) and IPC’s Connected Factory www.ipc.org/Connected-Factory-Initiative. eXchange (CFX) IoT messaging standard (IPC-2591), www.ipc-CFX.org i40today.com 29

Adaptive Acceleration Holds the Key to Bringing AI from the Cloud to the Edge By Dale Hitt, Director Strategic Marketing Development at Xilinx Emerging applications for AI will depend on System-on-Chip devices with configurable acceleration to satisfy increasingly tough performance and efficiency demands. As applications such as smart security, robotics, or This could be achieved by taking advantage of user- autonomous driving rely increasingly on embedded configurable multi-core System on Chip (MPSoC) Artificial Intelligence (AI) to improve performance and devices that integrate the main application processor deliver new user experiences, inference engines hosted with a scalable programmable logic fabric containing on traditional compute platforms can struggle to meet configurable memory architecture and signal processing real-world demands within tightening constraints on suitable for variable-precision inferencing. power, latency, and physical size. They suffer from Inferencing precision rigidly defined inferencing precision, bus widths, and In conventional SoCs, performance-defining features memory that cannot be easily adapted to optimize for such as the memory structure and compute precision best speed, efficiency, and silicon area. An adaptable are fixed. The minimum is often eight bits, defined by compute platform is needed to meet the demands placed the core CPU, although the optimum precision for on embedded AI running state-of-the-art convolutional any given algorithm may be lower. An MPSoC allows neural networks (CNN). programmable logic to be optimized right down to Looking further ahead, the flexibility to adapt to more transistor level, giving freedom to vary the inferencing advanced neural networks is a prime concern. CNNs precision down to as little as 1-bit if necessary. These that are popular today are being superseded by new devices also contain many thousands of configurable state-of-the-art architectures at an accelerating pace. DSP slices to handle multiply-accumulate (MAC) However, traditional SoCs must be designed using computations efficiently. knowledge of current neural network architectures, The freedom to optimize the inferencing precision so targeting deployment typically about three years in the exactly yields compute efficiency in accordance with future, from the time development starts. New types of a square-law: a single-bit operation executed in a 1-bit neural networks such as RNNs or Capsule Networks core ultimately imposes only 1/64 of the logic needed are likely to render traditional SoCs inefficient and to complete the same operation in an 8-bit core. incapable of delivering the performance required to Moreover, the MPSoC allows the inferencing precision remain competitive. to be optimized differently for each layer of the neural If embedded AI is to satisfy end-user expectations, and network to deliver the required performance with the – perhaps more importantly – keep pace as demands maximum possible efficiency. continue to evolve in the foreseeable future, a more Memory Architecture flexible and adaptive compute platform is needed. As well as improving compute efficiency by varying inferencing precision, configuring both the bandwidth and structure of programmable on-chip memories can further enhance the performance and efficiency of embedded AIs. A customized MPSoC can have more than four times the on-chip memory, and six times the memory-interface bandwidth of a conventional compute platform running the same inference engine. The configurability of the memory allows users to reduce bottlenecks and optimize utilization of the chip’s resources. In addition, a typical subsystem has only limited cache integrated on-chip and must interact frequently with off-chip storage, which adds to latency and power consumption. In an MPSoC, most memory exchanges can occur on-chip, which is not only faster but also saves over 99% of the power consumed by off-chip memory interactions. 30 An insight into Industry 4.0 January/February 2019

Connected Factory bringing electronics to life lectronics.net i40today.com 31

Silicon Area performance, increased efficiency, and size/weight Solution size is also becoming an increasingly important advantages at power levels above 15W, too. consideration, especially for mobile AI on-board drones, The advantages of such a configurable, multi-parallel robots, or autonomous/self-driving vehicles. The compute architecture would be of academic interest inference engine implemented in the FPGA fabric of only, were developers unable to apply them easily in an MPSoC can occupy as little as one-eighth of the their own projects. Success depends on suitable tools silicon area of a conventional SoC, allowing developers to help developers optimize the implementation of to build more powerful engines within smaller devices. their target inference engine. To meet this need, Xilinx Moreover, MPSoC device families can offer designers continues to extend its ecosystem of development tools a variety of choices to implement the inference engine and machine-learning software stacks, and working in the most power-, cost-, and size-efficient option with specialist partners to simplify and accelerate capable of meeting system performance requirements. implementation of applications such as computer vision There are also automotive-qualified parts with hardware and video surveillance. functional-safety features certified according to industry- Flexibility for the Future standard ISO 26262 ASIL-C safety specifications, which is very important for autonomous-driving applications. Leveraging the SoC’s configurability to create an An example is Xilinx’s Automotive XA Zynq UltraScale+ optimal platform for an application at hand also gives family, which contains a 64-bit quad-core ARM® AI developers flexibility to keep pace with the rapid Cortex™-A53 and dual-core ARM Cortex-R5 based evolution of neural network architectures. The potential processing system alongside the scalable programmable for the industry to migrate to new types of neural logic fabric, giving the opportunity to consolidate control networks represents a significant risk for platform processing, machine-learning algorithms, and safety developers. The reconfigurable MPSoC gives developers circuits with fault tolerance in a single chip. flexibility to respond to changes in the way neural Today, an embedded inference engine can be networks are architected, by reconfiguring to build the implemented in a single MPSoC device, and consume most efficient processing engine using any contemporary as little as 2 Watts, which is a suitable power budget for state-of-the-art strategy. applications such as mobile robotics or autonomous More and more, AI is being embedded in equipment driving. Conventional compute platforms cannot run such as industrial controls, medical devices, security real-time CNN applications at these power levels systems, robotics and autonomous vehicles. Adaptive even now, and are unlikely to be able to satisfy the acceleration leveraging programmable logic fabric increasingly stringent demands for faster response and MPSoC devices holds the key to delivering the more sophisticated functionality within more challenging responsive and advanced functionality required to power constraints in the future. Platforms based on remain competitive. programmable MPSoCs can provide greater compute www.xilinx.com 32 An insight into Industry 4.0 January/February 2019

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Yamaha Pitches Advanced M2M connectivity Concept By Ms Oumayma Grad, Marketing Communications Manager, Yamaha Motor Europe, NV The 1 STOP SOLUTION method links the company’s smart production machines and software to overcome limitation in information sharing in an advanced M2M environment. In recent years, the proliferation of high-speed Yamaha Motor has taken this trend in a timely manner, communications infrastructure and the reduction of and developed “Intelligent Factory,” an Internet of Things communications and storage costs have been advancing (IoT)/machine-to-machine (M2M) integration system (Fig. rapidly. Against this backdrop, the trend of the fourth 1) using the latest technologies. For the introduction industrial revolution, typified by Industrie 4.0, has spread of Intelligent Factory, Yamaha Motor is proposing a explosively, and the momentum of investments in related practical four-step process (Fig. 2). First, in Steps 1 technologies has been building globally. and 2, the company focuses on and actively proposes the automation and labor saving of the surface-mount Fig. 1: Intelligent Factory outline technology (SMT) line based on the M2M connectivity. In this process, Yamaha has made possible mutual cooperation, not only among Yamaha’s SMT machines, but also with other companies’ machines. In fact the company already has a track record of installing that kind of numerous production lines. As a practical problem involving M2M linkages among machines of different manufacturers with various development concepts and business scales, there is a significant amount of proprietary information that cannot be mutually disclosed. Therefore, information sharing is virtually limited to standard basic information, such as board IDs and bad marks. In addition, it is considerably difficult for manufacturers with different resources and situations to simultaneously develop software for mutual cooperation. Hence, naturally, there is a limit to the synergetic effects that can be attained through cooperation. 1 STOP SOLUTION Fig. 2: Steps to the introduction of Intelligent Factory To achieve advanced M2M connectivity that overcomes the said limits, Yamaha Motor vigorously promotes “1 STOP SOLUTION,” the company’s original concept. It solely uses Yamaha products to link intelligent SMT machines and software to maximize synergetic effects. Yamaha Motor already has a full lineup of main machines on a mounting line: surface mount device (SMD) storage systems, printers, dispensers, screen printing inspection 34 An insight into Industry 4.0 Delivery of components from the SMD storage system and transfer using AGV January/February 2019

Fig. 3: An example of 1 STOP SOLUTION Yamaha line (SPI) machines, mounters, and automated optical 6) Feedback of defect information and instruction of inspection (AOI) systems. Connecting each machine on stop command from AOI to mounter prevents the a mounting line comprising of these Yamaha products mounter from continuing to produce defective PCBs through advanced M2M connectivity without a black (Fig. 6); 7) SPI image of mounting defect found by AOI box in an “Intelligent Factory” maximizes the effects of is instantaneously displayed, and at the same time, all mutual cooperation of machines and software. Thus, it related images, such as those of printer and mounter are becomes possible to achieve a highly efficient mounting shown to speedily determine the cause of defect (Fig. 7). line through true total management. Future Efforts Figure 3 shows an example of a full Yamaha SMT line through “1 STOP SOLUTION.” Some functions through Based on the examples given above, advanced M2M M2M connectivity between machines, include 1) Transfer through “1 STOP SOLUTION” enables a variety of of instructions from the production plan, or board ID mutual cooperation functions, and results to reductions information read by the machine at the start, among of work time, labor and human errors and improvement machines enables production switchover and automatic of quality through speedy implementation of defect setup changes on the total line without requiring special countermeasures, thereby bringing out potential skills; 2) Upon the receipt of information on production capabilities of the whole mounting line and improving switchover, components are delivered from the SMD efficiency as a whole. storage system and transferred to arbitrary setup changeover locations specified through the linkage Aside from the above-described examples, Yamaha using the automated guided vehicle (AGV) to reduce Motor also provides various mutual cooperation the burden on the worker (Photo 1); 3) Feedback of functions unique to Yamaha machines connectivity. print position from SPI to solder paste printer ensures In addition, Yamaha is determined to develop further stable print position accuracy (Fig. 4); 4) Feed-forward advanced connectivity functions in stages to improve of bad mark from SPI to mounter reduces takt time overall efficiency of SMT factories. loss (Fig. 5); 5) Components that are needed to be www.yamaha-motor-im.eu supplied are notified from the mounter to the SMD storage system at the necessary timing in order of precedence to automatically deliver the necessary amounts of components and supply them at a time; Fig 4: Feedback of print position from instruction of SPI to printer Fig. 5: Feed-forward of bad mark from SPI to mounter Fig. 6: Feedback of defect information and stop command from Fig. 7: Display of SPI image found by AOI AOI to mounter i40today.com 35

Convection Soldering Systems in the Age of Industry 4.0 Smart Reflow Permits Predictive Maintenance By Paul Wild, Hans Bell, Lukas Ziegler, Rehm Thermal Systems GmbH Introduction – Today and Tomorrow Figure 1: Number of Sensors A number of years have passed since the term Industry Based on the example of a convection soldering Used in the Vision Soldering 4.0 was first coined by the German Federal Government system, this article demonstrates what modern smart System, 2008 through 2017 at the 2011 Hannover trade fair, and in the meantime sensors and intelligent systems are capable of with the associated vision, as well as the research agenda, regard to monitoring the condition of soldering system are characterized by increased clarity and have taken components, and how this additional information can a distinct direction. Association work conducted by the contribute to predictive maintenance. VDMA, Bikom and ZVEI has also had a very positive As shown in figure 1 using the VisionX convection effect. Industry 4.0 and the Internet of Things involve soldering system as an example, more and more new a pioneering alignment of the modern manufacturing sensors are becoming necessary in particular for the world, as well as networking of production equipment optimization of maintenance intervals, for more precise such as machines, devices and sensors with each other process timing, and for monitoring and controlling the and with internal and worldwide information systems. consumption of resources. Goals include greater flexibility, an increased degree Already today, reflow soldering systems are optimized of automation and capabilities which permit self- to a great extent with regard to their (isolated) control optimization of manufacturing processes, and at the functions, as well as their energy consumption, same time reduced investment and R&D expenditures, sustainability and manufacturing efficiency. They can as well as minimized consumption of resources. In be linked with a production line monitoring system which order to map out the actual manufacturing sequences forwards data to a manufacturing execution system of an intelligent digital factory, all essential process data (MES) and to enterprise resource planning (ERP). The has to be acquired and evaluated with suitable sensor software used in reflow soldering systems permits technology and software. traceability concepts by means of which process data, system status, alarms and other information can be transmitted. Communication with the manufacturing world is also viable, for example via a mobile production- line assistant system such as ASYS PULSE Line Assist which makes it possible to monitor an entire SMD production line using a tablet or a smartwatch, is capable of controlling handling modules and even permits self- organizing material logistics with autonomous transport robots (see figure 2). Table 1 compares current and future options for incorporation into information systems. Table 1: Incorporation of Reflow Soldering Systems into Information Systems TODAY TOMORROW The reflow soldering system is linked to the The reflow soldering system communicates with the entire production line control system manufacturing world The reflow soldering system is linked to The reflow soldering system communicates with the product – MES and ERP knowledge concerning what is to be produced and how Traceability concept (transmission of machine Reflow soldering systems possess forward-looking intelligence and process data) and can autonomously optimize reflow processes 36 An insight into Industry 4.0 January/February 2019

of pyrolysis, replacing the absorber granulate once a year is entirely adequate. Where cold condensation is concerned, maintenance intervals fluctuate greatly depending on process characteristics. The condition of both systems is continuously monitored by installing pressure monitoring sensors (see figure 3) at the pyrolysis unit and the cold condensation tract, and the system operator is informed of any pending maintenance requirements. Availability of the soldering system can be increased and operating costs can be reduced thanks to forward-looking intelligence integrated into the separator systems. Figure 2: Incorporation of the Reflow Soldering System Vibration Monitoring into a Mobile Line Assist System As indicated by the measurement results shown in figure In order to continue development of data exchange with 4, contamination of the overall reflow soldering system the reflow soldering system towards the evolution of a is never homogeneously distributed throughout the cyber-physical system, new smart sensors and software entire process. Concentration of volatile hydrocarbons components will be required which are capable of is higher in preheating at process temperatures of 150 communicating via a data infrastructure with numerous to 200° C than it is in the peak zone and the cooling mechanical and electronic system elements, as well tract. Contamination of the conveyor system can as with the product to be produced. Step by step, this thus not be ruled out, even if it functions very well. vision is being transformed into reality. If this contamination exceeds a tolerable level, the Predictive Maintenance conveyor chains may begin to vibrate and, in unfavorable cases, vibration can be carried over to the PCBs to be Today, maintenance work is conducted primarily at specified time intervals. The duration of these intervals depends on the manufacturer’s system-specific recommendations and process circumstances such as the number of shifts and system utilization. With regard to the pursuit of the defined goals of the intelligent factory such as increased flexibility and self-optimization of the manufacturing process, time-based maintenance is too rigid and insufficiently cost-optimized. Additional smart sensors are required in the reflow soldering system in order to make the transition to condition-based servicing in the sense of predictive maintenance. Pressure Monitoring For many years now, reflow soldering systems included Figure 4: Concentration of Volatile Hydrocarbons in a VisionXP for Lead-Free Processes in Rehm Thermal Systems’ VisionX series have been equipped with two time-tested residue management soldered thus impairing positioning of the components. systems: pyrolysis in the preheating zone, as well An intelligent chain lubricating system which doses as cold condensation and filtering in the cooling oil depending on the soldering system’s process zone. And thus residues in all states of aggregation – temperature can contribute to a significant increase in gaseous, liquid, solid (particulate) and crystalline – are the intervals between required maintenance. effectively and energy-efficiently absorbed from the Monitoring of system vibration can also be advantageous. process atmosphere. Deposited residues are initially There are two ways in which vibration data can collected within the system and finally removed during maintenance procedures. Experience gained with more be used. On the one hand, than a thousand system demonstrates that in the case observing existing oscillation at the conveyor level serves the purpose of quality control for the manufacturing process. On the other hand, further potential sources of vibration within the system, for example components with moving parts such as motors, fans and pumps, can be monitored as well. This concept involving condition monitoring of machine components allows us to draw conclusions concerning their operating statuses, thus making predictive maintenance possible. Figure 3: Condition Monitoring of the Pyrolysis Unit (left) and the Cold Figure 5 shows the sensor Figure 5: Vibration Monitoring for the Condensation Cooling Tract (right) for monitoring vibration in the Conveyor System of a Convection conveyor system of a VisionXP+ Soldering System vacuum reflow soldering system. Any wear of, or interference with i40today.com 37

Figure 6: Measured Vibration Values for Conveyor Monitoring Rehm Thermal Systems’ in a VisionXP+ Vac Convection Soldering Oven VisionX series have been equipped with Figure 7a: Fan in Undisturbed Normal Operation two time-tested Figure 7b: Out-of-Balance Fan residue management 38 An insight into Industry 4.0 systems: pyrolysis in the preheating zone, as well as cold condensation and filtering in the cooling zone. the mechanical system which occurs during production is detected and evaluated. As a result, the operator has enough time to plan and implement suitable action before it’s too late and the system comes to a standstill. The example in figure 6 shows numerous vibration values measured in conveyor direction over a period of time. The maximum value in the diagram is 27 mg which is non-critical for the production conditions of a reflow soldering process. An evaluation of the vibration frequency spectrum is better suited for monitoring system components. The frequency spectrum of a fan depicted as an example in figure 7a (vibration sensor in X direction) demonstrates a small peak with an amplitude of 7 mg at a fan frequency of 35 Hz in undisturbed normal operation. Amplitude is increased to roughly 150 mg when the fan is out-of-balance. Smart Motors A new generation of motors known as electronically commutated motors (abbreviated EC motors) permits direct communication with the motor system for the first time in the history of motor technology. Not only is direct digital control of the motor possible: the motor can now supply data concerning it’s operating status to the reflow soldering system’s information system as well. More than 60 different parameters permit comprehensive monitoring of the motor’s operating status and thus make it possible to detect problems in advance. Figure 8 illustrates monitoring of IGBT temperatures at two motors. Motor 2 has already exceeded the permissible limit value temperature. This information triggers, for example, a warning in the system software and a corresponding display, which in turn results in various measures. Summary When reflow soldering systems are equipped with smart sensors, system components can be monitored intelligently, thus making it possible to detect problems in advance. This permits predictive maintenance and contributes to increased systems availability and minimized operating costs. Some smart sensors, e.g. those used for vibration monitoring, also contribute to quality assurance for the products produced in the system. www.rehm-group.com January/February 2019

DATES TO BE CONFIRMED Join the i4.0 Connect Forum 2019 i40connectforum.com Partners leading the Industry 4.0 movement i40today.com 39

CONNECT FORUM First i-Connect Forum in cooperation with Held In San Jose - and Great Success! IPC and i4.0 Today By i4.0 Today Editor successfully rolled out the first of the i4.0 Connect Forum seminars on November 6th & 7th 2018, in San Jose, CA. KEITH BRYANT SIMON FRIED DR. DONGKAI SHANGGUAN YXLON NANO INTERNATIONAL DIMENSIONS FLEX “Industry 4.0 For “Precision Additive “Our journey towards Inspection” Manufacturing” Industry 4.0” TBHUOCHRSTTAEN BMOIKBLOSEY HALAUSRSAAINBI SIEMENS AEGIS FLEX SOFTWARE “Digital Enterprise “Our Journey Suite for Electronics “Digital Twin in Towards i4.0” Industry” Production” 40 An insight into Industry 4.0 January/February 2019

The event, which is the first in a series of seminars A full listing of speakers and topics are listed, along with taking place throughout Europe and USA for now, a selection of photographs from both days. was well attended by a high profile of professionals http://i40today.com/i40-connect-forum/ from the electronics industry. The attendees came together to hear first-hand experiences, challenges and The next event is currently solutions our industry leaders have taken to achieve being scheduled for Eastern smart manufacturing. Europe, in June 2019. The event was MC’d by Mr Dave Bergman from IPC, and the first day kicked off with Keynote Speaker, Mr Stay tuned for full details to be Thorsten Buchta, Head of Vertical Sales, Siemens released at IPC APEX 2019. presenting on “Digital Enterprise Suite for Electronics Industry”. DAVID ROGERS DAVID SUH NHGOUAYEN SIEMENS KOH YOUNG OK AMERICA, INC. INTERNATIONAL “Digital Twin in Production” “Data-driven Analytics to “Industry 4.0 Enable a Smart Factory” IPC-CFX” JSACSIBOENRRAS MB ALLEN BDEARVGIDMAN SALINE LECTRONICS KIC IPC “The smart “Let’s Get Started” “IoT2: IPC-CFX factory journey” Standards Update for Industry 4.0” i40today.com 41

Manufacturing Agility, Evolved. Adaptive, modular FactoryLogix, a uniquely adaptive manufacturing execution MES, built for an and operations solution, drives enterprise-wide compliance, Industry 4.0 world. quality, and efficiency. Designed for today’s manufacturing reality, it connects business-critical systems, processes, and people— unleashing the transformative benefits of Industry 4.0. Delivering Industry 4.0 Benefits Reduce Costs | Increase Revenues | Optimize Quality Achieve Compliance Requirements | Improve Customer Satisfaction Holistic. Modular. Adaptive. Proven. • Digital Manufacturing Engineering (DME) • Quality Management System (QMS) • Manufacturing Process Execution (MES) • RMA/MRO - Returns & Overhaul • Lean Materials Management (WMS) • Industrial Internet of Things (IIoT) • Adaptive Planning • Active Rules Engine • Manufacturing Intelligence • Regulatory & Customer Compliance 42 An insight into Industry 4.0 Learn more at www.aiscorp.com January/February 2019

YOUR TEST AND INSPECTION PARTNER Automated SMT Inspection for the Connected Factory Smart Factory Inspection Made Easy Unleash the Potential of your Production Line with TRI’s Total SMT Inspection Solutions. 3D AOI 3D SPI 3D CT AXI ICT/FCT Printer Pick & Place Re ow Oven Insertion & Wave Soldering Partners Visit Us at Jan. 29 31, 2019, San Diego, CA, U.S.A. Booth # Test Research USA, Inc. www.tri.com.tw 832 Jury Court, Suite 4, San Jose, CA 95112 Tel. +1-408-567-9898 Email: [email protected] All other trademarks are the property of their respective owners. i40today.com 43

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