TME is Helping Dynalab Stay on “Track” with Traceability

TME is Helping Dynalab Stay on “Track” with Traceability

Background

An industry leader in the assembly of multi-technology circuit boards, cables, and electro-mechanical products. Based in Ohio, the organization has been providing electronic manufacturing services (EMS) since 1981. The company offers complete “turn-key” services, including wire harness/cable construction and electromechanical assembly, to customers who specialize in industrial controls, precision instruments, energy, healthcare, military and telecommunications industries.

The company operates a 100,000 square feet manufacturing facility located in Columbus, Ohio.

Challenge

The organization was seeking a comprehensive MES solution that was capable of capturing and analyzing all data related to the high speed board assembly process. Due to customer demand and strict industry regulations, they needed a system could provide work in process (WIP) tracking, quality control and component traceability to support their customer expectations and the company’s drive to deliver high quality products with shorter time-to-market. The company also required a flexible MES system that could support custom features and interfaces.

“Our challenge was to identify a solution capable of handling a high speed board assembly process and the large amount of automated test data required by the customer. We had to balance the benefits of obtaining a fully supported, commercially available MES product against developing the custom features and equipment interfaces required by our customer. We found the perfect solution with TME MES from MASS Group.”

– General Manager of the organization

Solution

MASS Group developed a comprehensive traceability solution by integrating TME MES software with barcode technology.

Today, the company tracks the production of PC boards via fixed-mount scanners that are tied to serial terminals. Scanners collect data from the PC boards as they move along on the conveyor belt. Test data is dumped directly into a buffer and TME MES processes the test data prior to allowing the board to go to shipping.

MASS Group assisted them in configuring TME MES to collect data from their various and proprietary equipment types. The detailed steps of the manufacturing operation are tracked, including the serial number and lot of each component used in the final product. The work flow is controlled through automatic and manual operations across 15 types of equipment, including surface mount part placements, wave solder, reflow and drying ovens. The equipment and functional and final tests are all integrated directly with the MES.

Inventory consumption information is captured directly from various equipment types at each production step to allow complete genealogy tracking for a finished product. At no time is the workflow interrupted during data processing. If the information is still in the buffer, data verification is made directly from the buffer instead of waiting for all the information to process. During packaging, the PC boards are scanned with a PDA to verify that they’ve made it completely through quality control before they are allowed to be placed in a box.

Results

With TME MES the company can track the entire manufacturing process, from the receipt of component inventory to the packaging and shipment of orders. Most importantly, they can quickly and easily customize TME MES to read and collect the test data from their specific equipment types resulting in:

  • Improved overall quality
  • Shorter cycle times
  • Increased scheduling flexibility
  • Reduction in overall costs

“TME MES has worked very well in enabling us to meet our external customer’s reporting requirements. It is another example of how our continuous improvement efforts have yielded significant results allowing for the increased scheduling flexibility, shorter cycle times, and lower costs that will allow us to compete in the growing worldwide Electronics Manufacturing Services arena.”

– President of the organization