Production for Chip Mounters
Production sites for chip mounters
Chip mounters are manufactured at JUKI INDUSTRIAL EQUIPMENT TECHNOLOGY CORPORATION, the mother factory for electronics assembly & systems.
Chip mounters must run at high speeds and maintain high reliability over uninterrupted 24-hour production cycles, employing structures and controls for the micron-level positioning of extremely small electronic components.
JUKI achieves low-cost and quick delivery by producing parts such as electronic circuit boards, harnesses, precision machined parts, and sheet metal in its own factories.
Production management
JUKI INDUSTRIAL EQUIPMENT TECHNOLOGY CORPORATION divides its roles among three factories in Akita Prefecture. The progress of processes (total assembly, sub-unit assembly, electronic circuit boards, harnesses, sheet metal parts, precision machined parts, parts shipping and distribution) is synchronized at the three factories according to an overarching production plan. The resulting system produces only the “necessary quantity,” just when it is needed. The visualization systems in place to control production allow the line managers to grasp any process stagnation or delays at a glance.
How a chip mounter is completed
1Parts machining
By processing the key chip mounter parts such as electronic circuit boards (PCBs), harnesses, sheet metal parts, and precision machined parts in-house, we can produce them just-in-time.
- The electronic circuit boards (PCBs) are manufactured in our own factory using JUKI’s latest chip mounters. Multiple inspection machines are deployed on the line to ensure quality.
- For sheet metal parts machining, we provide an integrated sheet metal process that handles the punching, bending, welding, and painting. The welding is performed with the latest laser welding equipment. In the near future we will be further reducing labor and lead times by deploying in-house finishing robots to handle previously manual finishing processes.
- For precision parts machining, we have several multi-pallet 5-axis machining centers that enable the unmanned machining of high-precision parts. We are also working to reduce labor and lead times by replacing manual finishing work with in-house finishing robots.
2Assembly
The parts are supplied to the assembly process on a just-in-time basis in exactly the number required, as specified in the production plan. The parts are requested in a “call-out kanban system” and transported to each process by AGV. The transported parts are completed just when the total assembly of the next sub-unit begins.
In the total assembly process, the sub-units are assembled to the base frame with the required mounting accuracy.
To achieve high-speed, high-precision placement of components, micron-level mounting accuracy is required for both total assembly and sub-units. Meantime, we are enhancing productivity by upgrading our jigs, tools, and equipment to meet the labor and lead time requirements.
3Parameter setting and inspection
After total assembly, the chip mounter is completed by setting the various parameters according to the specifications.
In the process of checking placement accuracy, the level of finished product quality is checked by actually placing electronic components on a measurement jig board and measuring the placement accuracy with a three-dimensional measuring machine.
4Packing and shipping
The finished products are packed in the factory and shipped. Depending on the shipping destination, the products are loaded into containers in the factory before shipment.
