Ericsson automation and. automation and design for. design for manufacturing. Manufacturing at Ericsson Tallinn WINTER SCHOOL

Transcription

1 Ericsson automation and automation and design for design for manufacturing Manufacturing at Ericsson Tallinn WINTER SCHOOL

2 Agenda Ericsson company, Tallinn Factory, products and production processes introduction Automation study - Workshop 1 Design for Manufacturing - Exercise Pre-developments and trials in lab Key takes away Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 2

3 This is Ericsson Presentation for Winter School in TTU

4 1980 s 1990 s 2000 s Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 4

5 Ericsson at a glance NETWORKS Create one network for a million different needs IT Transform IT to accelerate business agility MEDIA Delight the TV consumer every day INDUSTRIES Connect industries to accelerate performance 42,000 Patents 1 billion Subscribers managed by us 222,6 B. SEK Net Sales 24,100 R&D Employees 2.5 billion Subscribers supported by us 180 Countries with customers 31,6 B. SEK In R&D 62,400 Services professionals 111,000 Employees Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 5

6 Ericsson Supply Tallinn

7 Ericsson supply in Tallinn Acquired 2009 Volume production and R&D related activities Today Supply Multisite Latest mobile technology produced (LTE, 5G) 11 BSEK turnover, 10% of Estonia export 2100 employees: 40 nationalities, 24/7 operations 125 NPI runs in Month part# with saldo Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 7

8 Production AREAS Module Production Center SMA lines Radio & Digital Final Assembly and Test Make to Stock Node Production Center Assembly lines Indoor RBS Outdoor RBS Main remote Make to Order Upgrade and Expansion Pick and Pack (Low touch/high Touch) SW download Pick and Pack to order Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 8

9 Logistics in Tallinn mzn jkkj Ericsson Inbound WH jkk kkkll jkkj jkkj Inbound WH Outbound WH jkk Airport Harbour Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 9

10 Business compliance ISO 9001:2008 (Quality Management System) ISO 14001:2004 (Environmental Management System) OHSAS 18001:2007 (Occupational Health and Safety Management System) AEO (Authorized Economical Operators) C-TPAT (Customs-Trade Partnership Against Terrorism) Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 10

11 Production process

12 PRODUCTION TECHNOLOGY what is inside Sma Paste Printing Solder Paste Inspection Dispensing Pick & Place Assembling xray inspection Offline Automated Optical Inspection Reflow oven Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 12

13 PRODUCTION TECHNOLOGY what is inside Production Line Set Up TRX assembly Flip&Marry Test area Pre-troubleshooting Final Assembly PA assembly Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 13

14 A E Est smart factory D B Machine Intelligence Connectivity Shop floor WH SMA FA Pack NOW AUTOMATION 2020 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 14

15 Line Automation Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 15

16 Functionality Outcome of the workshop Line concepts Functionality How many products does it support? Scalability In case of % demand increase Scalability Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 16

17 Assembly line evaluation criteria's Capacity pcs per month Functionality - How many products does it support? Scalability What will happen in case of % demand increase? Flexibility What will happen if design of the product will slightly change? Existing equipment reuse dispenser, SMA equipment, screwing robots in-house line reconfiguration can we change something by ourselves? Cost of the line Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 17

18 Map the processes Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 18

19 Map the processes Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 19

20 #1 Platform specific line Dispensing Platform specific Automated assembly and screwdriver Test Platform specific Automated Final assembly Very high output and resource utilization Less space needed Platform dedicated In case of demand drop custom equipment may be scrapped Work in progress ~35-50pcs Incoming material buffer size in production sets Incoming material needs preparation e.g. loading to trays Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 20

21 #2 Conveyor line with generic equipment Dispensing ROA Assembly Front panel press Cover/USB assembly Automated screwdriver Test Dust plug assembly PTC lid assembly Labels placement Standard equipment / COTS High output Same machines can be used in different lines More floor space and equipment to maintain Work in progress 50+pcs Incoming material buffer size in production sets Incoming material needs preparation e.g. loading to trays Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 21

22 #3 Flexible line with 6-axis robots Dispensing Assembly Screwdriver Test Dust plugs assembly PTC lid More flexible than previous versions Assembly operations done by 6-axis robots and COTS machines Medium output Equipment can be reused Work in progress ~35-50pcs Incoming material buffer size in production sets Incoming material needs less preparation e.g. Robots can pick them from supplier package Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 22

23 #4 Flexible cell with 6-axis robot Dispensing app Gripper Screwdriver Assembly Unit Very flexible Easier and shorter for new product introduction No need for other equipment Low output, throughput time = cycle time Small incoming material buffer in product (2 sets) Incoming material needs less preparation e.g. Robots can pick them from supplier package Constant application changeover Requires biggest factory transformation Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 23

24 5. Flexible automated line via matrix layout Perform one action only, but with different parameters, e.g. screwing different types of screws with different torqs at different locations, depending on final product, etc. Node A Node B Output Product Input PCB Node C Node D Perform one action only, but with different parameters, e.g. taking and placing a cover on top, etc. Perform one action only, but with different parameters, e.g. Taking and puting PCB into the bottom cover, etc. Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 24

25 Node A Node B Node C Node D Node E Node F Node G Node H Output Product Input PCB Node I Node J Node K Node L Node M Node N Node O Node P Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 25

26 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page Modular automation

27 Inbound material Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 27

28 Workshop 1 Capacity pcs annually Functionality Supports 3 different products Scalability % demand change Flexibility design is not frozen, possible changes Throughput time 1 hour Cost Most optimal Platform specific line Conveyor line with generic equipment Flexible line with 6-axis robots Flexible CELL with 6-axis robots Node concept Modular automation Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 28

29 Risks and challenges RFQ ~20% Defines technology level Defines common line setup Defines optimal technical requirements and limitations Minimizes rework need DFA ~40% Minimizes number of need operations and equipment needs Simplifies the operation requirements Defines the required technology level Optimal cost SFA ~20% Long term purchasing agreements for key components (PLC, robots, applications, etc.) LTR ~20% Long term cooperation with chosen integrators R&R and smaller NRE Better pricing for E/// Cost risks Total cost of ownership becomes too high because of not complete standardization Investment cost is too high because of not finalized sourcing agreements and technical requirements Minimum production volume requirements Time risks Dependencies on external inputs (MES Compass, sourcing, etc.) Resource conflicts with other projects Quality risk Major rework because of requirements changes or not understanding the requirements. Lack of alignment between stakeholders and platform owners Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 29

30 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 30

31 EST GARAGE #1 A E in Radio D B DESIGN SUPPLY Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 31

32 Justification Now: Design of product Production Automated assembly, design+deployment Time We do not know exactly what we need from product for automated assembly, lead time for assembly line, precise cost estimations. At the point, when we can say what we actually need, it s usually too late to change design. Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 32

33 Justification Possible option: Current set of working solutions and corresponding requirements Design of product Adjustment of existing solutions Deployment Production Continuous development of automated solutions Time When design of product starts, we can already have tested automated solutions with defined requirements, as well as more precise cost for them (and shorter lead time, as majority of design work is already done for solution). This way it is far easier for design to implement needed features from the beginning of project (and keep them throughout project). Moreover we don t stop further development of solutions, making them more efficient, cheaper and having less requirements on design of product. Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 33

34 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 34 DFM-FA principles and findings Example

35 Variance of screws Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 35

36 Avoid preliminary assembling Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 36

37 Rounded guiding pins Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 37

38 Can we dispense gasket? Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 38

39 Chamfer of the vent hole must less than the radius of O-ring Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 39

40 Ability to scan board label after EMC cover assembled Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 40

41 Screws tightened from top side to get rid of unnecessary flipping of the product. Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 41

42 Guiding features Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 42

43 Bulkhead positioning and guiding Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 43

44 Work with supplier to achieve required tolerances Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 44

45 Find the caps suitable for automation Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 45

46 Make marking for not symetrical components Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 46

47 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 47 developments

48 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 48 Developments

49 KEY TAKEs AWAY Automated line main criteria: Capacity, Functionality, Scalability, Flexibility, Cost Automated line concepts: Platform specific line, Conveyor line with specific equipment, Flexible line with 6 axis robots, Flexible cell with 6 axis robots, Node concept, Modular automation. Design for manufacturing: It shall be possible to build all products within the same mechanical platform in the same FA process. One direction assembly (Sandwich assembly), good chamfers on guiding pins, areas for grippers, avoid preliminary assembling of components, few variance of screws. Exciting development projects! Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 49

50 Ericsson Supply Site Tallinn Ericsson Internal EEE-12: Uen, Rev AH Page 50