regional center europe, middle east, africa veldhoven, the ... - icco · therefore iflex is the...

Do more, better

ASIA-PACIFIC

Assembléon Asia Ltd.

T: + 852 2167 1000

EUROPE

Assembléon Netherlands B.V.

T: +31 40 272 3000

THE AMERICAS

Assembléon America, Inc.

T: +1 770 751 4420

assembleon.com

© Assembléon 2013. All rights are reserved. Reproduction in whole or in part is prohibited without the prior written consent of the copyright owner. The information presented in this document does not form part of any quotation or contract, is believed to be accurate and reliable and maybe changed without notice. No liability will be accepted by the publisher for any consequence of its use. Publication thereof does not convey nor imply any license under patent or other industrial or intellectual property rights. Date of release: June 2013 9498 389 0076.1

Regional Center Europe, Middle East, AfricaAssembléon HeadquartersVeldhoven, The NetherlandsVeldhoven, The Netherlands

With below 1 defect per million placements (dpm),

iFlex sets the industry quality standard for ultra-

repeatable production. iFlex uses Assembléon’s

established and recognized single-pick/single-place

action which is the only key to providing best quality in

placement, and adds flexible production. That fulfills

the need of the industry’s trend towards high-mix

production, with increasing customization leading

to greater product variety. iFlex virtually eliminates

product change-over times to maintain maximum

throughput whatever is on the line. iFlex is a complete

series of machines in one. Three basic pick & place

modules can be configured in any combination to meet

all production needs and volumes efficiently.

With iFlex, too, low reject levels prevent costly rework

stations and spoiled boards, to minimize the real costs

of production. Therefore iFlex is the ideal solution for

today's high mix production.

Assembléon's placementquality in a smart flexible package

Do more, better

Combining industry requirements in one smart solution

Dealing with increased product variety, electronic

equipment manufacturers are facing several key

challenges:

to always deliver:

• in a high product mix environment

• at highest quality

• on time to customers

• at competitive pricing

and thus you need to:

• deliver high quality boards

• adjust to supply/demand dynamics

so you can:

• improve production efficiency

• keep costs under control

• do more, better.

An iFlex production line can consist of any combination

of three available iFlex modules. The independent dual

lanes bring lane flexibility. They allow you to assemble

a variety of boards simultaneously and independently

on a single manufacturing line. Throughput is reliable,

and iFlex modules are scalable in 7.1, 24 and 51 kcph

steps. It connects to any Manufacturing Execution

System across an open CAMX data interface.

So, you have a single point for traceability,

performance, process and warehousing data.

iFlex, by default, embeds Mentor Graphics’ MSS software

suite for NPI and MES (New Product Introductions

and Manufacturing Execution Systems). That gives a

single tool to plan, schedule and distribute production

across the factory – including equipment from multiple

manufacturers - and a tool that can manage and plan

your parts inventory.

Traceability turns your requirements into benefits,

giving you the insurance of providing the proof of your

operation, the assurance that you do it right the first

time and that you manufacture with world class quality.

iFlex T4 iFlex T2 iFlex H1Placement heads 8 4 2Maximum Output 70,000 cph 35,000 cph 9,000 cph

Minimum From 0.4 x 0.2 mm From 0.4 x 0.2 mm From 0.4 x 0.2 mmcomponent size (01005) (01005) (01005)(L x W)

Maximum 17.5 x 17.5 x 15 mm 45 x 45 x 15 mm 120 x 52 x 30 mm component size (L x W x H)Feeding positions 128 tapes 128 tapes 142 tapes, 30 trays

Example Line: iFlex T4, T4, T2, H1

Quality

A major influence on production quality is the pick &

place machine. Assembléon’s single-digit dpm routinely

gives a First Pass Yield of over 99,9%, against an industry

average below 95% for most common applications.

That can reduce rework and scrap costs by 70%, which

can save millions a year for high-volume production.

The difference in yield is largest for high-pin-count ICs

and micro-miniature components, and these are the real

tests for a machine’s repeatability. Many electronics

manufacturers see the move to 01005 (0402M) as a

quality and cost risk for mainstream production with their

current equipment. There is no such problem with single-

pick/single-place. The iFlex handles everything from

complex Ball Grid Arrays down to 01005 components

with the same high throughput and same high quality. Error free production from the very first board

Quality

QualiTy can’T bE inspEcTED inTo proDucTs – iT musT bE DEsignED in

Error free new product introduction (npi) Cut your data preparation time by 50%

• Easy to use onboard NPI tools

• Immediately synchronize back to product library manager

• Edit from any module location for changes belonging to any other module

• Unique reel-ID labeling

• Approved vendor list (AVL) management

• RoHS compliant control

• Moisture Sensitive Device (MSD) control

• Centralized parts and program management

• Release management and versioning

• Factory and/or line release of parts and programs

• Fail safe setup verification

• Continuous setup monitoring

• Reel expiration date monitoring

react fast to last moment npi changes

manage your material

Define parts and programs only once

Error free setups• Multiple high quality CAD importers

• Gerber engineering tools

• Virtual Sticky Tape

• Process workflow and documentation

generate error free programs

Closed loop parts roundtrip – define parts and programs only once for your complete factory.

Manage parts

New Parts

New setupNew

programsProgram with

new data

NPI Synchronization: line released part, process and program data.

Quality

Qualityclosed loop placement force for every componentNever a cracked component Our services guarantee the quality

of your equipment for as long as

you have it.

Placement force verification services.

Machine accuracy verification services.

• Single-pick/single-place process

• 100% component monitoring

• 100% reliable accuracy

• At highest speed for all components

• No component spread

Highest first pass yield • 100% placement process verification

• 6 sigma approach – know your process

placement blueprint

• Advanced board collision detection

• No impact force

• < 1 defect per million placement quality

• Detailed Batch and PCB traceability data

• Traceability Reporting

never a cracked component

World class manufacturing

1.5 [N]Blueprint

0

up

Forc

e

Z-axis [mm]

Pre-Tension

Start ofSpringstroke

SetPoint

End ofSpringstroke

100%

1 10 20 50 75 100 200 500

Componentsper board

Non-linear DPM Scale

1000

500

200

100

AQL

Turret equipment(larger wheel = worse)

Lowimpacton yield

Highimpacton yield

95%

90%

85%

80%

75%

70%

Firs

t Pas

s Yi

eld

%

Relation First Pass Yield and DPM

Extremeimpacton yield

related services

Flexibility

The higher the product variety, the harder it becomes to

make manufacturing efficient. The trend towards build-

to-order small batch manufacturing is accompanied by

shortening response times. So, manufacturing must be

both flexible and efficient, with minimum time spent

on setups, changeovers and production ramp-up and

limited capital of parts in stock.

The standard benefits of dual lane are already quite

understood and accepted. The iFlex brings dual lane

to the next level by introducing independent dual lanes.

With independent dual lanes, a manufacturer can

produce in volume on one lane, while frequently and

independently changing jobs on the second. That allows

a variety of products to be assembled simultaneously on

a single manufacturing line.

morE proDucTs a Day

Flexibility

Fast turnaround prototyping and reduced introduction times

iFlex modulesConsistent high quality output for component sizes from 01005 to large connectors

single-pick/single-place: predictability always within 5%

single-pick/single-place

• One placement head for 01005

to 45 mm square

- only 8 different nozzles for the

whole component range

- no need to change heads or

nozzles during setup changes

• Same speed for all components

- same output predictability over

all jobs

iFlex T4

Max. output per hour 70,000

IPC 9850 output per hour 51,000

Accuracy, CpK > 1 40 micron

Component range (L x W) 0.4 x 0.2 mm to 17.5 x 17.5 mm

Component height 15 mm

Maximum Board size*:

Dual lane 525 x 254 mm (per lane)

Single lane 525 x 460 mm

iFlex T2



Accuracy, CpK > 1 40 micron for chips, 35 micron for QFP

Component range (L x W) 0.4 x 0.2 mm to 45 x 45 mm





iFlex H1



Accuracy, CpK > 1 40 micron for chips, 25 micron for QFP

Component range (L x W) 0.4 x 0.2 mm to 120 x 52 mm





60 kcph

iFlex T4

iFlex T2

Chips FC Melf SO SOL IC LargeIC AI.Cap Radial Large oddform

SMD Connector

iFlex H1

Output IPC 9850

50 kcph

40 kcph

30 kcph

20 kcph

10 kcph

Flexibility

* up to 800 mm board length on request

Fast feeder preparation• Loads within 20 seconds

• Automatic pitch programming

• No adjustments for operators

guided feeder setups• Clear operator setup assistance

• Fastest way for error free setups

least amount of feeder changesProduction planning

• Feeder grouping

• Product Planning

• Checks if sufficient parts are on stock to produce batch

• Balances the loads of production lines

material change flexibility• Automatically adapts

to new package

• Automatically adapts to new orientation

ramp-up without pick errors• Pick position teach wizards

• Automatically initiated for pick critical components

Fast online changes• Easy to use editors

• Complete program for product can be edited at any module

iFlex segmented changeover and setup flexibilityFast segmented changeover, fast and random feeder setups and fast trolley exchanges for more products a day

automatic conveyor adjustment

random feeder placement

Feeder exchange on-the-fly• No production interruptions

Fast trolley exchange• Less than 1 minute

Fast tray feeder trolley exchange

Offline setup preparation Online setup and changeover

8 mm 12 mm Stick

Green job finished Blue job finished

Setup upcoming job(s) (Red/Yellow)Green job continues

Setup upcoming job (Red)Yellow job continues

• Less than 1 minute

Flexibility

iFlex independant dual lane2 lanes, different heartbeat

Dual-lane assembly gives you two active lanes feeding

two pick & place modules. Both work simultaneously at

the line ‘beat rate’, so doubling the throughput.

Dual lanes give assemblers valuable extra flexibility.

For example, you can assemble two different boards

simultaneously to deliver a complete main/daughter

board set to final assembly. Or run NPI on one lane while

producing in volume on the other. And you don’t have

to wait for the line to finish building one product before

loading another.

moveable conveyor rails• Supports multiple dual lane standards

• Easy switch between dual-lane and single-lane operation

standard Dual lane • Double your throughput

• Assemble simultaneously e.g. top/bottom

independent dual lane flexibility• Any product on any lane

• Lane independent changeovers

• Each lane produces at own heartbeat

At the same time, assemblers want greater flexibility to quickly change rail widths for

high-mix production, and to switch efficiently from dual-lane to single-lane operation

when they need to assemble larger boards. The iFlex dual lanes show how next-

generation equipment is responding to customer demands for greater space-

efficiency, faster changeover and reconfiguration.

• Rear and front program fully independent

• Ability to run NPI and production together on one line

Flexibility

Commitments to on-time delivery mean that

manufacturing lines must deliver what has been

promised. Equipment that is not producing is wasting

time, and if your estimates are regularly out by 10%

(or more), then you will have 10% less business than

you predicted.

Now, you can plan and quote for products as never

before, confident of the exact time and cost of

assembly. Reducing machine idle time to virtually zero

means you can predict your throughput and response

times accurately.

With the iFlex, small batch manufacturing becomes

more efficient to handle. Only the exact number of

components and boards may be supplied to produce

the batch. That demands guaranteed pick & place

quality to avoid component shortages or reduced yield,

in order to deliver the products as promised.

Send out reliable quotes and deliver on time as promised

Efficiency

Efficiency

incrEasE your proFiTabiliTy

Efficiency

iFlex EfficiencyWhen it comes to a high product mix, it is throughput that counts

Preparation Monitoring Production

minimize downtime between jobs• Feeder grouping

• Least amount of setup changes

• Least amount of feeder changes

Feeder intelligence• High pick rate

• Adaptive pick

• Automatic pitch settings

• Controlled tape movement

• First-time-right picks

consistent output over all jobs• One head for all components

• Single pick / single place concept

• Minimum de-rating

• Production predictability within 5%

• Minimum nozzle exchanges required

reliable feeding, all the time• Feeder maintenance monitoring

identify and correct line bottlenecks on time• Machine and line monitoring

• Changeover time monitoring

• Pick rate performance monitoring

constant flow of boards through the line• In-machine buffer positions eliminate daily

line dynamics

• Unique fast tray caching for consistent tray speed over all applications

Just in time supply of reelsto production line• Accurate component consumption registering

• In time warning of reels running empty

1. Line performance services

analyze and improve your

Overall Equipment Effectiveness.

2. Assembléon’s multiple award-

winning service includes web-

based ordering of original parts

– 24/7 again.

related services

cost control

Provide flexibility at competitive pricing cost controlThe high cost of field recalls, the possible loss of

reputation, and the growing need to meet legal and

safety regulations make product quality and

production reliability top priority.

The cost of reject boards – fully populated with

expensive components – is high enough but a low

First Pass Yield will also demand a whole department

to test, trace faults, and repair boards. That is becoming

more difficult with each generation of new, smaller

components. The latest 01005 components, for

example, are almost too small to see and correct.

Low First Pass Yields mean that a large proportion

of valuable output will result in just so much scrap.

With the energy efficient iFlex, you start saving from

the first board. And we help you to reduce day-to-day

variation in your whole production process to

continually reduce the Cost of Placement.

go grEEn - anD saVE monEy Too

cost control

built-in simplicityMaximizing your productivity

Designed for low maintenance• Less than 40 hours per year

• Accessible

• Detailed diagnostics

• Clear visual instructions and help files

sustainable• Re-use of proven technology

• Light weight carbon beams

• Low mass movement

• Minimum air consumption

• High output per m2

1,840 mm

1,160 mm

Clear (line) board count visibility via user interface

Designed to last• Lifetime nozzles >> 20 million picks

• Nozzle tip replacement only

plug and play• Simple user interface - few buttons only

• Minimum operator training required

• In your language of choice

• Touch screen operation

High area productivity• High line throughput on minimum floorspace

iFlex is designed for highest

machine uptime, and all the

services we offer have a single goal:

to keep machines running 24/7.

remote support

• 24/7 support

• Resolve errors fast

• Send first-time-right parts

assembléon service

Assembléon’s multiple award

winning service includes around the

clock web-based ordering of original

parts at competitive pricing

assembléon training

• On-site training

• Customized training

• Advanced training

related services

Line solutions Specifications

Loader

T4

T2

T4

T4

T2

T2

T4

T4

T2

T2

H1

H1

H1

H1

Loader

Loader

Loader

Printer

Printer

Printer

Printer

Printer

Printer

Oven

Oven

Oven

Oven

Unloader

Unloader

Unloader

Unloader

SMT Line 1 (dual lane): 160,100 cph (IPC 9850)

Application: Very high volume – e.g. Smart Phone

Processes: Package on Package, 01005

Feeding capacity: 472

Tray capacity: 30

SMT Line 2 (dual lane): 109,100 cph (IPC 9850)

Application: High volume - e.g. Computers,

Hard Disks

Processes: 0201, QFP


Tray capacity: 30

SMT Line 4 (single lane): 55,700 cph (IPC 9850)

Application: High mix – Product variety with

approximately 70% common parts

Processes: 01005, QFP, connectors, oddform


Tray capacity: 30

SMT Line 3 (single lane): 80,000 cph (IPC 9850)

Application: High mix - Product variety with

approximately 30% common parts

Processes: 01005, QFP, connectors, oddform


Tray capacity: 30

iFlex T4 iFlex T2 iFlex H1

Maximum output per hour 70k

(51k IPC 9850)

35k

(24.3k IPC 9850)

9k

(7.1k IPC 9850)

Placement Quality < 1 dpm < 1 dpm < 1 dpm

Placement Accuracy Cpk > 1 40 micron for chips 40 micron for chips

35 micron for QFP

40 micron chips

25 micron for QFP

Minimum Component size 0.4 x 0.2 mm (01005) 0.4 x 0.2 mm (01005) 0.4 x 0.2 mm (01005)

Maximum Component size 17.5 x 17.5 mm (0.69 x 0.69”) 45 x 45 mm (1.77 x 1.77”) 120 x 52 mm (4.72 x 2.05”)

Maximum Component height:

- Standard

- Optional

15 mm (0.60”)

N/a

15 mm (0.60”)

N/a

25 mm (0.98”)

35 mm (1.38”)

Programmable Placement Force 1.5 to 8 N 1.5 to 8 N 4.0 to 30 N*

Maximum board size**:

- Single Lane standard

- Dual Lane

- Dual Lane in Single Lane mode

525 x 558 mm (20.3 x 21.9”)

525 x 254 mm (20.3 x 10”)

525 x 460 mm (20.3 x 18”)

525 x 558 mm (20.3 x 21.9”)

525 x 254 mm (20.3 x 10”)

525 x 460 mm (20.3 x 18”)

525 x 558 mm (20.3 x 21.9”)

525 x 254 mm (20.3 x 10”)

525 x 460 mm (20.3 x 18”)

Minimum board size: 50 x 50 mm (2 x 2”) 50 x 50 mm (2 x 2”) 50 x 50 mm (2 x 2”)

Board thickness 0.3 to 6 mm (0.01 to 0.24”) 0.3 to 6 mm (0.01 to 0.24”) 0.3 to 6 mm (0.01 to 0.24”)

Automatic toolbit exchange Nozzles Nozzles Nozzles, grippers

Max. tape feeding positions (8 mm) 64 single tapes

128 twin tapes

64 single tapes

128 twin tapes

71 single tapes

142 twin tapes

Feeding options

(special feeders on request)tape, stick tape, stick tape, stick, tray, tubes, others

Data Interface(s) CamX CamX CamX

Footprint (L x W) 1,170 x 1,844 mm

(46.06 x 72.60”)

1,170 x 1,844 mm

(46.06 x 72.60”)

1,170 x 1,844 mm

(46.06 x 72.60”)

* lower forces: conditions apply** up to 800 mm board length on request

4,668 mm

4,668 mm

3,498 mm

3,498 mm

Feeder trolley• 34 feeder slots for

68 feeding lanes

• Tape cutting

Tape splicing• Guarantees uninterrupted

production

Tape loading units• Inline and offline

• Near machine tape loading

Tray trolley• Multiple tray handler

• Fits 30 trays

• 10 high speed tray cache positions

Feeder storage carts• Stores up to 50 feeders

(8 mm)

• Stores up to 100 reels (8 mm)

Feeding Options:

Machine options:

re-use belt feeder• Transports rejected component out of system

• Enables re-use of a rejected components

• Does not interrupt production process

intelligent tape feeders• 4 mm to 88 mm

intelligent twin tape feeder• Doubles 8 mm tape count

Feeders:

label feeder• Pre-printed label feeding

stick feeder• SO-IC 8 to PLCC 100 in sticks

• Custom top plates

• Generic top plates

carrier tape tray• Feed small pieces of tapes

• 8 mm to 200 mm wide tapes

• Ideal for New Product Introductions

nozzles and grippers• Standard nozzles

• Customized nozzles and grippers

• Standard gripper set

accuracy and placement verification tools• Closed loop measurement

and verification process

• Also available as service

Feeder service shop• Quick feeder analysis

• Enables feeder parts repair

• Calibration and verification

nozzle maintenance kit• Fast cleaning of nozzles

• Enables nozzle part replacement

Options

multi-language• User interface and help text available in many

different languages

service Tools

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