Referenzen-neu4_ENG.pdf - 第2页
The information provided in this brochure contains merely general descriptions or characteristics of performance with in actual case of use do not always as described or which may change as a result of further developmen…
Liebherr Elektronik GmbH and SIPLACE
Setup changeovers
with no time lost –
thanks to SIPLACE LES
The challenge
Although Liebherr Elektronik GmbH
supplies mostly other Liebherr Group
companies, it has to compete against
non-group electronics manufacturers.
Management makes continuous impro-
vements to raise its competitiveness.
The industry-speci c job structure poses
special challenges, because the custo-
mers in the construction, rail and aeros-
pace industries require their products in
small lots. Few runs exceed 100 units;
most are smaller than 50. As a result,
the frequent changeovers required by
the small lot sizes hurt the production
lines’ productivity.
The SIPLACE solution
In 2009, Liebherr raised its placement
performance by adding a new SMT line
with two SIPLACE X2 placement machi-
nes. By implementing SIPLACE LES,
the company recently improved and
synchronized its entire process chain
from detailed production planning and
warehouse operations to the pre-setup
department and the actual setup pro-
cesses on the line in order to minimize
the time required to set up new jobs.
The placement machines, the software
and SIPLACE process innovations
like Active Feeder Pool or Floating
Setup now allow Liebherr Elektronik to
produce small lots with a high degree of
ef ciency.
Liebherr Elektronik
In the Lindau plant of Liebherr Elekt-
ronik GmbH, 450 employees produce
over 2,000 products to order and in
a wide range of lot sizes. The plant’s
main customers are companies in the
Liebherr Group who supply electronics
as well as complete control and display
modules to customers in the construc-
tion, rail and aerospace industries. The
lot sizes for many modules and clusters
range from 1 to 100 units; most batches
for the aerospace industry are even
smaller than 50 units.
„The integrated control and optimization of the entire work ow
harbors huge ef ciency reserves for any electronics manufacturer.
SIPLACE LES allows us to put these reserves to use.“
Peter Horatschek, Head of Production Scheduling
A very effective team both before and after the successful implementation of SIPLACE LES (left to right):
Jan-Holger Hein, SIPLACE Product Marketing Manager Software; Peter Horatschek, Head of Production
Scheduling, Liebherr Elektronik GmbH; Peter Reck, Head of SMT Production, Liebherr Elektronik GmbH.
High-mix/low-volume production
SIPLACE X platform –
More productivity, exibity
and placement accuracy
SIPLACE LES – More ef cient use
of component storage, feeders and
production lines
Floating setup – Changing products
non-stop
www.liebherr.com
The information provided in this brochure contains merely general descriptions or characteristics of performance with in actual case of use do not always as described or
which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms
of contract.
ASM Assembly Systems GmbH & Co. KG
Rupert-Mayer-Str. 44 – 81379 Munich, Germany
Phone: +49 (89) 20800-0 – Fax: +49 (89) 20800-27438
www.siplace.com – siplace.de@siplace.com
Speed …
Prior to implementing SIPLACE LES,
Liebherr Elektronik had modernized its
SMT production in 2009. The company
replaced two SMT lines from another
equipment manufacturer with two
SIPLACE X2 placement machines. The
upgrade delivered more productivity,
exibility and placement accuracy. In
particular, Liebherr was able to redu-
ce the volume of manually installed
components. Just like at many other
European electronics manufacturers,
however, rising diversication and acce-
lerating product changes forced Liebherr
to focus more and more on improving
the exibility of its SMT production if it
wanted to remain competitive.
… is not everything
„The performance was excellent, and
the SIPLACE X2 line was far from its
capacity limit when it rst went into
operation. But we could already foresee
that the declining lot sizes and the re-
duction to a single yet much faster SMT
line would lead to a signicant increase
in the number of setup changeovers
per time unit, resulting in much more
activity around the line,” remembers
Peter Reck, head of SMT production
at Liebherr Elektronik. The question:
How could Liebherr optimize its setup
processes and reduce the downtime
caused by product changeovers?
The answer: With software that would
improve the efciency of its component
warehouse, its feeders and its produc-
tion line. After visiting other users and
conducting an intensive evaluation, the
company decided to implement SI-
PLACE LES.
Planning with foresight
Today, SIPLACE LES schedules the
production jobs on the basis of volume
and deadline information imported from
Liebherr’s Baan ERP system. Another
interface connects SIPLACE LES with
the materials management system. That
way, the material requirements for the
production jobs, the warehouse invento-
ry and the consumption on the line are
continuously synchronized. Jobs are
scheduled for the next two days.
SIPLACE LES takes not only the
delivery deadlines into account, but
congures a setup-optimized produc-
tion sequence. It forms “setup families”
by scheduling products with similar
components in sequence so that as few
feeders and components as possible
need to be changed.
No paper and minimum run-around
The entire production management
is totally paperless. Employees recei-
ve their instructions on monitors and
conrm what they have done on PCs
or PDAs. The system even takes lead
times into account. It noties the ware-
house staff about upcoming orders early
to give them plenty of time to pick the
corresponding items and post them in
the system.
Feed the Line
In the preliminary setup area, the so-
called Active Feeder Pool, materials
are assigned to the intelligent SIPLACE
X-feeders by scanning their respective
barcodes. Since SIPLACE LES knows
not only each individual order but all
subsequent jobs and setups, it avoids
unnecessary tear-downs and ware-
house movements: The SIPLACE X-
feeders indicate via their LEDs whether
they can be removed or are still needed
for another product. If the latter is the
case, they are “parked” in the Active
Feeder Pool, which is maintained as
an active storage location in SIPLACE
LES.
From product to product with no
breaks
Line setups are executed on the-y
(“Floating Setup”). LED signals on the
X feeder modules signal which feeders
can be torn down. Feeders can be ad-
ded and removed while the line keeps
running (“hot-swap”). The exact feeder
position is secondary, because each
new feeder automatically registers its
position with the machine. The software
recognizes the feeder ID and the mate-
rial assigned to it. Placement programs
are downloaded automatically, and the
production of the next product can com-
mence with no interruption.
SMT production manager Peter Reck
concludes: “Nowadays there is very
little that differentiates placement
machines from leading equipment
vendors. Software and process com-
petencies are much more important
when it comes to selecting the right
technology partner.”
Liebherr Elektronik GmbH and SIPLACE
After investing in a modern SIPLACE X line, Liebherr Elektronik GmbH opti-
mized the setup processes in its SMT production.
The material is installed on xed component carts in the Active
Feeder Pool. The reels are then assigned to the feeders by scan-
ning their respective barcodes.
A10011-ASM-CS01-X-7600
Facts and Figures: Liebherr Elektronik
Manufacturer of electronics modules and
entire systems
450 employees
Over 2,000 active products
lot sizes from 1 to 100 units
Annual SMT production volume: Approx.
300,000 circuit boards; over 65 million
components
2,500 components per product
Up to 200 different SMDs per product per
product