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PROJECT

Introduction of Material Towers for the Automation of Inbound and Outbound Management of Semiconductors and Electronic Materials

Problem Background

In this client's factory, which has a chip mounter line, they carry out the process of mounting semiconductors onto boards. A shelf was placed next to the line for reel materials of semiconductors, and about 10,000 types of materials were stored there.
Every day, workers would pick and transport materials visually while comparing them with a withdrawal list, and there were often mistakes such as picking errors. Detailed management such as first-in-first-out was also needed.
Ten people worked on this task daily, but the production efficiency was never satisfactory due to the constant walking, standing, and squatting inside the space. As the number of production items increased, the storage space also expanded, and the sense of the problem grew.
Additionally, during inventory checks, there was a need to confirm each material individually, requiring a full day's worth of labor.

LOGITO's Solution

Solution Overview

1.Data Analysis

We introduced a material tower and proceeded with the automation of material storage and retrieval operations.
First, based on the data received from the client, we calculated the expected daily number of reel storage and retrievals. Then, we compared the labor hours between using the material tower and manual operation, and calculated the type and number of material towers needed, considering the investment payback period.

2.Automation of Storage and Retrieval

By introducing the material tower, we automated the storage and retrieval operations.
In this case, we introduced eight units of single storage and retrieval type SMD BOX SISO. We installed them in a cell format, building a system where one person can easily carry out the storage and retrieval operations.

3.Full Automation

Eventually, by introducing a six-axis robot and conveyor line, we realized automatic storage and retrieval operations for materials in the SMD BOX without human intervention.

Effects of Introduction

Workers reduced from 10 to 2 (8 personnel reduction)
Reduction in inventory checking labor hours

LOGITO's Strengths

Gradual Automation

The goal was complete automation, but suddenly introducing multiple devices can increase the load on the control side, making mid-course corrections difficult. In this case, we started with the introduction of only the material tower, eliminating the wastes of ""finding target part numbers,"" ""walking around the warehouse,"" and ""checking materials."" Once the operation began to run smoothly, we introduced a six-axis robot and a conveyor line to achieve full automation.

Selection of Necessary Equipment

We conducted a preliminary analysis by gathering information such as the expected monthly storage and retrieval volume, types of materials, inventory checking labor hours, current number of workers, and cost-effectiveness. Then we determined the possible investment amount and the optimal material tower selection. Neotel Technology, the manufacturer of the material towers, offers a wide lineup and customization, making it possible to provide the best equipment for the customer.

The step-by-step approach to automation allowed for careful implementation and control, while the detailed analysis and customization ensured that the solution was tailored to the customer's specific needs. By identifying and eliminating inefficiencies and gradually integrating technology, LOGITO provided a solution that significantly improved efficiency and reduced labor.

CONTACT

LOGITO is a logistics automation solution provided by DJK.

We will contact you within one day after receiving your inquiry, excluding weekends and national holidays.
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