NU6 3: New Process at Work: Automation by GG STR REg

New process at work: Automation

In FPC manufacturing, majority of the process is labor intensive. It involves a lot of mechanical inspection using low power microscope, punching processes using 35 ton press machine and pasting processes using jigs and lamination equipment. All process is done by operators and inspector who load, inspect and unloads FPC to particular equipment. A typical FPC backend process is shown below.

Figure 1. FPC Manufacturing: Backend or Lower Process

To be more competitive, our group has been task to look on automating our process. We are now looking into automating pasting and punching processes. Automating the process maybe easy because of the available technology that we have, but if you consider the cost, then it becomes difficult. A typical cycle time of pasting process is about 30 seconds. The process includes picking a stiffener to be pasted into a jig, taking the FPC and removing adhesive separator, loading the FPC into a jig and activating lamination equipment. Manually, the operator use jigs with guide pins and insert the stiffener and FPC in the guide holes. The accuracy of registration should be within 100 microns; otherwise the product will be rejected. The task, automate the process and improve the cycle in less than 30 seconds. Whoosh. The idea is to automate picking and placing the stiffener automatically in the jig, loading the FPC after removal of separator, and laminate the FPC and stiffener. Once you have the concept, you must now assess the cost and benefit of the investment.

I think this is where entrepreneur thinking on being innovative and creative comes into play. An entrepreneur does not have to own a business to become one. He must have the passion and interest to create things and improve the task assigned to him. The operation must be effective and efficient to justify the investment.

The advantage of automation aside from utilizing less manpower is the consistency of process output and faster cycle time. If trouble occurs on the process, equipment troubleshooting and repairs are easy. For labor intensive process, human error sometimes can be very difficult to correct. The disadvantage of automated system is the high cost of equipment and requires big space. But that is one objective of the entrepreneur, to innovate and create new ideas with less or no cost at all. 3