This video shows how Z-AXIS maintains an accurate SMT parts inventory.
Reels and SMT Parts Inventory
Surface-mounted parts are usually packaged on reels. That’s efficient for manufacturing but challenging for inventory control since the average reel contains thousands of hard-to-count components.
During physical inventories and cycle counts, some manufacturers unreel their SMT parts and pass them through a counter. This is labor-intensive, however, so Z-AXIS has developed a more efficient solution.
Our inventory control system integrates our ERP with a database from Mycronic, the manufacturer of our SMT pick-and-place machine. There are multiple steps and checkpoints along the way.
First, our receiver scans an incoming reel’s barcode and prints a label that contains the reel’s carrier number, the manufacturer’s part number, the Z-AXIS part number, and the number of components on the reel.
We then move the reel to our stockroom, where we scan both the label on the shelf and the label on the reel. If the Z-AXIS part numbers match, we put the reel on the shelf in the proper stocking location.
When it’s time for production, we remove all of the reels that we need for the job and load them into feeders that snap into magazines. These reels then become part of a kit that’s wheeled out to the production line.
SMT Parts Usage and Inventory Counts
At our Mycronic pick-and-place machine, the reel carrier numbers are scanned and the feeders are loaded. Because the carrier numbers are linked to Z-AXIS part numbers, we know we have the right components.
We also know if the parts are in-spec. As each part is picked, a camera measures the part’s length and width. In-spec parts are placed on the board, out-of-spec parts are put in a cup, and the reel count is decremented.
When the reel is empty, our inventory control system zeroes the count and reports any discrepancies between the number of expected parts and the number of processed parts.
That’s important in case some of the pockets in the carrier tape were empty, or if any of the parts weren’t processed. Instead of counting every part each year, we update our count at the end of every reel.
If the reel isn’t empty at the end of a job, it’s returned to inventory so that the remaining parts can be used. At the end of each month, we synchronize our Mycronic database with our ERP system for accurate SMT part counts.
Finding Innovative Solutions
By integrating inventory control throughout our operations, Z-AXIS maintains a count of SMT parts with less labor, greater efficiency, and increased accuracy.
How can we help you with your next electronics design and manufacturing project? Contact us.