PSI in Industrial 4.0
Author: Gilbert Chen
Time keeps going and production systems follow the steps, through crawl, working, running to flying now. The speedy changes make people out of breath. We, PSI, are living in the field now. Only way is to learn and be the skill flyer. Let PSI be a good player in the challenge business world.
- Data collection automation
PSI is a low to middle volume EMS company. There are 50-80 various products flowing in our production line. Since 2012, Customer base of PSI increases rapidly. Therefore, operation management is more and more complex gradually. We started to plan data collection and operation automation in 2012. Up to 2016, PSI cooperated with NXN technology to build “Real time data collection and traceability system.” We, ourselves, also built the following systems, such as “Sales ordering system”, “BOM auto-transfer system”, “Automatic production scheduling system”, “Material shortage simulation system”, “Product technical information management system”, etc. Because of this MIS system, PSI achieves the good score of 98% on time delivery and 0.14% return rate.
- Data analysis and Process flow automation
Although PSI finished MIS system in 2016, it is still a big headache to find the deviations and adjust from the big data, need many manpower to do the tasks. Then, internal wrong operations are still happened frequently. We did some brain storming meetings and started to process the second stage operation system improvement plan. It’s Data analysis and operation processes automation. Use logic thinking to let computer system calculate and provide the deviation reports. People need to handle the problems reported from computer only. It’s increase the efficiency and accuracy a lot. The other was to change the handover way from people to people to computer handover itself. It’s higher the performance of processes handover and lower the error rate. Since 2016, we finished several systems, such as “ Cloud exchange system”, “Technical data auto- transfer system”, “Customer order and BOM auto-imported system”, “ Auto-create working order and Shortage purchasing requirement system”, “Semi-product auto-transfer system” up to now. We’ll work and finish “Sales order auto-management system”, “Purchasing order auto-place and tracking system”, “Auto working order scheduling system” continuously. Hopefully, we can be the one with zero deviation rates in the low to middle volume high-mix production world.
- Production automation
PSI did many efforts in system management automation for the past few years and got very good achievements as well. but it seems not enough to let PSI stand on a better position to face the highly competitive markets. We got to think more about production automations that are mature in the high volume production company. It’s our first year of industrial 3.5 in 2019. We have some targets during this year and next year, such as “Screw driving Automation”, “Burn-in timing-up alarm system”, “Connector test auto-tooling system”, “Chip SMT parts auto-counting system”, “Automatic Soldering System”, “Whole process Bar code control system” and “Chip SMT parts warehouse auto management system”.
- Quality management automation
AI (Artificial Intelligence) is not only the tool of Campus or Research institute, but also be used in the industrial field. It’s under understanding stage for PSI now. We have a target to use AI big data analysis capability to do the judgment of production quality problems, to change the cosmetics inspection way from visual check to camera inspection by AI in 2010. Then, we can say quality zero defect in PSI.
Keep processing is the motivation for not to be knock out. When we try hard and progress fast, the company can be survived eternity. PSI owes the capability to absorb new acknowledges and fit into real application of our company. Through continue progress, PSI will be more and more brightness.