Case Studies
Extreme Tag
Case Study1Automating the Management of Expensive Consumable Parts
— Preventing Installation Errors and Visualizing Replacement Timing
- CompanyJUKI Sanki Technology Co., Ltd.
- IndustryManufacturing
- Product/ServiceMounting equipment for PCB assembly
- Implemented SolutionSKE Extreme Tag – Metal Version
- Implementation Date2024
Implementation
Customer Challenges / Issues
In PCB assembly processes, mounting machines need to use a wide variety of nozzles depending on the shape of each electronic component. However, issues frequently occurred on-site due to incorrect nozzle installation or insufficient management of usage count and replacement timing, resulting in continued use of worn nozzles.
In particular, nozzles gradually deteriorate through repeated use, making regular replacement essential. Accurately tracking which nozzle was used, when, and how many times had been a significant challenge for the customer.
Reasons for Implementation
Although the company had previously considered improving management efficiency using RFID, they faced challenges because the nozzles are small and made of metal, making it difficult to attach RFID tags and maintain reliable communication.
The solution came in the form of the Extreme Tag – Metal Version, which features a compact design and metal compatibility. This tag could be attached directly to the nozzles while maintaining stable communication even in a metal environment.
After a trial implementation on a limited number of mounting machines, nozzle management accuracy improved significantly. The results were highly rated, and the company has now started selling mounting machines with standard RFID support.
〈Key Points for Adoption:〉
- Size suitable for attachment to even small nozzles
- Stable communication in metal environments
- Automatic recording of nozzle usage history and replacement timing
- Significant reduction of on-site errors and losses
Post-Implementation
How the Challenges Were Addressed / Work Procedures
Extreme Tags were embedded and sealed in each nozzle, and dedicated reader-writers were installed within the mounting machines. The system was designed so that each nozzle passes in front of the reader-writer, ensuring reliable tag reading.
〈Conditions for Solving the Challenges:〉
- Automated individual identification of each nozzle
- Prevention of misusage and incorrect installation
- Enhanced traceability of maintenance history
A management system was implemented that communicates with the RFID tags each time a nozzle is replaced, automatically verifying that the correct nozzle is installed. This allowed for thorough prevention of installation errors.
Additionally, the system counts the usage of each nozzle via RFID communication every time the machine is used and automatically notifies users when it is time for proper replacement.
〈Key Points of the System:〉
- Automatically identifies installed nozzles to prevent installation errors
- Counts nozzle usage via RFID communication
- Management system automatically notifies users of appropriate nozzle replacement timing
Benefits / Results
By centrally managing nozzle usage and replacement status via RFID, operational efficiency was improved and the incidence of errors and malfunctions was significantly reduced.
〈Summary:〉
- Reduced consumable part replacement tasks, achieving a substantial improvement in operational efficiency
- Prevented installation errors and ensured timely replacements, significantly minimizing equipment malfunctions
Customer Feedback
“Not only has our operational efficiency improved, but the time required for training has also been greatly reduced, leading to higher overall production efficiency.
We have received requests from other departments to observe the system, and we plan to gradually expand its use across the company.”
Comments from Our Team
“Establishing the method for attaching the tags to the nozzles required repeated trial and error. Through continuous evaluation, we were able to determine the optimal attachment method. As a result, the Extreme Tag has been successfully adopted for mass production.
Furthermore, the product has gradually obtained radio certification in various countries, and mounting machines equipped with Extreme Tags have been widely introduced in overseas markets as well!”