Circuits Assembly - December 2008 - (Page 23) Cover Story Figure 2. An SMT line at Plexus' Neenah campus. Figure 3. A subassembly line in Building 5. separate to ensure the security of customer IP. “We pride ourselves on keeping that information separate.” Reuse is important to the medical OEMs that make up more than 20% of Plexus’ annual sales. (Plexus has a long history as an EMS to medical OEMs, although Juniper Networks is the firm’s largest customer, at 19% of sales.) These OEMs take the platform approach whereby a concept can be leveraged and reused across various products. Test strategies are a collaborative effort between manufacturing engineers and customers, as well as the test equipment OEMs. The Plexus workcell approach is a sight to behold. Don’t expect long, parallel SMT lines. In Building 5 at the company’s Neenah, WI, headquarters, the layout is such that within the 100,000 sq. ft. manufacturing plant are four distinct factories – each complete with an SMT line (Figure 1). (Staff must swipe their employee badges before passing ESD testing and entering the factory floor, only the second time in 17 years I’ve seen that clever setup.) Inside, banners outline each “factory’s” borders. “We blended a dedicated factory with a cellular model,” explains Kim Debenack, engineering manager. “This model makes us less rigid because we can run product anywhere, on any line. What we are going for is product velocity, not just velocity of placement.” Building 5 handles 10,000 part numbers across five to six customers, at a rate of 15,000 assemblies per month. Nearly everything built is a system with direct order fulfillment. Debenack says board build cycle time has dropped to two days from 21 since this novel setup was implemented several years ago. A separate focused factory is integrated into Building 5 to handle repair services. Adds Buseman, “We’re looking at what the next level of service would be.” Process optimization across Plexus’ far-flung operations is driven by Van Dreel. Twice a year, he organizes summits involving representatives from engineering and quality. The group has two goals: to prioritize needed activities and processes, then formalize them into projects and execute them around the globe. Flexibility is key. The number of engineering change orders in Building 5 tops 100 per month. The Neenah site uses DEK printers, Universal placement, Electrovert reflow, Vitronics Delta-Max selective solder, Agilent 3070 and Teradyne test equipment. Oracle circuitsassembly.com and Agile ERP systems, coupled with homegrown MES tools, round out the picture. The organic supply chain management tools develop sourcing solutions based on such factors as component cost, variability and lead times. Equipment evaluations are performed all over the world. However, there is limited variation from plant to plant. For example, Plexus’ Buffalo Grove, IL, site uses Assembléon A5 placement Mission Possible. Versatility that beats complexity. It’s not just a promise, it’s a fact! assembleon.com/facts assembleon.com/facts Circuits Assembly DECEMBER 2008 23 http://www.assembleon.com/facts http://www.assembleon.com/facts http://www.assembleon.com/facts http://www.circuitsassembly.com
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