Revolutionizing Electronic Component Manufacturing: Continental India's Smart Technology Integration

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"Our AGVs and cobots can pick and deliver components directly to the production line, significantly reducing cycle times and improving efficiency." — Sebastian Ananthaswamy, Head of Operations, Continental India

September 2024 : In the complex and fast-paced world of electronic component manufacturing, the ability to maintain high productivity and quality is critical. Continental India has successfully harnessed advanced manufacturing technologies to not only boost efficiency but also to ensure the utmost precision in their operations. Sebastian AnanthaSwamy, Head of Operations, Continental India, offers a deep dive into how these innovations are driving their success.

Harnessing the Power of Smart Warehousing

Continental India's journey into advanced manufacturing begins at their state-of-the-art warehouses. In an industry where a small 150 by 150 mm PCB can contain over 650 components, precision in handling is crucial. "We’ve moved beyond the traditional concept of ‘a place for everything and everything in its place,’” says Ananthaswamy. “Today, each tray in our vertical carousels is equipped with RFID technology. This, combined with our advanced ERP systems, allows us to efficiently manage and track over 40,000 different electronic components."

This system ensures that the first-in, first-out (FIFO) principle is meticulously maintained, reducing errors and ensuring that the right components are always available when needed. The integration of this technology has drastically improved the speed and accuracy of warehouse operations, laying a strong foundation for the subsequent stages of manufacturing.

Streamlining Production with Automation

One of the key challenges in electronic component manufacturing is maintaining a rapid production cycle while dealing with highly complex assemblies. At Continental India, smart AGVs (Automated Guided Vehicles) and cobots have become integral to addressing this challenge. “Our AGVs and cobots can pick up and deliver components directly to the production line,” AnanthaSwamy explains. “This automation not only reduces cycle times but also minimizes the risk of human error, particularly in repetitive tasks.”

This approach is particularly effective in a lean manufacturing environment, where space and time are at a premium. By integrating these technologies, Continental India can maintain a fast-paced production environment, meeting the demands of multiple product lines without compromising on quality or efficiency.

Ensuring Quality with Advanced Data Management

Quality control is another area where Continental India has made significant strides, thanks to smart manufacturing technologies. The EVA Pro middleware system, integrated with their MES (Manufacturing Execution System), plays a pivotal role in this. “EVA Pro captures and analyzes data at every stage of production, from the placement of components on a PCB to the quality of the solder joints,” says AnanthaSwamy. “This data, stored for a minimum of 10 years, allows us to trace every component and ensure that we meet the highest quality standards.”

The level of detail captured is staggering. For instance, even the force with which a component is placed on a PCB is monitored to prevent defects like solder splashes. "We deal with forces measured in micro-Newtons," AnanthaSwamy notes. "This kind of precision is essential for ensuring the reliability of the final product."

With millions of data points collected daily, Continental India’s MES server becomes a treasure trove of information, allowing for real-time monitoring and quick identification of potential issues. This capability is crucial not only for maintaining current production quality but also for addressing any future field failures with pinpoint accuracy.

Continental India’s adoption of smart manufacturing technologies has transformed their operations, allowing them to achieve higher productivity, maintain rigorous quality standards, and adapt swiftly to the demands of the electronic component industry. By leveraging these advanced tools, the company ensures that they are not just meeting but exceeding the expectations of their customers, setting a new benchmark for efficiency and precision in the industry.

Note: Mr. Sebastian Ananthaswamy was speaking at Rockwell Automation presents CXO Roundtable on "Smart Manufacturing - Champions of Change," powered by Pro MFG Media.

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