How we at Gatema PCB reduced the lead time of PCB production

Optimizing the production process through digitalization means, among other things, thinking about the future. Automation is nothing new, but in recent years, several technologies have matured – such as AI (Artificial Intelligence) and RPA (Robotic Process Automation) – that have the potential to change the way companies operate. AI algorithms can save companies time, simplify operations and automate production processes.

 Artificial intelligence can help manufacturing companies handle large volumes of data, technical documentation and evaluation results. Data is a major driver of development and continues to be one of the key trends in digital transformation. However, today’s manufacturing environment requires an integrated system capable of collecting, processing, consolidating and utilizing large volumes of data from online and offline environments and machines. Such a system can also evaluate data for predictive purposes and use the resulting insights to support future production planning, optimize the production process and improve company operations in general.

Helios Nephrite handles all of this with ease. The Production module is invaluable in a manufacturing environment. It enables online monitoring of production status. Imagine that production is regularly monitored at the end of each shift, providing daily updates on its actual status. You can see exactly what is currently in progress and put this information into context with order delivery dates. By optimizing the production process in this way with the help of the Helios Nephrite ERP system, production lead times can be significantly reduced.

Thanks to Gativa WMS, the associated warehouse management solution, and the Gativa REVA MES system, which monitors and evaluates machine data, production processes can be streamlined and customer delivery times reduced.

We use the unique Gativa MES REVA for the production of Gatema PCB. It collects up-to-date and accurate data from production equipment and connects it with the mechanisms and tools needed to manage and plan all related events and processes within the manufacturing company. Radim Vitek, Gatema PCB Production Manager, confirms: “Nowadays, customers place great emphasis on product quality, cleanliness and mechanical quality, while at the same time demanding very fast delivery. We have managed to achieve this by implementing this system.”

The production of each PCB is highly customized, and every production order is unique, reflecting the specific requirements of the customer. The Production module of the Helios information system, together with the Gativa MES system, has made production tracking significantly more precise since its implementation.

The order configurator, which can be found on our website, has contributed significantly to this improvement. The configurator is directly linked to the Helios information system. The gradual optimization of the production process with the help of the information system has led to a significant reduction in PCB production lead times and, consequently, faster delivery to customers.

The implementation took place while production was fully operational and was completed quickly and successfully. Today, 90 employees in our company work simultaneously with the information system and its Production module.

“Each customer order is unique, thanks to the web-based configurator the requirements of the board parameters are refined. The configuration is automatically loaded into the Helios information system and the workflow ensures that the information is sent to the data preparation department.“

“The time required for the entire data-entry process in production is reduced significantly. In addition, the need for complex checks during technical production preparation and the creation of the production workflow is eliminated, as these steps are already stored and automated in the information system. There is no risk of someone making a mistake when transcribing the customer’s parameter requirements, and there is no need to manually reconcile customer data with production parameters. Everything is automated in the Production module,” explains Petr Vareka, Head of the Helios Information System Implementation Team.

During the actual PCB production process on the shop floor, the Production module automatically loads the program used to control the relevant production line or machine, such as a drilling machine, press, milling machine or CNC machine. On the shop floor, the production operator confirms the work operation by scanning its barcode, and this information is transferred to the Production module. Each job contains precise information about the start and end times of individual operations. Material planning and the issuing of materials to production are also linked to the workflow.

“For example, take the drilling process for printed circuit boards. The drilling method, countersinking, specific drilling locations and drilling depth are all recorded in the manufacturing process under a specific code. The Production module provides the machine with the program stored on the network containing the drilling procedure. The operator only needs to confirm the program on the machine. This prevents delays because the Production module ensures that the work instructions for the production operation are followed through to the next workstation,” explains Vareka.

The information system therefore tracks and records exactly where each board is in the production process, significantly improving visibility into order status.

“We were able to streamline production data preparation to a minimum. If an order arrives from a customer with the correct data, we can see the individual processing steps in the information system, such as drilling, milling, motif inspection, solder mask application and so on. If neither the information system nor the production preparation technician identifies any limitations, the PCB can actually enter production within a few minutes.“

“Of course, chemical and physical processes take their time, and some stages inevitably add to the overall processing time. Nevertheless, we can now produce a quality PCB in approximately 14 hours, whereas without the information system, the same process used to take 10–14 days,” says Vaclav Ambroz, Head of the Technical Preparation Department.

Specific needs of the company in the production of printed circuit boards

“A major advantage of the Helios information system is its ability to be adapted to the specific needs of a manufacturing company. At Gatema PCB, the Production module has been customized in many areas,” explains Jiri Merinsky, the lead programmer of the Production module.

Implementation of the Production module of the Helios information system

The gradual increase in the number of production orders and the expansion of PCB manufacturing technologies led the company’s management to decide to implement an information system. In 2000, management decided to address the increasingly unsustainable situation caused by manual monitoring of the production process. The implementation of the system was completed quickly and without any production downtime.

The complete implementation, including ongoing support for the system’s operation, is provided by Gativa, a company belonging to the same holding company.

What have we gained thanks to the Production module?

• Perfect overview of the status of the PCB order, from the creation of the quotation and order through the production process to dispatch.
• Evaluation of order profitability throughout the production process.
• Reduction and prevention of non-conformities during the production process.
• Evaluation and prevention of downtime in PCB production.
• Planned maintenance of machines to support a smooth production process.
• Reduction of machine downtime and its impact on the production process.
• Faster communication with customers through online configuration and automation of the workflow throughout the ordering and production process.
• Better management and accumulation of PCB production at the semi-finished goods stage.

The ideal partner for the digitalisation of industry

Data transmitted using RFID technology forms one of the foundations of Industry 4.0. This proven technology can be used not only for information transfer and location tracking, but also for the globally unique identification of objects. Industry 4.0 requires the digital identification of workpieces, tools, containers, machines and other equipment. These objects must also be able to exchange information.

Using RFID transponders, current machine data can be read and automated status messages can then be sent to a defined recipient. The conclusion is clear: Helios supports communication and know-how in the field of RFID technology through its modules and integration solutions, helping companies achieve one of the fundamental goals of Industry 4.0 – connected, data-driven and efficiently managed production.