Production Assistance

Yamaha’s SMT YSUP software offers advanced setup automation and comprehensive production monitoring, all designed to reduce errors and significantly enhance operational efficiency.

By streamlining machine setup and providing real-time insights, YSUP empowers manufacturers to optimise production workflows, minimise downtime, and ensure consistent quality across every stage of the process. Some of the features of Production Assistance include:

Set-up Verification
Material Time Limit Management
Rank Monitoring

Set-up Navigation
Parts Remain Counter
Remaining Components Monitor

Set-up Verification

The system seamlessly correlates ID information to prevent operational errors, ensuring accuracy at every step. Whether you’re using a wired or wireless reader, it guarantees that the mounter aligns parts in the correct position. For solder printers, it checks that both the stencil and squeegee are precisely set, minimising the risk of mistakes and enhancing the overall efficiency of the production process.

Scan each ID and it’ll verify the reel, tray parts and items for the solder printer.

Offline Setup

Setup Navigation

Line utilisation can be significantly boosted by performing external setup. By connecting to a PC, it’s possible to recreate a machine-equivalent environment, streamlining the process and reducing downtime.

The pie charts below highlight a clear contrast in productivity. Notably, the sections related to external setup show a significant difference—especially when a PC is connected to simulate the machine environment, streamlining the overall operation i.e., The first pie chart shows that 58.3% of the time is spent on production when external setup is used, while the second chart shows a lower production time of just 41.7%.

Parts Remain Counter – Line Control

The Yamaha YSUP software goes beyond basic functionality by including a Parts Remain Counter, which actively monitors the remaining parts in real-time. This feature not only provides timely alerts before parts run out, but it also helps ensure that parts are prepared in advance. As a result, machine downtime is minimised, and overall operation efficiency is significantly improved, allowing you to focus on maximising productivity without worrying about unexpected shortages.

Material Time Limit Management

The Production Assistance system offers powerful Material Time Limit Management, a feature that helps safeguard against the use of expired parts and solder paste. By tracking the expiration dates and ensuring only fresh materials are used, it significantly reduces the risk of production errors and improves product quality. Additionally, it allows you to check part information in real-time, even while external setup is taking place, ensuring that everything is running smoothly without any delays. This streamlined process helps prevent costly mistakes, enhances operational efficiency, and supports a seamless, error-free production flow.

Humidity Management i.e., MSD, PCB
Temperature Management i.e., Solder Paste
Warranty Management: All Parts

The diagram above illustrates how parts requiring careful management can be effectively tracked and maintained throughout their entire lifecycle, seamlessly aligning with your specific workflow.

Example: Utilising Parts Remain Counter to Track Component Usage in Realtime.

Utilising Production Assistance package (YSUP-MI & Parts Remain Counter (YSUP M-Tool) to maximise the production time by proactively tracking part usage and alerting operators before part depletion.

PART REMAIN COUNTER WARNING

Powered by YSUP-MI and the Parts Remain Counter, the system tracks component usage in real-time. Every time a part is picked, the counter updates instantly. When a reel’s quantity drops below a preset threshold (e.g., 300 parts), the system activates an amber signal tower light and visually highlights the low-reel parts—so the team can replenish proactively, not reactively.

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PART SEARCH & SETTING REEL IN ADVANCE

The operator will take note of the parts, get the reels from storage, and insert the reels into the spare feeders in advance.

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REPLACE FEEDER

When a reel runs out, every second counts. Thanks to our streamlined process, operators can now swap feeders and verify parts in just 30 seconds or less—a major improvement over traditional methods.

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RESOLVED

Utilising the Production Assistance package (YSUP-MI & Parts Remain Counter (YSUP M-Tool) to maximise the production time.

Additionally, Hawker Richardson can supply the Smart Rack by Scienscope, a smart, organised reel storage system that integrates directly with Yamaha machines. When a part needs replenishing, the Smart Rack identifies and lights up the exact reel location, so operators can grab it fast and keep production moving.

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