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
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.–
Programming & Scheduling
Production Assistance
Monitoring & Analysis
Traceability
Maintenance
Machine-to-Machine
Frequently Asked Questions About YSUP Production Assistance Software
What is Yamaha YSUP production assistance software?
Yamaha YSUP production assistance software is an SMT line support tool designed to improve setup accuracy, reduce human error, and optimise production efficiency through real-time monitoring and smart operator guidance.
How does YSUP production assistance improve SMT setup accuracy?
YSUP uses setup verification tools that match component IDs, feeders, and machine configurations to ensure the correct parts are placed in the right positions, preventing setup errors before production begins.
What is SMT setup verification software and how does YSUP use it?
SMT setup verification software ensures all materials, feeders, and tools are correctly configured before production. YSUP performs automated checks using barcode or ID scanning to validate reels, trays, and printer setups, reducing costly mistakes.
How does YSUP reduce downtime in SMT production?
YSUP reduces downtime by monitoring production in real time, alerting operators before components run out, and enabling faster setup changes through guided workflows and external setup tools.
What is the YSUP parts remain counter and how does it work?
The YSUP parts remain counter tracks the number of components left on each feeder during production and alerts operators when stock is running low, allowing proactive replenishment and preventing machine stoppages.
What is material time limit management in YSUP?
Material time limit management is a feature that tracks component shelf life and usage conditions, such as moisture-sensitive devices and solder paste, ensuring expired materials are not used in production.
How does YSUP help prevent SMT production errors?
YSUP prevents errors through automated setup verification, real-time monitoring, guided setup navigation, and validation of materials and components, ensuring consistent and reliable production processes.
Can YSUP support real-time production monitoring and operator alerts?
Yes, YSUP provides real-time production insights, including component usage tracking and visual alerts, enabling operators to respond quickly to issues and maintain continuous SMT line operation.