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Integrate your ERP to BPM Programmers with API

Integrate your ERP to BPM Programmers with API

by | Mar 11, 2021 | Technology, White Papers

Integrate your ERP to BPM Programmers with API

“If you can imagine it, we can make it happen”

— James Cawkell, Director, The Adaptsys Group

ERP API Abstract

BPM Microsystems process software, BPWin, is arguably the best in the industry. But even relatively easy-to-use software has a learning curve. As a standalone unit, an automated programming system (APS) is disconnected from the manufacturer’s process workflow software. Most manufacturers have a Material Requirement Planning system (MRP), Manufacturing Execution System (MES) such as Intellect eQMS, or Enterprise Resource Planning (ERP) such as Oracle and SAP. Would you like to have your ERP “talking” with your APS? This whitepaper explores some real-world solutions implemented to give you an idea of what is possible when connecting your APS to your manufacturing system through an API (Application Programming Interface).

API Defined

An application programming interface, or API, according to Wikipedia, is a computing interface that defines interactions between multiple software or mixed hardware-software intermediaries. It defines the kinds of calls or requests that can be made, how to make them, the data formats that should be used, the conventions to follow, etc. It can also provide extension mechanisms so that users can extend existing functionality in various ways and to varying degrees. (See Wikipedia article here)

Production Programming Advantages

BPM programming equipment, with the activation of BPWin API, has the capability to interface with your enterprise software in a maintainable and standard interface. BPWin API allows users to solve simple to complex process problems during the programming cycle. Designed specifically for BPM Automated Programmers, the API automation object model gives you the ability to utilize any programming language for interface to BPWin software. BPWin API is a breakthrough in programming equipment connectivity, that digitizes the information being generated throughout your device programming operations, and makes it available where, when, and how you need it.

Control and Monitoring API

The BPM API includes two major modules: Control and Monitoring. Control API (CJobControl Object) allows the external programs to control JobMaster related functions in BPWin software

Configure the programming cycle with commands such as select the device, load the data pattern file, set device options, Start or stop the programming cycle, and more. Monitoring API (CJobMonitor Object) allows for programmer system status to be exported in real-time for monitoring through verification, auditing, and logging of data from within BPWin software.

Language-Independent API

BPM’s API works with any language that supports Component Object Model (COM): Labview, C++, C#, Java, JavaScript, VB6, VB.net, etc. COM is flexible with your developer’s skill sets, and shouldn’t require additional resources. Component Object Model interface technology is the basis for several other Microsoft frameworks, including OLE, ActiveX, COM+, DCOM, etc.

With a basic understanding of the BPM API, it’s possible for your internal development team to write the API; it’s also possible to outsource the project. BPM and their European partner, The Adaptsys Group, have extensive experience writing custom APIs. Competent third-party developers have also been successful in building APIs (this usually requires at least some interaction with BPM’s technical team and a thorough project specification).

Simple Monitoring Applications

It’s fairly straightforward to hook in real-time monitoring into your MES or ERP, to inform the job is completed, or that there is an issue that the technician needs to address. Moving raw goods inventory (blank programmable devices) into finished goods (programmed/tested devices) is also fairly easy. The API can also be set up to alert the supervisor or technician (via text message or email) upon completion of jobs, or to notify them when it’s time to switch out trays or reels.

Case Study: Automated Work Order

A large automotive contract manufacturer in Europe tasked the Adaptsys Group. (BPM’s Partner for Germany, France, Switzerland, UK, etc) with developing an API that functions as an automated work order to integrate their BPM Automated Programming Systems with their MRP system. It creates an electronic work order, operator checklist, and does finished goods allocation. 

The automated work order is written in OPC UA, a machine-to-machine communication protocol for industrial automation developed by the OPC Foundation. OPC UA is an open-source, java-based programming language that is focused on communicating with industrial equipment and systems for data collection and control (See Wikipedia article here). BPM’s API is agnostic when it comes to programming– as long as it interfaces with COM.

The interface is a simple web-based form. The data entry process is used to set up the initial data for a given programming job. The first field in the form called “Programmed Device Name” is entered and later cross-referenced in a second form as a unique name for the parts to be programmed. This programming name can then be used multiple times to program the same device type with the same program code yet still made unique by the use of the Job ID from BPWin. The remaining fields are used to set specific information related to the job, which is later called upon to create the Job Sheet. The job sheet would be used by a production operator, to scan barcodes to automate the setup of the BPM Microsystems device handler.

The next step is to create the Job Sheet for production use. Upon submit, the data is saved to the SQL database and pulls in the linked data to populate a PDF document, which is automatically downloaded. This PDF contains the required job data in the form of barcodes, which are used by the production operator to set up the system.

Setting up and running the automated programmers

This is an example of a manufacturing process flow to handle devices to be programmed, from the time they enter the production environment, until the time they are programmed and tested, finally to move to finished stock.

  1. Receive Job Sheet. The sheet contains required fields in a barcode format. 
  2. Barcode Job. This contains a link to the .abp file (BPM’s proprietary job file format which also contains the APS workflow instructions) stored on the customer’s server, to load the .bp file (specific to the job) and program file, set the device type, and device configuration stored within. 
  3. Barcode Pressure Plate. Scan the barcode for the correct Pressure Plate for the sockets. 
  4. Barcode Parts. Scan the received parts to ensure they match the job. 
  5. Barcode Quantity. Scan the correct batch quantity that is to be programmed. 
  6. Verify Setup. The final screen before programming, the Verify Screen ensures everything is set up correctly: Verify the socket modules, check devices, and pressure plates match those specified; check the quantity is correct. On-screen field highlighting of failed fields is used to assist. 
  7. Start Programming. When the verification passes, the job can start.

This electronic “checklist” virtually eliminates mistakes. If an incorrect barcode is received, the system returns an error message that allows the error to be quickly corrected. 

Post programming data and product handling

Upon completion of the job, the job summary log is saved to the electronic work order for review. It then automatically prints a sheet of labels with barcodes with the following information: Custom device reference, Device quantity on the reel or tray,  Label number, job completed date, Input media ID, and Output reel ID. A specific barcode is generated so that the socket modules and pressure plates are moved from a production status to hold. Finally, the customer’s database is updated to indicate the correct quantity of finished devices are verified or scrapped and allocated to appropriate stock locations.

Inventory Management

Inventory ManagementBPWin API can also be used to create custom inventory management. Whether for IoT (internet of things), Industry 4.0, or advanced traceability standards, each device can carry a unique serial number, which can contain more information than is possible with laser or inkjet marking. In addition, advanced security protocols for data encryption can be used as well.

In Conclusion

This paper is not intended to explain how to set up your API; the goal is to give you a taste of what is possible. If you are new to device programming, you may be interested in a work order set-up, or at the very least, notifications and feedback. If you’ve been utilizing device programming, you may have identified some functionality that you wish existed, or perhaps a process that is overly repetitive or requires employee interaction. Once you’ve identified the process, BPM can assist you in developing an API, or provide your developers with the framework to write it yourself.

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Programmable Device Shortage Update

Programmable Device Shortage Update

by | Mar 8, 2021 | Announcements, News, Technology

In an article published in Forbes on February 25, President Joe Biden signed “Executive Order on America’s Supply Chains” to address the global semiconductor chip shortage. Designed as a 100-day review of supply chain effectiveness, and citing that the United States accounts for 12.5% of semiconductor manufacturing, this Executive Order is a part of a continuous stream of policy assuming that “made in America” is good for America.

According to a new Reuters article, here are some updates on the on-going global chip shortage.

General Motors

GM has extended production cuts at four of their North American plants due to chip shortage. It’s being reported that the shortage could cut up to $2 Billion from their 2021 forecast.

Ford

The shortage is hitting production of the most popular truck in the world:  F-150 pickup trucks. Ford could lose 10% to 20% of planned first-quarter vehicle production.

Volkswagen AG

The chip shortage will impact production at Wolfsburg and Kassel plants. VW was the first major automaker to announce that chip shortages were affecting production. Volkswagen is the world’s second-largest car company (behind Toyota).

Groupe Renault

The chip shortage could reduce Renault production by about 100,000 vehicles this year. Renault is a French automaker.

Honda

Honda has announced a cut in its 2021 sales target by 100,000 vehicles due to the chip shortage. Honda is fifth in sales worldwide.

Nissan

Nissan, Japan’s third-largest automaker and #10 in the world have lowered its target by 150,000 vehicles due to the chip shortage.

Tesla Inc

Elon Musk said Tesla’s plant in Fremont, California shut down for two days in February due to “parts shortages”.

Automotive Suppliers

Visteon

Visteon, a major automotive component supplier, has said uncertainty around the semiconductor shortages will lead to some plant closures in the first half of 2021 before things stabilize in the third and fourth quarters.

Stellantis NV

Stellantis‘ factories in Germany and Spain were impacted due to the programmable device shortage. Union sources told Reuters in February that Stellantis planned to slow production at its plant in Italy, and furlough 7,000 workers. Stellantis’ supported brands include Alfa Romero, Chrysler, Dodge, Jeep, Ram, Fiat, and Opel.

Other Industries

Sony

Sony’s Chief Finacial Officer Hiroki Totoki said it is difficult for the company to increase the production of the popular gaming system, the PS5, amid the shortage of semiconductors. The PS5 launched in November of 2020, and is one of the most popular systems in the world.

Why There is a Global Programmable Device Shortage

Why There is a Global Programmable Device Shortage

by | Feb 9, 2021 | News

Part III

Why There is a Global Programmable Device Shortage

Top Reasons for Global Chip Shortages– Whose Fault is it Really?

l

Overview

Causes for the Programmable Device Shortage

  • There’s never been a greater disruption for Automotive Manufacturers, except for the two World Wars
  • Covid-19 restrictions are the major cause of global supply chain shortages, especially for programmable chips
  • Other factors include:

• Just in time inventory management
• Redundancy gap for critical parts
• Increased demand from consumer electronics verticles, such as laptops and gaming systems
• Because programmable devices require value-added services, which include programming, it can take longer for finished components

There’s never been anything close to the disruption to the Automotive industry (World Wars excluded), but there have been regional shortages in the recent past. A tsunami off the coast of Japan flooded Renesas Electronics in March of 2011– the same tsunami that caused the nuclear power plant in Fukushima to fail. While the world was focused on Fukushima, the auto industry in Japan was focused on Renesas, a major programmable device supplier of everything from transmissions to touchscreen information systems. The big three Japanese automakers, Toyota, Nissan, and Honda, were forced to slow or stop output for several weeks.

Fast forward to March of 2020– just nine years later, the entire planet was shutting down over the coronavirus pandemic (see article) which disrupted the delicate global supply chain, causing a programmable device shortage. Semiconductor manufacturers were caught in the crosshairs of canceled orders and business restrictions. Automakers closed factories as demand plummeted. Consumers were on lock-down for weeks, and in some cases, months.

By late summer, demand for trucks and SUVs surged, in large part due to pent-up demand, but also as people shifted away from mass transit for health reasons. However, demand was even higher for laptops and advanced gaming systems for the newly work-from-home employees and others cooped up looking for something fun (and safe) to do.

Who’s to Blame

If you want to pick the number one cause, COVID-19 wins in a landslide. When the new coronavirus started to spread, there was no way to know how bad it was going to be, so governments and businesses took a very conservative approach; many areas experimented with lockdowns and social distancing in an attempt to stop the spread. As scientists and doctors began to understand the disease better, we began to develop ways to deal with this “new reality.” But the disruption was devastating in every way imaginable: many people lost their jobs, many businesses closed, and those that didn’t have to figure out how to keep going under serious constraints.

COVID-19 is a new disease, caused by a novel (or new) coronavirus that has not previously been seen in humans. Because it is a new virus, scientists are learning more each day. Although most people who have COVID-19 have mild symptoms, COVID-19 can also cause severe illness and even death. Some groups, including older adults and people who have certain underlying medical conditions, are at increased risk of severe illness. On February 11, 2020 the World Health Organization announced an official name for the disease that is causing the 2019 novel coronavirus outbreak, first identified in Wuhan China. The new name of this disease is coronavirus disease 2019, abbreviated as COVID-19. In COVID-19, “CO” stands for corona, “VI” for virus, and ”D” for disease. (from CDC.gov)

When everything “closed” in March/April 2020, many automakers canceled orders for parts and components that automotive OEMs provide; this caused a cascade of cancellations that eventually made it back to the semiconductor manufacturers. While orders for automotive chips were cool, the demand for laptops, game consoles, and other consumer electronics became white-hot. Semiconductor manufacturers shifted production to high-demand inventory, and in many cases were at capacity.

Just-in-Time

Just-in-time inventory management is also a major cause of the worldwide dilemma. Automobiles are a low-margin business, so shaving costs with lean manufacturing makes sense. However, when demand rebounded and inventory of programmed devices fell behind, they were quick to point fingers at their vendors who supply finished components for their lines. The chipmakers and vendors blame the automotive industry for canceling orders, keeping their inventory low, and not preparing in advance for when things rebound, contributing to the programmable chip shortage.

Redundancy Gap

Lack of redundancy is another culprit. For instance, 56% of global chip manufacturing revenue originate from one company: Taiwan Semiconductor Manufacturing Co. (TSMC). TSMC supplies the suppliers. Similarly, new and intricate microcontrollers often have their own issues– complex chip designs are often from a sole source, and it takes years to qualify a second supplier. (Source: Bloomberg)

Squeaky Wheel

As large as the global automotive industry is, they are relatively small in comparison to consumer electronics megacorporations, such as Apple, Sony, and Samsung. Consumer electronics typically are a higher margin than automotive devices, and the electronics giants are willing to pay a little more to ensure on-time delivery.

Cost of Capacity

Semiconductor manufacturers are running at capacity to try to meet demand. Similarly, many have plans to expand fabrication capacity in 2021, but won’t impact supply for years, at a cost of billions. (See Semiconductor Factory list)

Value-add Adds Time

Finished components, such as transmissions, engines, entertainment systems, etc. are usually built by contract manufacturers, such as Continental and Bosch. A shortage of chips causes a cascade of issues. Unlike a simple transistor, before many microprocessors can be soldered to the board, they go through programming and testing. Depending on the complexity of the data and/or the volume, programming times can be quite long.

Automated programming systems use advanced robotics to pick, place, program, test, and finally load to trays or tape. If additional processes are needed, such as laser marking for lot and piece numbers, or 3D inspection for bent pins, this can add to the time required. Once programming is completed, the chip can be soldered to the board (which usually will undergo further testing). In conclusion, finished boards can be added to the final assembly, tested, packaged, and shipped to the end-customer. (Read more on offline in-house programming)

Who’s to blame?

Ultimately, it doesn’t really matter. Hopefully, lessons can be learned, and adjustments can be made. Eventually, automakers may be faced with the dilemma of whether to continue playing “chicken” with vendors as their finished product inventories dwindle. One thing for sure: the complexity and reliance on programmed devices will only keep growing, especially as Electric Vehicles (EV) and Autonomous Driving Systems become more prevalent.

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Programmable Device Shortage Spreads to Consumer Electronics

Programmable Device Shortage Spreads to Consumer Electronics

by | Feb 4, 2021 | News

Part II

Programmable Device Shortage Spreads to Consumer Electronics

No shutdowns reported in consumer electronics plants; Chip Shortage Demand driving up prices and lead-times

l

Overview

  • Shortages are causing ripple effects in other electronics products, such as NextGen Gaming Systems, Laptop Computers, Cloud Computing, Artificial Intelligence systems, and Smart Phones.
  • There have been no reports of plants or lines shutting down because of the chip shortage.
  • Many Semi houses are investing in capital equipment in an attempt to meet the demand
  • Complicating the supply chain issue, programmable devices can’t be used without value-added services: programming, inspection, soldering, and test
  • In a break from “just-in-time” inventory, executives are contemplating higher-than-normal stock, as chips don’t take up much space compared to other components
  • Chinese New Year celebrations could cause some short-term logistical headaches starting this week

Programmable device shortages are causing many automakers to reduce forecasts, or in some cases, to close plants. For instance, shortages are causing ripple effects in other electronics industries, such as NextGen Gaming Systems, Laptop Computers, Cloud Computing, Artificial Intelligence systems, and Smart Phones. The good news is that, as of now, there have been no reports of plants or lines shutting down because of the chip shortage.

Circuit boards traveling down the SMT line at BPM Microsystems manufacturing facility in Houston Texas.

Semiconductor shortages are expected to last for the foreseeable future; many Semi houses are investing in capital equipment in an attempt to meet the demand. TSMC in Taiwan plans to increase CapX by 54% in 2021, with additional plans for new factories in the US (source). 

Supply Chain Issues

Rising demand is causing price pressure on raw materials used in semiconductor manufacturing. In addition, there are only a handful of advanced foundries capable of producing advanced chips required for video processing, advanced gaming systems, computing, and 5G phones.

For instance, programmable devices can’t be used without value-added services: programming, inspection, soldering, and test. Therefore, without uploading the code to the device for a specific application, a chip is just a small, fairly expensive, and not very useful paperweight.

See “Six Ways to Program Devices” article here 

Auto Production Update

Automotive and industrial equipment manufacturers will continue to experience programmable device shortages at least through mid-2021. Microchip, NXP Semiconductors, and Silicon Labs are among suppliers that have raised prices, in addition to warning of shortages throughout this year.

As of the first week in February, General Motors is the latest automaker to report they’re “trimming output” in four factories (source). Thus far, Volkswagen has been among the hardest hit; VW is considering purchasing critical chips directly from manufacturers for the first time (source). In a break from “just-in-time” inventory, executives are contemplating higher-than-normal stock, as chips don’t take up much space compared to other components.

See article “Programmable Device Shortage causes Auto Makers to Cut Output, Idle Plants”

Other Headaches

Chinese New Year celebrations could cause some short-term logistical headaches starting this week. All offices and factories close for about 3 weeks, allowing workers time to travel home and back. Therefore, if you were counting on ordering/receiving inventory from warehouses in China next week, you’ll have to wait.

For more information on Chinese New Year and some tips on planning ahead, please visit https://www.ewmfg.com/chinese-new-year/

Jon Bondurant is the Chief Operating Officer of BPM Microsystems. He says, “We keep a minimum of six months inventory of critical  electronic components of our programmers and accessories.” In addition, when quantities fall below thresholds, they show up on weekly reports. In conclusion, this helps to ensure that BPM won’t get caught up in supply chain issues, or has some time to find an alternative source.

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Programmable Device Shortage causes Auto Makers to Cut Output, Idle Plants

Programmable Device Shortage causes Auto Makers to Cut Output, Idle Plants

by | Feb 2, 2021 | News

Part I

Programmable Device Shortage causes Auto Makers to Cut Output, Idle Plants

Canceled orders and lack of a backup plan leads to $61 Billion in losses so far in global programmable device shortage

l

Overview

  • Affecting Ford, Fiat Chrysler, Honda, Volkswagen AG, Toyota, Nissan
  • Supply chain disruptions started with canceled orders for chips when automakers closed plants due to Covid
  • Over 100 different chips used in an average car, helping to control everything from infotainment systems to anti-lock brakes
  • Semiconductor manufacturers shifted inventories to consumer products in high demand during the automotive lull, such as gaming systems and laptop computers
  • 280,000 fewer vehicles produced than forecast and may balloon to over 500K (AutoForecast)
  • Other verticals are beginning to be affected: Smart Phones, Laptops

It’s being called “Chipageddon” as Automotive Plants around the world deal with programmable device shortages due to Covid-related shutdowns in the spring of 2020. Now automakers around the world are idling lines as they scramble for critical components to meet the market demand.

  • San Antonio, Texas Toyota plant is only able to produce 60% of demand for the full-sized Tundra Pickup
  • Louisville, Kentucky Ford plant is idle for a week and has laid off almost 4,000 workers
  • Volkswagen AG is cutting production in the first quarter of 2021 in China, Europe, and North America
  • Fiat Chrysler is idling its Jeep plant in Toluca, Mexico, and its sedan plant in Brampton, Ontario (Canada) in an effort to shift production to higher selling models
  • It takes 6 to 9 months of lead time for the industry to get devices because of complex logistics and just-in-time inventory management

Pent-up demand for automobiles ramped up in the late 3rd Quarter of 2020, and automakers and OEMs were caught off-guard when they were told: “wait.” For instance, when they canceled their chip orders, Semi-houses shifted their production to consumer chips in the covid-driven stay-home new reality: new gaming systems from Microsoft and Sony and a huge uptick in laptop orders from stay-at-home employees and students.

Growth of Programmable Devices in Automobiles

On average, a modern car has over 100 chips on-board, and a programmable device shortage of any of the components will cause the production line to grind to a halt. In addition, most manufacturers utilize “just-in-time” inventory to save cost and space, but saving pennies has cost billions: $61 Billion so far.

However, for devices that require programming, this can result in an even greater bottleneck. Infotainment systems, with massive data demands, require up to 20 minutes to program a single device. Electric vehicles (EV) are the fastest-growing segment; while only constituting 3% of global sales, the onboard chips are about three times more valuable than gasoline cars.

Add to the complexity the fact that most of those chips require additional programming for their specific applications. Some lower density devices can be programmed in-circuit; high-density memory devices are usually programmed (either at a programming house or in-house) on an off-line Automated Programming System.  (See “What is the Best Way to Get Devices Programmed” Article)

Logistical Nightmare

With the complexity of the supply chain and the additional demand for consumer chips, automakers may face up to nine months lead time. Above all, in many cases, slower-selling vehicles can’t get parts, as pickups and SUVs take priority.

The global semiconductor market is paced to be valued at over $129 Billion in just 4 years, nearly triple 2019 (read more). Driving growth are infotainment systems, smart dashboards, self-driving technology, and green vehicles (many battery efficiencies have been led by programmable devices). See Automotive Programming

Automotive programmable device makers include STMicroelectronics, Nvidia, TSMC, Infineon Technologies, NXP Semiconductor, Texas Instruments, and Toshiba. 

China Hard-Hit

China has been especially hard hit by the chip shortage; it has the largest automotive market in the world but imports the vast majority of chips used to manufacture automobiles.

The components in a car require a more robust architecture than your smartphone: high temperatures, g-forces, etc. Therefore, autos have much longer lifespans than consumer-grade electronics, so the devices need to be durable and reliable and may take up to five years to design and develop.

As of publication, the worldwide shortage has not yet affected non-automotive chip inventories; while semiconductor manufacturers shift production to automotive customers, this may cause other inventories to shrink while they make up for demand.

In Conclusion

  • Just-in-time inventories need to be balanced against the prospect of line-down due to a lack of components. Manufacturers should inventory a minimum of six months of back-up devices to mitigate shutdowns
  • Canceled orders for chips have caused semiconductor manufacturers to shift to more profitable and/or more stable inventories
  • Chip shortages are causing strains on OEMs and programming houses to keep up with the demand for programmable devices
  • Manufacturers of other products should take heed now, or they may get caught in a logistical nightmare too
  • To ensure the most bullet-proof inventories for manufacturing lines, contact BPM about in-house solutions for programmable devices 
    • Output can pace with the production line by adding shifts and/or adding machines in combination with strategic outsourcing
    • In-house off-line programming provides unmatched efficiencies, producing a lower cost per device, and drastically lowering lead-times
    • Source Code can be updated daily, allowing the line to have the latest revision
    • Keeping your source code in-house makes your intellectual investment more secure from theft

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Global semiconductor shortage forcing automakers to cut production

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Semiconductor Shortage Delays Global Automotive Sector Recovery

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Ford trims Explorer, Lincoln Aviator output due to ongoing chip shortage

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