A Digitalization Step to Enhance Quality and Efficiency in PCB Production: Transport Cart Lifetime Tracking Application

In industrial production environments, digitalization plays a strategic role in quality control, traceability, and sustainability. As part of Alpplas' digital transformation efforts, the Transport Cart Lifetime Tracking Application implemented at our Istanbul facility stands out as a strong and tangible example of the transition from manual systems to a digital infrastructure.

Designed to ensure quality in PCB production and sustainably enhance process efficiency, this system places digitalization at the core of managing auxiliary equipment that directly impacts production processes.

Manual Tracking and Increased Scrap Risk

One of the critical steps in PCB production is the wave soldering process, during which a masking process is applied to protect areas that should not be exposed to solder. The transport carts used in this process are made of high-temperature-resistant durostone material and have a limited lifespan.

Previously, the lifespan and maintenance cycles of these transport carts were tracked manually using forms. However, manual tracking processes posed various challenges, such as operator errors, time-consuming procedures, and the lack of data analysis capabilities. In particular, the continued use of expired carts in production, without being noticed, led to declines in product quality and increased scrap rates.

Sustainable Quality Control with Digital Tracking

To provide a permanent solution to these challenges, the Transport Cart Lifetime Tracking Application was developed, transitioning all tracking processes to a digital platform, ensuring transparency, control, and traceability in production.

Key Features of the Application:

• QR Code Integration:
  Each transport cart was assigned a unique QR code, making them fully traceable.

• Digital Usage and Maintenance Tracking:
  The usage count, maintenance history, and current status of the carts can be monitored in real-time through a user-friendly interface.

• Automated Notification System:
  When a cart reaches its designated lifespan or its maintenance period approaches, the system automatically notifies the relevant unit managers, allowing preventive actions before disruptions occur.

• Digital Instruction Integration:
  Maintenance and inspection processes are conducted according to predefined standard maintenance instructions in the system, ensuring consistent application.

• Reporting and Decision Support:
  The system generates detailed reports, facilitating process analysis and providing data-driven insights for continuous improvement.

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  Achieved Gains

  With the implementation of the Transport Cart Lifetime Tracking Application, the following improvements have been achieved in Alpplas’ production area:

  • Ensuring Product Quality:
    The use of expired carts has been prevented, eliminating potential quality issues in PCBs.

  • Reduction in Scrap Rates:
    Strengthened control mechanisms have significantly decreased defective production and scrap amounts.

  • Transparency and Planned Management in Maintenance Processes:
    Timely maintenance has extended equipment lifespan and prevented unplanned downtimes.

  • Increased Process Speed and Efficiency:
    The traceability provided by the digital system has accelerated operations while minimizing errors.

  • Reduction in Human Error:
    With automated tracking and notification systems, the need for manual intervention has decreased, limiting error-prone areas.

  A Strong Step in the Industry 4.0 Journey

  At Alpplas, we integrate smart systems and digital traceability into our production processes, fostering a data-driven decision-making culture at every step. The Transport Cart Lifetime Tracking Application is one of the simple yet effective solutions implemented in line with this approach, making a strong contribution to our Industry 4.0 vision.

  Digitalization is not just a technological transformation—it is also a strategic step toward sustainable quality, operational excellence, and employee safety.

  As Alpplas, we remain committed to advancing on this path.

  Nesil Nur Akar
  Senior Production Specialist