Our customer Rohde & Schwarz operates a highly specialized circuit board manufacturing facility at the Teisnach plant, which supplies prototypes, functional samples, and series parts for in-house products as well as external customers. Modern, largely automated production systems are used to manufacture conventional multilayer, sequentially built, and HDI circuit boards. This also includes complex RF multilayers based on FR4, PTFE, and ceramic materials. These are designed for the highest quality and reliability requirements.

Before the introduction of iLIMS, many processes were only partially digitized:

• manual Excel evaluations
• separate systems for laboratory and quality data
• limited transparency regarding analyses and limit violations
• labor-intensive maintenance of existing Lotus Notes databases
• high time expenditure for reports and evaluations

A solution was sought that automates laboratory processes, makes data centrally available, and improves traceability.

Efficient organization of sampling:

At each sampling point, three samples are taken daily. To make this process efficient and error-free, a barcode-supported system has been implemented.

The following applies:

• Each sampling point has fixed barcodes on the sample containers
• Only one sample is active in the system
• A scan script automatically recognizes the correct sample when scanning
• If multiple samples are found, a popup opens automatically to select the sampling point

This keeps the sample workflow simple and safe for employees – even with a high number of daily samples.

Automatic calculation of chemical additions:

A central component of the solution is the automated support for bath control. When measured values exceed defined limits, iLIMS automatically calculates the required amount of chemical additions.

The calculation is based on:

• Daily measured analysis results
• Reference values stored in the master data
• Volume of the respective sampling point

This allows necessary corrections to be made quickly and understandably.

Integration into the existing SAP landscape:

For the connection to SAP, an existing web service could be used. As part of the implementation, an extension of the interface was initiated.

The solution:

• A request for the interface adjustment was triggered through the corporate headquarters in Munich
• The technical implementation took place during the further course of the project
• Ongoing operations could be ensured in the meantime

As a result, the project could be implemented as planned.

Transparency through dashboards:

To quickly identify limit violations, clear dashboard displays have been set up.

These provide:

• Display of current measurement data per facility
• Immediately visible limit violations
• Direct display of required chemical additions

A special dashboard gadget updates automatically every five minutes and immediately indicates when limits are exceeded or chemical additions are required. This allows responsible staff to react quickly and initiate appropriate measures.

Digital laboratory processes with iLIMS

With the introduction of iLIMS, a central laboratory information management system was finally established, which digitally maps the entire laboratory workflow. This includes, among other things, automated examination planning, structured sample collection and sample entry recording, digital result recording, as well as automatic monitoring of limit values including notification in case of deviations.

Furthermore, various data sources could be merged in a central system for the first time – including the analytical laboratory, the cross-section laboratory, as well as quality data from production. This created a consistent data basis that connects laboratory, quality assurance, and production, enabling significantly better transparency over production processes.

Images: © Rohde & Schwarz