Flexible and automated production is integral in meeting the challenges of SMT (Surface Mount Technology) assembly. The full meaning and implications of flexible production and its impact on automated electronics manufacturing must be understood and specifically defined. The trend towards smaller and more varied production lots requires more flexibility in the production line set up because the current state of the industry is lower volumes and higher production mixes.

The ability to change over rapidly in production from one lot to another is important, but it is equally if not more important for the change-over process to be cost efficient in order to maintain satisfactory margins for the manufacturer. The ideal to which the electronics assembly industry moves towards is total automation.

In a completely automated factory, solder paste would automatically be deposited on the stencil, feeders would be self-programming and if all things where perfect, AOI would not be necessary. When evaluating your own production line for improvements, evaluation criteria should include:

• Operational status of the SMT line
• Reasons for any SMT down time
• Number of operators on the SMT line
• Automation level and any areas for improvement

If a higher degree of automation has already been achieved, additional decision considerations for equipment upgrades include:

• Is the line loaded automatically through a bare board line loader?
• Is the screen printer equipped with an automatic under stencil cleaning tool and 2D or 3D paste Inspection?
• Is the Pick and Place machine running without downtime? If so, can the feeders be configured for two different jobs?
• Are smart, inexpensive feeders being used?
• Is the reflow oven easy to clean and equipped with exchangeable filters?
• Is the line self-loading or are the boards unloaded manually?

All of these issues can be resolved relatively easy with "smart" equipment. Often, the result will be a search for and evaluation of newer, more efficient equipment. Taking a closer look at a typical pick & place machine, most suppliers are offering chip-shooters and fine pitch placers with the capability of placing the widest range of components. In terms of flexibility, even with the work-balance between two modules, one of the two machines will always finish earlier than the other. The resulting machine downtime will require the mandatory balancing efforts by the machine operator.

The method of board handling in your line is also an important factor in evaluating production automation upgrades. Is someone carrying the printed circuit board (PCB) between the printer, the pick and place machine and the reflow oven? These steps can be automated through PCB handling and conveyor systems. An appropriate automation upgrade will reduce redundant labor costs and increase efficiency and throughput.

Increased levels of automation are often difficult to realize in a small to mid-size company when the impact of such a move is not fully documented and quantified. A return on investment (ROI) calculation is the best way to illustrate the financial return from investing in automated systems such as the MIMOT Advantage 3 pick and place system used at the EMPF (Figure 6-1). The calculation must take into consideration the benefits, including the elimination or reduction (reallocation) of salaries, increased quality, and enhanced process stability. Other important factors to consider in the decision process include the tractability and feasibility when looking to new, more efficient solutions.

At the EMPF, one of the automated systems which are utilized in the demonstration factory's manufacturing process is the Mimot Advantage 3 pick and place system. This system is a high mix / high speed system for all type of printed circuit boards and components. Placement is rated at 21,600 chips per hour and has a full range component capability - (I.E. 0201 through 55 mm x 55 mm).

The EMPF uses this system in our Boot Camp training classes. The students are taught the fundamentals of pick and place assembly, feeder programming and general system set up.

If you wish to see a demonstration of this system, please contact Jeff Stong at 610-362-1200 extension 224.