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Spurred by the trend toward increasing their highmix assembly capabilities, more than ever, SMT manufacturers are looking to increase the true flexibility of their production lines. With the ability to easily "flex" their production, the cost per mountedcomponent can be substantially reduced. The result is a classic "Win-Win" for SMT manufacturers. First, they're able to increase the level of profitability on each batch their facility produces. Plus, they're able to improve their chances of attracting the additional business needed to sustain their own company's growth. Six key parts How can a company install a production line that is truly flexible? What considerations go into selecting the right equipment needed to achieve this? How can quality be maintained at the same time efficiency is maximized? The answers to these questions and more can be found when all six parts of the Flexibility Wheel (Figure 1) are put into motion, to worktogether. It's also important to recognize and remember that true flexibility is not dependent on having machines with the fastest top-end speed. True flexibility is based on increasing throughput by minimizing time necessary for changeovers and setups. The goal is that SMT manufacturers have the capability to produce more circuit boards in the same workday. Part 1 - Full range component handling The ability to handle and place a full range of components on virtually any board is the starting point for truly flexible SMT production. This includes everything from 01005 size chips and CSP's to large and complex QFP's, CCGA's and connectors. Of course, the larger variety of component sizes that a single machine can pick and place, the easier it is for an SMT manufacturer to fully utilize that machine. Top speed is all-important to SMT manufacturers who concentrate on high-volume production. To optimize productivity, it often necessary to have two machine types– chipshooters and machines for fine-pitch mounting. Bycontrast, if high-mix capability is the goal, it may make moresense to have one or more all-in-one solution machines thatallow SMT manufacturers to achieve true flexibility. The efficiency of an all-in-one platform With an all-in-one platform, there is only one brand of equipment to service, one brand to maintain and one brand that people need to be trained to use. It also means that feeders can be unified, and the same feeder-types can be used for all machines. One drawback of having two different in-line machines (one for smaller components and the other for fine-pitch) is that it makes it difficult to divide the production line between two jobs, as well as two machines. This isn't a problem when an all-in-one platform has been installed, since both machines have identical capabilities to handle any type of component. Of course, on production lines that are built primarily for speed, flexibilitymay not be a concern. But today, many high-volume operations are also required to offer flexible production by running prototypes andother small batches. With a single, all-in-one platform, evenlarge operations can benefit from having a machine thatcan handle both high-speed production and prototypes,depending on changing production needs. Click here to view Figure 2. Part 2 - Smart feeder system Having "smart" feeders that support faster changeovers and setups is the second key part needed to achieve true flexibility for SMT manufacturers. The past decade has witnessed feeder technology that has evolved to enable faster, lighter and smarter solutions. As a result, the days of hassling with programming, threading and struggling withoversized feeder carts are numbered. Small and lightweight, truly intelligent feeders can be loaded in seconds, clipped onto the tape-reel, and stored anywhere. With their own unique identity, the machine software automatically recognizes the presence, absence and location of components when loaded into any slot. This kind of intelligent functionality ensures that pick positions never have to be programmed, nor does production stop when a feeder runs out of components. Thanks to the feeder's unique identity, the machine can alert the operator, re-optimize production, and continue mounting other components–all on its own. Another important thing to look for in a feeder is a dedicated barcode system, which provides easy tracking of component and inventory data, such as batch ID and quantity. Barcodes can also be scanned during loading and unloading, eliminating manual entry, and making setups and changeovers even faster. For feeders, simpler is better The more complex the feeder, the more likely it is to have problems down the road. A simple design means less maintenance and requires no fine-tuning to get proper component feeding. Furthermore, when lightweight individual feeders are combined with magazines, SMT manufacturers get the best of both worlds: the intelligence of single feeders along with the "gang loading" way ofthinking.  Part 3 - Any shape, any size PCB handling The ability to handle PCBs of any shape and size, from small boards to giant backplanes is the third key part to achieving true flexibility. In high-mix production lines, thetypes of jobs change more often, as so board types. This puts a premium on flexibility, not top-end speed.Since odd- or large-size boards often require specializedmachines and/or handling equipment, it is importantto purchase SMT equipment that can address the shape,size, thickness and weight demands of odd-shaped boardswith manual load tables and special handling units.Also important is the ability to switch between an in-linesolution for larger batches, and a specialized prototypingarrangement for smaller boards. When running prototype jobs, it is especially important to be able to easily handle changes. Flexible production requires having an SMT line with board autowidth functionality, enabling easy, automatic switching between different size boards. A flexible placement machine will enable handling of both, with the added bonus of running several boards as a "board train" with a large board handling unit to significantly decrease board transfer time and increase throughput. In addition, if the entire production is linked by barcodes, PCBs will be completely traceable–enabling manufacturers to know what was placed where and when. Click here to view Figure 4. Part 4 - Actual throughput In days gone by, the SMT industry put a great deal of emphasis on top-end speed. But in today's highmix environment, where small batches are much more prevalent, the primary focus is on how many boards are completed at the end of the day. This is how cost per mounted component (CPC) is calculated, a number more relevant and interesting than components per hour (CPH). Knowing the CPC is critical to providing better and more accurate quotes to customers because it provides machine utilization information that's necessary for productionscheduling. Save time and money For high-mix SMT manufacturers, success is directly linked to the ability to produce a lower CPC by reducing setup and changeover time. Therefore, it is necessary to have software that not only automates PCB assembly, but also assists in decreasing the time between two jobs. A good management software suite should include an application that makes engineering change orders easier by helping avoid problems associated with incorrect machine programs and package data. It should also offer the possibility of off-line programming, so that all of thework can be done simultaneous with production. The right software for optimizing throughput As a primary consideration, software packages should include a tool for optimizing and balancing lines. A good optimization tool can handle several jobs at the same time, for several machines, as well as provide the optimal kitting order to help complete production.Placing a component is one thing, however, if the component is new, unfamiliar or complex, it will need tobe programmed first. This time-consuming procedure caneasily be solved using a so-called "autoteach" function thatinstantly catalogues the new component package. Today, most manufacturers find it absolutely necessary to have software that eliminates manual data entry and provides complete traceability. Having this data correct and immediately available makes follow-up faster and easier, saving time in the production process.  Part 5 - Upgradeable machine platform If there's one constant in the SMT industry today, it's change. PCBs and components are changing all the time. Therefore, it is important to stay competitive and not have to worry about buying new equipment every few years. In fact, SMT machines should be the safest long-terminvestment that manufacturer make. That is why truly flexible production requires equipment that is ultimately upgradeable. An inflexible machine can become quickly outdated if it cannot be adapted to fit the changing needs of production. A machine that can be used for many years requires long-term quality and a robust design. With the right software, an older machine model can be easily updated, with added capacity or capability. Remember, aside from financing costs, buying a new machine means re-training personnel and even risking downtime later on due to a lack of familiarity with the equipment or software. Part 6 - Customer support and customization Last, but certainly not least, lack of good customer support decreases a machine's worth. So far, all five aspects of the flexibility wheel revolve around technical solutions. But there will always be a need for training, support and education, as well as assistance with new packages. A comprehensive maintenance schedule and service programcan go a long way to helping avoid problems. Also, it is essential to have a supplier who will help design special tools, or help to develop special board or component handling solutions. Flexible support means having more than a number to call when a machine breaks down – it means having someone who calls because they are concerned about your success. Finally, since many components today come in unusual packages and sizes, a range of customized grippers and other tools is important as well. It is important to be able to handle virtually anything a customer demands. | 
