SMT Capital Equipment Road Map
100% capacity
in 6 months
SMT Hours in
2020
Know you SMT capacity
SMT Hours in
2015
50K CPH Capacity = 1 hour placing 50K parts
Seven Steps
1
7
Present Case
Studies
supporting
ROI
6
Chart The
Past
Use the
software
Project The
Future
Driving
Factors
5
2
Calculate
Your Capacity
Choose your
Vender
3
4
2
Chart The Past
• SMT Hours Earned Over the Past 5 Years
• Since 2011 we have seen a 226% growth in SMT Hours Earned
Data provided by finance
3
Project The Future
SMT Hours Projections for the Next 5 Years
We will look at the net increase using 3 methods.
1. 50% Straight increase each year as seen from History
2. 20% Straight increase each year from lowest yearly increase
3. 20% increase the first year, decreasing by 4% (20%-16%-12%,
ect…) every year after
4
Calculate Your Capacity
• SMT Hours Earned VS Capacity
SMT lines
– 80% OEE netting hours in a 5 day work week per quarter
• total hours in a 5 day work week, across all smt lines per quarter
• With modest growth, we need to add an SMT
line capable of at least ****** SMT hours a
week, every year each year for the next 5 years.
We should never let ourselves be at maximum
production capacity, as we will be unable to
responded quickly to customer demand.
(Production hours per day) hours a day, times 5 days
a week, times 13 weeks equals = total hours per SMT
line in a quarter.
80% OEE of SMT hours worked equals = SMT line
hours per quarter.
5
More SMT Capacity Required
• By the start of the third quarter of 2016 we will need to add another SMT
line to keep up with production.
• The current lines we have are failing with limited parts available for repairs.
• Each line has a trackable CPH or you might use a factory standard. Many
factors will influence this number. The best to collect a running average over
several production runs.
If it is new equipment, de-rate the stated IPC placement rate by 20% to be in the
ball park. We will use 50,000 CPH for a duel CP7 line with a flex placer.
• Finance has been tracking the loaded production hours. They have your
production history
• You now have what you booked over the past 5 years and what capacity you
currently have. Now we just have to project and increase
6
Choose Your Vender
Top Tear Equipment Manufacture
A high production quick change operation that will last
20+ years.
Best in class technology
Best in class Service and Support
7
Driving Factors
• Manufactures planned support for their equipment.
• Technical capability of the SMT equipment.
– Can place 0250125 (.25mm X .125mm)
• Placement rate, Production tracking, Optimization.
• Quote placement time reduction.
03015 metric
0.3mm X 0.15mm
8
Technical Capability of the SMT
Equipment
• Efforts should be made to insure we can routinely place 01005
and 12 mil pitch devices with little effort.
• As new lines are selected, the key factors are:
–
–
–
–
Accuracy
Placement rate
Technical support, and
Offline setup
.65mm CSP
9
SMT Equipment at End of Life
• A CP6, small package camera went
out and was no longer carried by Fuji.
• The following equipment is at end of
life and should be replace in the next
5 years
–
–
–
–
screen printers
chip shooters ( all CP6’s lines)
flex placers
reflow ovens
As with any manufactured item, the old 10
year unwritten rule applies. If it's been
approximately 7-10 years since a model was
produced for new sale distribution, then
discontinuation of certain items for that model
is possible.
Dave Byker, Fuji America
10
Use The Software
•
•
•
•
•
•
Offline program and feeder setup
Optimal setups for multiple production programs
Real-time monitoring of production
Non-stop production Warnings before parts run out
Prevention of misplacements through smart feeders
Improve manufacturing processes
– Faster placement speeds
– Increase yield
– Enhance margins
11
High Capacity Line (104K CPH)
• Eight NXTIII M6 Modules (4-H24, 2-V12, 1-H08, 2-H02 heads)
– 03015 at ±25 μm@>1.00 Cpk
– 10 mil IC at ±25 μm@>1.00 Cpk
• 120 nozzles
• 534 x 610 mm PCB size
• All within the foot print of a single cp6
219,000 CPH Stated
130,835 CPH IPC
104,668 CPH at 20% de-rate from IPC
Reclaimed Floor Space
Further Floor space can be saved by placing these lines back to back
13
Present Case Studies
• Product “A” currently require 25% of the total SMT
hours available with a 7.56 sec top placement and 3.6
sec for bottom placement.
• The new equipment as quoted will deliver these in 2.06
sec and .61 sec respectively.
• Product “A” times will improve by 8.49 sec per unit for
a product savings of (8.49 sec X SMT line price)
• SMT labor savings are (reduction of head count)
There is also a return of capacity of 5188 smt hours with
a value of (5188 X Line price)**
14
Case Study / A Day of Small Runs
• A single customer required 147 total SMT hours (27
assemblies) in a single day.
• A single high capacity line would optimize that days
production running it by it self in only two days
• Return SMT production hours back to other production.
• Running small production 3 days a week (42%) nets 11,232
hours a year
15
Added Benefits Not Included in the
cost savings
• 22% energy reduction over perching a CP6 line and 122% with
the reduction of a CP6 line.
• In line Laser Bar code marker will all but eliminate labels on
the new line.
• Training a JIT work force burden will be reduced with each line
bought. No more added head count.
• Feeder setup group to reduce change over, and burden from
the SMT line.
• Software should be used to the verify the feeder bank before
it is brought to the line.
16
The Solution
Add a line each year, with more then double the placement
capacity of a current line that is ready for retirement.
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–
–
–
–
–
–
screen printer $166k
Placement modules $1.5 mil
Oven $100k
AOI $140k
Conveyors $120k
Software $100K
Laser PCBA marker $140K
17
Return on Investment
• “A” mas production (30% utilization)
• “B” production high mix (42% utilization)
• 10% Reduction of quoted times with the addition of a line yearly
savings on 50% setup reduction of this line
• Floor Space
– leased space annually for each line
– production line gain of 25%.
• Running these case studies offers a gross return of over $2mil
a year based on a variable cost payback
18