Analysis of the return on Investment from Semi-automatic to Fully automatic SMT Lines: Is It Worth It?
Many friends engaged in electronic manufacturing often choose to set up a semi-automatic SMT line first when they are just starting out. After all, it has low costs, simple operation and is suitable for small-batch trial production. But as the order volume rose, problems followed: speed couldn't keep up, there weren't enough staff, and quality was hard to control. At this point, people began to hesitate - should they upgrade to a fully automatic SMT production line? Is this investment really worth it?
Today, let's start from the actual scenario and help you do a good calculation to see exactly where the semi-automatic and fully automatic systems differ, and what the input and return look like respectively.
I. What is a semi-automatic SMT line? How automatic is fully automatic?
Let's briefly introduce these two concepts first. Otherwise, it's impossible to compare the investment returns.
Semi-automatic SMT lines typically include:
- Semi-automatic printing machine (requiring manual loading and unloading of plates and manual cleaning of steel mesh)
- Manual placement or a small number of automatic placement machines
- Reflow soldering (possibly an older model with manual temperature control)
- Most AOI inspections are still manual visual inspections
In the operation process, the level of human participation is very high, making it suitable for small factories or sample-making studios with daily shipments of several thousand points or less.
The fully automatic SMT line is different. The general configuration is:
- Automatic plate loading and unloading machine
- Fully automatic printing machine
- High-speed surface mount technology (such as Samsung SM471 Plus, JUKI RS-1, etc.)
- Automatic reflow soldering (precise temperature control, stable track)
- AOI automatic inspection machine
- Sometimes it is also equipped with inspection devices such as SPI and X-ray
The entire line only requires 1 to 2 personnel for equipment inspection and material loading, significantly enhancing efficiency and ensuring more stable quality.
Semi-automatic SMT production line
II. From an investment perspective, how much money does semi-automatic technology actually save?
Let's do a simple calculation first. The market price in 2025 is approximately like this:
Initial investment for semi-automatic lines (standard configuration for small factories) :
- Semi-automatic printing machine: 30,000 to 50,000 yuan
- A medium and low-speed surface mount technology (SMT) machine (domestic/second-hand) : 150,000 to 250,000 yuan
- Reflow soldering (68 temperature zone) : 6.1 million yuan
- AOI visual inspection + manual inspection: Basically no investment required
The total equipment investment is approximately 250,000 to 400,000 yuan
Human resource allocation: Usually, there are 3 to 5 people per shift, who are respectively responsible for surface mount technology (SMT), printing, material feeding, and inspection.
Suitable for: Small orders with a daily shipment volume of less than 50,000 points, sample making, and start-up factories.
III. How much does a fully automatic SMT production line cost? It looks expensive, but is it actually more cost-effective?
Fully automatic SMT complete line configuration (medium-sized production line standard)
- Plate-loading machine + fully automatic printing machine: 150,000 to 200,000 yuan
- High-speed surface mount technology (SMT) placement machines (such as Samsung SM482 Plus) : 30.5 million yuan (second-hand) or 801 million yuan (new)
- High-precision reflow soldering: 150,000 to 250,000 yuan
- AOI automatic inspection: 50,000 to 100,000 yuan
- Auxiliary equipment such as unloading machines and buffer tables: 50,000 to 80,000 yuan
The total equipment investment is approximately 600,000 to 1.2 million yuan
Manpower allocation: Only 1 to 2 people are needed per shift, mainly responsible for line inspection and material replenishment.
Suitable for medium-sized enterprises or contract manufacturers with daily shipment volumes ranging from 100,000 to 1,000,000 units.
Four. Here comes the key: How is the investment payback period calculated?
Scenario simulation: Let's assume that a company has 3 million monthly order points and the difficulty of product mounting is moderate.
In semi-automatic mode:
We need 35 people per shift. The total cost of labor and management expenses is approximately 25,300 yuan per month
The depreciation of equipment (based on 300,000 yuan worth of equipment with a 3-year cycle) is approximately 8,333 yuan per month
Monthly comprehensive cost: approximately 38,000 yuan
However: The labor efficiency is low, the quality is unstable, rework is often required, the yield rate is controlled at around 95%, the monthly loss cost is high, and the delivery time is often tight.
In fully automatic mode:
The workforce has been reduced to 1 to 2 people per shift, and the labor cost has dropped to around 10,000 yuan per month
Equipment depreciation (based on 900,000 yuan worth of equipment with a 3-year cycle) is 25,000 yuan per month
Monthly comprehensive cost: 35,000 to 40,000 yuan
However, please note: The production efficiency is 2 to 3 times that of semi-automatic systems, the yield rate is stable at over 98%, there is basically no rework, and the delivery time is also easy to control.
Conclusion: Once the production volume increases, fully automatic is actually more cost-effective than semi-automatic.
Fully automatic SMT line
V. Besides efficiency, what other "hidden returns" are there?
Upgrading to a fully automatic SMT line brings not only production efficiency and labor savings, but also a bunch of easily overlooked but very important returns:
- Enhanced customer trust: Full-line automation is an important threshold for many large customers when choosing suppliers.
- Better quality consistency: The machine does not feel sleepy, distracted or make mistakes.
- It's easier to expand production: Doubling capacity only requires adding one more surface mount technology (SMT) placement machine, without having to hire several more people.
- Energy conservation and environmental protection + policy support: In some regions, upgrading automated equipment can also apply for government subsidies or tax reductions.
Vi. Summary: Upgrade to automatic mode for large volumes and maintain semi-automatic mode for small volumes
To sum up in one sentence: Quantity determines investment returns.
If your monthly output is below 300,000 points and semi-automatic systems can handle it, it's fine to save costs first.
But as long as your order passes this critical point, upgrading to a fully automatic SMT line is not only necessary but also cost-effective.
The most ideal situation? First, run the semi-automatic mode for a while to ensure that the orders are stable, and then gradually automate it. This way, the risk is the lowest and the return is the greatest.
If you are planning to build a factory or upgrade your production line and want to make a detailed configuration plan or ROI return cycle table, I can also help you sort out a more detailed suggestion. Welcome to chat with me at any time!
Your message must be between 20-3,000 characters!
