Suggestions for flexible SMT complete line configuration suitable for multi-variety and small-batch production

Suggestions for flexible SMT complete line configuration suitable for multi-variety and small-batch production

After several years in the electronics manufacturing industry, everyone knows a reality: it's easy to do a lot of work in large quantities, but it's really a hassle in small batches. Especially for those business models that involve multiple varieties, small batches, and frequent line changes, if the procedures are changed dozens of times and dozens of pieces of material are cut every day, it can drive people crazy.

Then, is there a "universal full-line configuration" suitable for this situation? There is an answer. The key lies in you understanding what a "flexible SMT complete line" is.

Today's article will talk about - in the scenario of multiple varieties and small batches, how to choose a flexible and reliable SMT production line? What equipment should be matched and how to combine them in order to neither waste money nor fail to efficiently cope with the frequently switching production rhythm.

First, let's clarify what "flexible SMT complete line" means?

Flexibility, in layman's terms, means "being flexible enough". Compared with the traditional standardized production lines that run for a single variety and operate non-stop throughout the day, flexible lines have higher requirements:

• It can quickly change materials and programs.
• It can mount devices with various packages and large size differences.
• Not pursuing extreme speed, but ensuring stability and no delay in work.
• Try to minimize switching losses and improve the comprehensive utilization rate.

Therefore, the core objective of the flexible SMT assembly line is not the speed of assembly, but rather the response speed and the efficiency of line changeover.

Flexible SMT complete line

What equipment should be equipped for the entire flexible SMT line?

Let's get straight to the point - How should a cost-effective flexible SMT production line be configured?

1. Automatic plate loading and unloading machine (optional)

   If the output is not too large, manual loading and unloading of the plates is also acceptable.

   If line cutting is frequent every day and the production line rhythm is tight, it is recommended to install a pair of automatic board loading and unloading machines (with a budget of approximately 15,000 to 20,000 yuan per set) to reduce manual intervention.

2. Fully automatic printing machine (Recommended standard configuration)

   A wide variety of products means you have to frequently change the steel mesh and the program. The memory program and automatic screen wiping function of the fully automatic printing machine are very practical.

   Recommended: Domestic brands such as GKG, Desen, and Jintuo, with a budget of approximately 100,000 to 200,000 yuan.

   It is not recommended to use semi-automatic machines as they are slow to change wires and have poor stability.

3. Surface mount technology (core of cores)

   For flexible production lines, the selection of surface mount technology (SMT) machines is of the utmost importance. It's not the faster the better, but the more "versatile" the better.

   Recommended configuration

   • A medium-speed and high-precision surface mount technology (SMT) placement machine can be selected from JUKI RS-1, Samsung SM482 Plus, Yamaha YS100, etc.
   • Compatible with 0603 to large IC packages, capable of attaching irregular-shaped components, and equipped with an intelligent visual recognition system;
   • It is recommended that the number of feida be 60 to 80 or more to facilitate the quick switching of multiple material trays.

   Second-hand phones can also be considered. It is more appropriate to keep the budget between 300,000 and 500,000 yuan.

   If the budget allows, you can build one fast and one slow aircraft.

   • One main high-speed machine (for running conventional components) + one precision machine (for attaching ics and irregular parts);
   • The advantage is high efficiency, while the disadvantage is that more manpower is needed for program switching.

4. Reflow oven (6 to 8 temperature zones are sufficient)

   The requirements for reflow soldering in flexible production lines are "stable, easy to adjust and not delicate".

   It is recommended to use domestic brands such as Jintuo, ETA and Jinko.

   The budget is approximately between 80,000 and 150,000 yuan.

   There is no need to pursue a large number of high-temperature zones. The key is to ensure stable temperature rise and precise temperature control in the cooling zones.

5. AOI Automatic Inspection Equipment (optional)

   It depends on whether your requirements for product quality are high or not

   If it is a Jiaotong University customer or there are many product categories and you are afraid of rework, then AOI must be equipped.

   For small-batch personal use, with high customer tolerance, visual inspection is also acceptable.

   The price of an AOI is approximately 50,000 to 100,000 yuan.

Flexible production line

What other configuration details should be noted for flexible production lines?

Apart from the main equipment, there are several details of the flexible SMT line that you must not overlook:

1. There must be enough feidams!

   When the feeder is not enough, changing the material requires constant disassembly and reassembly, which greatly affects the efficiency. It is recommended that each model be equipped with double the number of Feida. For instance, if a surface mount technology (SMT) machine can accommodate up to 80 units, you should equip 160 units.

2. The software should be flexible and easy to operate

   A wide variety of products means constantly changing programs. A set of user-friendly operation software is the lifeline. Give priority to choosing devices that can import BOM tables for automatic recognition, have quick parameter memory, and are convenient to connect with ERP systems.

3. Do not skip the spare fixtures and trays

   Flexible production lines are not short of varieties, but what they lack is a rapid response time. Preparing a batch of commonly used material trays, fixtures and board separation frames can help you save a lot of time for wire changing.

Approximate Budget Reference: How much does it cost to complete a flexible production line?

The following is a relatively standard budget for the entire flexible SMT line, for your reference only

If domestic second-hand equipment is used, it is not impossible to control the entire production line at 400,000 to 600,000 yuan. This is very suitable for small and medium-sized electronics factories with limited funds but a desire for quality.

To sum up: For flexible SMT lines, the key lies in "multi-functionality" rather than "high-end configuration"

Finally, let's get to the point. Conclusion:

• With a wide variety of products in small batches, the competition is not about speed but about response speed, line changing efficiency and product coverage capacity.
• When choosing a surface mount technology (SMT) placement machine, don't pick the fastest one; instead, choose the "most versatile" one.
• The small links such as the printing press, feeder and software determine whether your cutting line can be fast and smooth.
• Experienced technicians are more valuable than expensive equipment. Don't just invest money without investing people.

If you are currently planning a factory or don't know how to set up this line, I can offer you a personalized configuration suggestion. Budget, brand and functions can all be handled with just one click. Feel free to come and chat with me anytime!