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Automating Stencil Changeover to Improve Line Uptime
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fied, automated or eliminated. Once this is done, the produc-
tion line can operate with multi-role workers — people who can perform multiple tasks. The production line becomes more flexible by having multiple resources available, and this flexibility helps to reduce pro- duction lead time. Reducing operator involvement through automation not only cuts set
current stencil to a temporary con- tainer; removing the stencil; remov- ing PCB support tooling; installing new support tooling; installing a new stencil; adding solder paste to a new stencil; and loading a new program to continue printing. It is during these steps that
defect-causing problems can be intro- duced, which is why most SMT PCB manufacturing lines and facilities have a dedicated operator or techni-
Automatic stencil changeover eliminates 1/3 of all downtime.
up time and makes the process more efficient, but also minimizes human error and product loss. SMT lines are designed to deliv-
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er maximum throughput, expressed as boards per hour, which is also known as the “beat rate.” Beat rate takes into account available time, unscheduled downtime and sched- uled downtime. Available time is the maximum time during which the line can be manufacturing products. Unscheduled downtime is a period of downtime that has not been planned and converts direct cost into indirect cost. Scheduled downtime is a period of time where there are no operations happening at all. This is planned ahead of time to perform work to maintain the machines and enable the line to resume operation and con- tinue with production.
Automatic Stencil Changeover Over the last decade, the indus-
try has focused primarily on indirect- ly reducing set up time by improving the speed and efficiency of pick-and- place systems. With the increase in modularity, mounters have reduced set up time. Advanced feeder systems, such
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as “smart” feeders, have increased the level of automation in the process, with the added benefit of fewer errors (e.g. avoiding the placement of wrong components). Increasingly better soft- ware tools have played a key role in SMT line optimization. Now we are seeing improve-
ments in the screen and stencil print- ing process. Since 70 percent of all process defects originate during the solder paste printing process, it makes sense to focus on optimizing printing. During changeover, the printer
operator is responsible for exchang- ing the tooling and materials with those required by the next product. Those tasks include: removing and transferring solder paste from the
cian for the printing process. If dependence upon this person can be minimized or even eliminated through automation, that person is now free to perform other valuable tasks. By automating the changeover process at the printer, scheduled time for changing the line to a new product is reduced and an operator is not chained to one piece of equipment or one station in the line. By automating the stencil
changeover process, rolling of the sol- der paste, cleaning of the stencil, and perhaps handling of the PCB, certain operator-involvement steps can be eliminated. This reduces the number of potential variables for defects to be introduced into the print process. This also cuts set up time, leaving more time for printing and producing PCBs. Yamaha’s YSP10 solder paste
printer with automatic stencil changeover saves a significant amount of time. With this sort of system a full 1/3 of downtime can be eliminated, increasing available time for produc- tion and freeing up the operator to per- form other needed tasks. By automating setup time, the
amount of scheduled downtime is reduced and more available time is made for production. Also, more resources (operators) will be avail- able for other value-added tasks, potentially resulting in less indirect costs.
Automating changeover steps in
the stencil printing operation can have a significant impact in reducing changeover time and also in reducing potential defects caused by manually handling and transferring solder paste. Contact: Yamaha Motor
Corporation, 3065 Chastain Meadows Parkway NW, Suite 100, Marietta, GA 30066 % 619-276-4393 E-mail:
george_babka@yamaha-motor.com Web:
www.yamaha-motor.com r
See at SMTAI, Booth 223
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