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Production June 2025


Smarter SMT Starts at the Reel: How Splicing Kits Are Powering Efficiency in 2025


By Rob Sierra, Sierra Electronics I


n the fast-paced world of sur- face-mount technology (SMT), every second matters. With


the rising demand for quick-turn prototypes, smaller lot sizes, and just-in-time manufacturing, the pressure to reduce downtime and cut waste is more intense than ever. In this environment, reel splicing kits have gone from a niche accessory to an essential tool for optimizing SMT opera- tions.


Whether for high-mix, low-


volume builds or 24/7 production on high-volume lines, reel splic- ing kits from tapesplice.com re- main one of the most cost-effec- tive ways to improve feeder setup, changeover, and inventory efficiency.


Setup Waste SMT feeders still operate on


the same basic principle: compo- nents arrive in a carrier tape sealed with cover tape, indexed with precision for pick-and-place


machines. However, setting up a reel —even with today’s semi-au- tomated feeder loaders — still re- sults in unavoidable scrap. That first 12 to 18 in. of peeled cover tape usually means scrapped components, especially if they can’t be reintroduced into the feeder. For high-value or limited- supply parts, this isn’t just in- convenient, it’s expensive. Now imagine doing that


setup 20, 30, even 50 times in a single shift across multiple lines. That’s hours of cumulative down- time, hundreds of components wasted, and a significant dent in your production efficiency.


Reel Splicing Reel splicing allows opera-


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tors to join two reels together without interrupting production. Using a splicing kit — which in- cludes alignment shims, crimp- ing tools, and adhesive cover tape connectors — operators can quickly create a seamless transi- tion between reels. The result? Zero machine stoppage. Modern SMT lines, especially


in high-volume EMS factories, rely on continuous uptime to main tain profitability. Stopping machines for even a few minutes to change reels adds up fast. With a well-trained operator and a quality splicing kit, a new reel can be spliced in before the old one runs out, keeping the pick-and- place machine running at full speed.


Splicing carts have become


standard equipment on SMT floors. Stocked with everything from cover tape extenders to uni- versal shims and crimpers, they give operators mobile access to all necessary tools and reduce the time needed to perform splices at the machine.


Essential for High-Mix Builds


While high-volume manu-


facturers splice to keep lines run- ning, high-mix assemblers rely on cover tape extenders to pre- serve component inventory. Fre- quent reel changeovers in short production runs mean increased


scrap, and in many cases, there are no spare components to lose. Tape extenders add 20 in. or


more of usable leader to a reel, en- abling a proper set up without sacrificing pickable components. For contract manufacturers work-


Reel splicing allows opera- tors to join reels together without interrupting pro- duction. The result? Zero machine stoppage.


ing with consigned kits or exact part counts, tape extenders are often the difference between hit- ting or missing a delivery window. With the growing trend to-


ward low-volume, high-variabili- ty production — driven by sectors like aerospace, medical, and ad- vanced prototyping — this simple solution has become a best prac- tice.


A Win-Win Regardless of production


volume, the benefits of reel splic- ing and tape extenders are clear. High-volume lines minimize downtime and maximize ma- chine utilization with continuous reel splicing. High-mix/low-vol- ume lines reduce component scrap, improve kitting efficiency, and maintain momentum with tape extenders. Hybrid opera- tions gain flexibility to support both modes with a small invest- ment in universal splicing tools. Add to this the universal


compatibility of tapesplice.com kits — supporting feeder tapes from 8 to 56 mm across all SMT platforms — and the ROI be- comes impossible to ignore. As SMT manufacturing con-


tinues to evolve, success hinges on the ability to build faster, smarter, and with less waste. Reel splicing kits and tape exten- ders from tapesplice.com offer a low-cost, high-impact solution


for any assembly line. Contact: Sierra Electronics,


2774 Agua Fria Street, Santa Fe, NM 87507 % 505-424-1209 E-mail: rob@tapesplice.com Web: www.tapesplice.com r


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