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How to Improve Line Efficiency in Electronics? An Ultimate Guide

In the PCBs, the line efficiency refers to the ratio a pick-and-place robot

takes to place components over the surface of a PCB, which is divided

by SMT assembly staffing time. Line efficiency can be measured with

various methods. These include capacity utilization. Compare the

production process to the average line efficiency and acceptable

production; it gives the capacity utilization value.

Line efficiency plays an integral part in the production and assembly

process of PCBs. Therefore, one requires complete knowledge of line

efficiency when dealing with production lines. Manufacturers can easily

earn greater money if they fasten their assembly process of circuit boards.

Whereas if the manufacturer is facing problems with the system and

losing efficiency, thus resulting in underproduction. Therefore, in such

time they need to identify the root cause of the problem and remove it as

quickly as possible.

Table of Contents

Formula of Line Efficiency

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To calculate the line efficiency while using an SMT line, make sure to

consider its efficiency level. According to many experts, the efficiency

measurement of SMT seems a bit of a complex process.

The efficiency formula of the line refers to a P&P machine taking time to

place all the components on the PCB, which is divided by the SMT

production line time taken for staffing. In simple words, it refers to the

positioning time in hours by the staffing time in hours multiplied by 100.

This, however, provides a simple, accurate, and clear value of the

performance.

Many manufacturers seem reluctant to utilize the efficiency of production

lines instead of SMT lines. Because the efficiency of the production line

does not consider time during measurement, this happens because the

ratio is based on the actual staffing time instead of optimum time and

labor time. Therefore, remember that uncontrollable outside factors affect

the productivity level the most. Whereas the demand for the market the

PCB assembly volume needs a factory.

Moreover, one can easily measure the efficiency line number fastly and

without effort, as it allows the easy process of calculating SMT time and

placement time. The P&P operator needs to take readings of the

placement of components. With the help of these recorded readings, one

can easily identify the time of placement.

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Furthermore, one can also easily measure the time of staff hours if the

manager keeps all the records noted and safe in computerized form. Also,

even the break time of staff and employees is considered in the staff

hours. Therefore, to enhance the efficiency of the line, make sure to keep

all records, including the meeting, meals, and breaks of the staff. This

ensures all the workers work on the line all the time.

Thus, this gives an accurate, clear, consistent, and Jones efficiency value of

the line. As you know, SMT production line efficiency provides an effective

method to measure efficiency and productivity. Hence, use this method

from now on to measure your lines.

Improving Line Efficiency in Electronics

There are a few good methods for improving the efficiency of the

production line. Collecting data is considered very important as much as

the usage of data matters. Additionally, other than calculating the

efficiency of the line, you must find out the factor that affects the

efficiency of the line. It helps in analyzing the team’s performance also.

The collected data quality analysis helps in identifying the lagging behavior

of productivity. This, however, offers changes and alterations that help to

improve overall efficiency. A few possible reasons for productivity lagging

include the following. There may be too many operators or not enough

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operators on the production line. Production lines may contain poor

configuration and issues in the management of time. Moreover, the

functionality and outdated behavior of the machine and equipment used

in the production lines.

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Benefits Of Assembly Line Balancing

· Reduce Waste

Waiting for waste refers to a type of lean manufacturing waste. This simply

refers to any free time that happens during the non-synchronization of

operations. For instance, waiting for waste mostly happens when

operators wait for material and something else to finish the task.

Moreover, equipment downtime also comes in waiting for waste type. It

refers to a time when equipment doesn’t work. However, line balancing

makes sure that all machines and operators work together to create a

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balanced work environment. It does not overburden the machine or

operator. Therefore, this way, line balancing minimizes downtime. This

automatically reduces the waiting waste.

· Reduce Inventory Waste

The inventory waste serves as another waste type. It refers to raw

material excess, finished products, or unfinished WIP products. Inventory

waste determines the inefficient use of capital. However, line balancing

makes the production standardize. This means that one can easily avoid

excess inventory or build-ups. It reduces the free time and is sure that

only a minimum amount of WIP is left. At the same time, it brings the time

of production closer to desired time which guarantees delivery on time.

· Absorb Irregularities

Life balancing minimizes the amount of variation in the production line.

However, a balanced line refers to a stable line that has enough flexibility

to adapt to any type of change. For instance, if a customer requests

changes, the operation must realign fastly with line balancing. Moreover,

one can easily produce the impact of the changes on the balanced line.

Therefore, it makes it easy to modify an altered line to fix the rate of

production.

· Lower Production Cost

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A perfectly balanced line enables the machine and worker to operate in a

synchronized way. Operators are not getting paid for just standing idle.

Whereas machines also need to operate at their full potential. However, in

simple words, it maximizes the capacity of machines and manpower. Such

efficiency in the process leads to more profit and lesser costs.

Why Is Line Efficiency A Essential for The PCB Manufacturing

Industry?

The PCB manufacturer’s profit depends on several business metrics.

These metrics indicate the complex functionality of a production or

assembly unit. Line efficiency serves as one of those factors. Line

efficiency contains two types of methods to measure the efficiency of the

line assembly unit of PCB. These two factors include the Surface-mount

line Efficiency and the Production line.

The majority of manufacturers of PCBs tend to use SMT lines because of

consistent and precise results. They do not use the production line

because of its incompleteness. The ratio of production line efficiency does

not contain the optimum time and the labor time. Therefore, it creates

various types of challenges for the operators, which directly affects the

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efficiency of the line. At the same time, SMT production line efficiency

serves as the most used metric. It gives correct and easy measurement

with recorded staff time. Moreover, the output data to calculate the

efficiency of the line needs to go through analysis to find degrading factors.

This data helps in finding the lagging behavior of productivity, as we read

before.

Line efficiency refers to an essential business matrix that helps in

evaluating the resource output of the assembly. It is incorporated with

other factors like ORE and OEE, the overall equipment, and resource

effectiveness whilst measuring the efficiency of the production. Identifying

the efficiency of the line helps the contract manufacturers to reduce

manual labor and enhances the placement of components per line.

However, this reduces the risk of any delay in delivery.

Moreover, manufacturers of PCB tend to adopt diverse manufacturing,

which produces multiple products altogether. In such cases, optimizing

the production also depends on the time of changeover. Shifting from

batches of product one-on-one limits the overall line assembly utilization.

Main SMT Line Machine Efficiency

The SMT line of PCB assembly contains the following few essential

machines and equipment.

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· Pick & Place Machine

This P&P machine picks the SMT component and places it accurately over

the surface of the PCB using the robotic placement hand. However, the

tension in the surface of the solder pulls out the SMD automatically in

alignment later in the soldering reflow process to fix little errors in the

placement of the components.

· Solder Paste Mixer

The soldering paste mixer, as the name suggests, mixes the paste of

solder and powder efficiently and evenly. It helps in making the printing

process, reflow, and standardized functions and minimizes the

requirement of manual labor.

· Oven

In the SMT line, both oven and reflow differ from each other. The oven

bakes the PCBs to remove any type of moisture and comes in the last of

an SMT line.

· SMT Loader

The SMT loader places the circuit board in the soldering printing

equipment racks automatically.

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· Solder Paste Printing Machine

The soldering paste printing device prints the soldering paste to draw off

the board. It comes after the P&P device in an SMT Production line.

· Solder Paste Inspection Machine

SPI refers to a Soldering Paste Inspection device. It analyzes the volume,

thickness, and area of soldering paste over the surface of the PCB after

the soldering printing process.

· Reflow Machine

The reflow machine comes after the P&P machine. It melts the soldering

paste between the SMT components and PCB to create a welding

connection between them. After that, it cools down the solder paste and

solidifies the welding bond.

· AOI

The AOI machine sandwiches the reflow soldering machine in between

two AOI. The first machine identifies any type of failures and errors in the

placement of components before sending it to reflow. The second AOI

checks the errors and failures of soldering after the reflow.

· Docking Station

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The docking station provides an intermediate stop between distinct

machines of the SMT Production line.

· SMT Unloader

The SMT unloader, as the name suggests, operates in the opposite way of

the SMT loader. However, it receives the assembled board and stores it

after the soldering reflow process.

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Types Of SMT Production Line Efficiency

The design of the SMT line type contains the following details:

1. One line contains a layout of a single rail P&P machine.

2. The two-to-one line contains a layout of single or dual-rail P&P

machine

3. Tow-to-one contains the layout of a dual-rail P&P machine

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4. The three-to-one line contains a layout of a single-rail P&P machine

5. Combination of multiple line layouts.

SMT Line Cost

SMT line contains around 60 to 70% pick and places robots. A large P&P

machine that has a capacity of 100,000+CPH costs about $700,000.

Whereas P&P with a middle range capacity of 12 to 35,000 CPH costs

about $100 to $200,000.

However, the majority of brands usually cost one line of SMT of about

$8,000,000. This seems so expensive. Therefore, we introduced high-tech,

advanced SMT lines at a lower cost. It provides reliable and

high-quality PCB production while keeping the production cost low.

SMT Line Efficiency Development Trends

SMT production lines have several ongoing trends. Some of them include:

· CIMS Application

CIMS refers to a computerized Incorporated manufacturing system. It

basically links the production process and the design to minimize the time

that preparation for SMT Production takes.

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· Efficiency Improvement

Efficiency is considered as the source of high output. At the same time,

SMT lines are continuously obsoleting the human factor. However, to

improve efficiency, try to implement a centralized CMS for the whole SMT

line.

· Environmental Protection

SMT production lines use materials like glue, solder paste, flux, and

packaging material, which lead to environmental pollution. Although, the

majority of PCB assemblers and manufacturers have started using an

eco-friendly production process. They first identify the source of pollution

and analyze how much quantity they use in the process. Then they look

for methods to minimize their effect on the surroundings and create an

eco-friendly environment.

· Flexible Production Environment

Internet development and grid IT provide process data control along with

data management of products. This improves the functions of SMT lines.

Moreover, they help in increasing maintenance management. Thus,

eventually, make a flexible data integration production setup for SMT

production lines.

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Conclusion

SMT lines play an important role in the assembly process of Printed Circuit

Boards. These SMT lines contain various types of high-tech machines that

perform different types of functions. This article has explained all the

details that you might need to know regarding SMT production lines.

However, if you still have any type of query. Feel free to contact us.

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