Date Published:Dec. 16. 2024
Surface-mount technology (SMT) line width changeover automation cuts workload by about 130 minutes per month.
Interviewed personnel for this case:
Mr. N: Manager, Manufacturing Department, Component Mounting Section
Operation and management of the manufacturing site
Mr. I: Supervisor, Quality and Production Technology Department
Maintenance of manufacturing equipment
Operation and management of the manufacturing site
Mr. I: Supervisor, Quality and Production Technology Department
Maintenance of manufacturing equipment
Location Where Our Product Was Introduced
Introduced into the intermediate conveyor between the equipment of 3 out of 5 lines manufacturing PCBs
Product Introduced
Could you tell us about the challenges before introducing our product?
The PCBs we manufacture are of high variety and low volume, which makes the utilization rate of machines in the surface-mount technology (SMT) line particularly important. However, due to the high variety and low volume, there were many line adjustment tasks, and we wanted to automate the entire SMT line to improve the utilization rate.
In terms of automation, conveyors do not add value, making it difficult to justify the investment. Initially, we considered proceeding with in-house development while consulting with other companies. However, when trying to proceed in-house, it became clear that time and costs were also significant challenges, and we struggled to make progress. As a result, we spent about a year without being able to address the issue.
In terms of automation, conveyors do not add value, making it difficult to justify the investment. Initially, we considered proceeding with in-house development while consulting with other companies. However, when trying to proceed in-house, it became clear that time and costs were also significant challenges, and we struggled to make progress. As a result, we spent about a year without being able to address the issue.
What was the trigger that led you to learn about our product?
While we were struggling with the issue, a representative from another company introduced us to NBK's handle automation unit. We immediately held an online meeting with NBK, and they provided us with a demo unit. When we actually installed it on the conveyor and used it, we found it very easy to use, so we proceeded with considering its implementation. Although we had been struggling to solve the issue, learning about the handle automation unit allowed us to make rapid progress in addressing the problem.
How has the impact been after introducing our product?
A handle automation unit was installed at the width adjustment points of the conveyors between the equipment, automating the line adjustment process.
We initially implemented it on one line for testing, and not only did it eliminate the need for manual width adjustment tasks, but it also removed the need for workers to move to the adjustment points, significantly reducing setup time.
Specifically, the following quantitative results (per line) were achieved, which led us to implement the system on three lines so far, and we are currently working towards implementing it across all lines.
| Handle (7 locations) | Unit | Reduction | |
| Time | 122.7 seconds | 13.2 seconds | 109.5 seconds |
Average number of width changes per month 72.8
| Handle (7 locations) | Unit | Reduction | |
| Time | approximately 148 minutes | approximately 16 minutes | 132 minutes |
In addition to the reduction in workload, there were many other ripple effects. The standardization of tasks allowed both new and experienced workers to complete the work in the same amount of time, eliminating the risk of forgotten tasks. If tasks were forgotten or there were slight misalignments in width adjustments, the PCBs could fall off. Of course, defects occur, but with the rising cost of electronic components, the potential loss becomes significant. Therefore, the elimination of manual adjustment tasks has been extremely beneficial.
Could you tell us the key factors that led to the decision to implement the product?
The fact that the product is affordably priced even when implemented across the entire process, and that it can be easily installed by adding attachments to the equipment, was also a key attraction.
Some of the latest conveyors come with adjustable widths, but since conveyors are durable and do not directly generate profit, it is difficult to justify the investment. We wanted to make the most of our existing equipment, so the ability to automate at a low cost was greatly appreciated.
Some of the latest conveyors come with adjustable widths, but since conveyors are durable and do not directly generate profit, it is difficult to justify the investment. We wanted to make the most of our existing equipment, so the ability to automate at a low cost was greatly appreciated.
■ SANWA ELECTRONICS CO, LTD
We support everything from PCB mounting and assembly, manufacturing of mounting and transport jigs, to the assembly of finished products.
We offer customers maximum efficiency in mounting and optimization of mounting conditions, taking into account the entire process from PCB design to component mounting and integration into the final product.
For inquiries regarding this matter, please contact us here.
▼The handle automation unit introduced in this case study can be found here.
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Improved productivity/workability
Automation/robots/motorization
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