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SMT Line Changeover Time

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DeP

#48689

SMT Line Changeover Time | 28 March, 2007

Trying to find the ideal changeover time on an SMT line with stencil printers, GSM'S, and HSP's? What are other company's getting? What does SMT world consider ideal?

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#48692

SMT Line Changeover Time | 28 March, 2007

Ideal is 10 to 15 minutes. With the p&p gear you've got, feeders, feeders and more feeders are the answer to fast changeovers. Your goal should be to have a nearly complete setup for the next board all loaded on feeders, so you are just removing old feeders and installing the new ones for the new board.

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SWAG

#48694

SMT Line Changeover Time | 28 March, 2007

Yes, pre-loaded feeders is the best way. If you do not have that option as you are high mix or do work for different companies that have many different part numbers, I would guess that your printer will take about 15 minutes to get ready, each HSP feeder will take about 3 minutes and each GSM feeders will take about 4 minutes to load and install on machine. (I find that GSM feeders are a bit more difficult to load than HSP). Allow at least 15 minutes for set-up verification. Then you need to factor in start-up (shooting feeders on GSM) and tweaking B-offsets on HSP if needed to get the parts to successfully pick from feeders + tweaking vision in programs if needed. This first panel could take you 4 to 5 times the cycle of a "dialed-in" panel at minimum if you have trouble. After that, AOI + visual inspection can take a bare minimum of 15 minutes at which time you might consider halting SMT production or not. The times I estimate are assuming you have only one operator doing all this. Add all this up based on your build and throw an operating factor at it for B.S.ing and bathroom breaks.

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charlie

#48739

SMT Line Changeover Time | 29 March, 2007

What are you doing for bottomside tooling? Take a look at Grid-lok Automatic tooling --- sets instantly. This will cut some time.

charlie

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Scotceltic

#48747

SMT Line Changeover Time | 29 March, 2007

A feeder verification tool like Bartector will stop any need for time wasted manually verifying the correct part to the correct feeder. Also, there are plenty of pieces of SMT placement equipment out there that offer offline feeder pallet tables that allow you to an offline already loaded pallet with the current feeder table on the machine. Also, never understimate the value of good operators that have feeders loaded ahead of time and ready to go.

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oldsmtdude

#48779

SMT Line Changeover Time | 30 March, 2007

Way to many variables here.

I could have 3 or 4 setups on a HSP/GSM line if the boards are simple. Preprint boards to change the printer while still running... Thus a minute or two. Yet changing over a full GSM and 4 carriages on the HSP takes a ton of time.

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#48784

SMT Line Changeover Time | 30 March, 2007

"This is how I rate changeover time capability (includes PCBA first article):

Greater than one hour: improvement needed, competitive disadvantage Approximately one hour: good, about average for the industry Approximately 30 minutes: very good, close to best in class. Approximately 20 minutes or less: excellent, com-petitive advantage."

Rapid setup and changeover is a mindset. Without a sense of urgency, rapid setup and changeover is impossible. Unfortunately, setup and changeover often are viewed as something that just happens rather than a process that needs to be developed and refined. Auto racing is a superb example of the rapid setup and changeover concept. A critical element associated with auto racing is the ability to make rapid pit stops to service the racecar. This concept can be applied directly to assembly line setup and changeover. A pit stop does not simply happen. The pit stop team is highly motivated to service the racecar in the shortest possible time. When they accomplish their task efficiently they give their team a competitive edge. Rarely does a team win the race if their pit crew performs poorly. Setup and changeover in a manufacturing operation must be viewed in the same manner."

From :http://smt.pennnet.com/articles/article_display.cfm?article_id=181020

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oldsmtdude

#48923

SMT Line Changeover Time | 6 April, 2007

But a race team can't compete if the car or driver sucks.

Several times I've seen managers spend way to much effort on changeover when everyone operating the machines knows there's more waste in lack of PM, bad programming and sloppy optimization.

If you can at least put a real effort into making the car fast and consistent surprisingly the pit crew will pick up the pace.

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#48944

SMT Line Changeover Time | 10 April, 2007

Greetigs DPed,

10 minutes and 48 seconds.

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