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Equipment Maintenance costs

John Martell

#10895

Equipment Maintenance costs | 22 June, 1999

I was wondering if anybody could give an estimated cost of equipment maintenance per year for a complete SMT line for a medium volume facility?

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DNC

#10896

Re: Equipment Maintenance costs | 22 June, 1999

| I was wondering if anybody could give an estimated cost of equipment maintenance per year for a complete SMT line for | a medium volume facility? | Deon Rresponse:

Hi John,

Your question is very generalized. I think that in order to make a good calculated guess you must make take the following in consideration:

1-What type of equipment? This must also include how mechanical is it? 2- Maintenance required? Checklist. 3-How much equipment? SMT pick and place, printer, reflow, wash? 4- Trained in in house maintenance personnel? If not, getting a in house person factory trained is well worth the cost. 5- If answer to #4 is yes. Then: Hourly shop rate X Amount of time per month required + 10% + cost of maintenance supplies X 12 months? 6- In answer to #4 is NO. Then you need to gather all of your data on the equipment you are considering to purchase and do your homework.

I'm sure a lot of the guys here can also give some more tips in order to help you better calculate cost.It really varies on the type of equipment you have. Hope this helps.

Regards,

Deon Nungaray SMT Mfg. Engineer GMI USA CA

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#10897

Re: Equipment Maintenance costs | 22 June, 1999

| I was wondering if anybody could give an estimated cost of equipment maintenance per year for a complete SMT line for | a medium volume facility? | John: Budgeting for maintenance from two perspectives:

1 We budget 1 percent of the capital cost of the machine each year and spread it monthly for appropriation purposes. 2 Practically, budgeting maintenance costs have room for a tremendous amount variability. Some machines require more maintenance than others because of:

� Type of machine. Wave solder and in-line cleaning machines require lot of maintenance compared to a stencil printer or a reflow oven. � Manufacturer of machine. Some wave solder machines require more maintenance than others because they�re piece of carp. � Age of the machine. When a reflow oven becomes loaded-up with no-clean flux, it requires more maintenance to keep the machine from drolling flux resides on boards during processing than a new machine.

So, we "build-up" the cost of maintenance, based on the written maintenance plan for the equipment.

TTYL

Dave F

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Dean

#10898

Re: Equipment Maintenance costs | 22 June, 1999

| I was wondering if anybody could give an estimated cost of equipment maintenance per year for a complete SMT line for | a medium volume facility? | Equipment maintenance falls distinctly into two categories. 1. Preventative maintenance. 2. Failure / repair maintenance My assumption is you are interested in info on PM's. as Failure maintenance is difficult to predict 9aka predictive maintenance). Also, a "complete " smt line can mean different things to different people. Example: would you include wave and wash equipment? Some shops use glue machines some print epoxy. You get the point? I'll give you a scenario. Three distinct business models High volume 1 to 2 million placements per week (40 hours). medium volume, high mix, high complexity, 500k to 1million parts per week (40hrs) low volume, prototypes, box-o-parts build, high to low complexity up to 500k parts per week. PM time per high vol. line is 8 hours per month PM time per medium volume is 8 hours per month PM time per low vol. line is 5 hours per month.

Repair / failure maintenance varies per line ( as does the equipment brands). Some are better than others (and I'll leave it at that as litigation is pending...just kidding!)

Some high volume shops perform NO PM's and run them til they drop, then swap them out and repair offline! Maby once a year or 18 months give 'em and overhall and off you go again. Unfortunately as an EMS shop we can't get away with that mentality.

Dean

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John Martell

#10899

Re: Equipment Maintenance costs | 23 June, 1999

Thanks, that makes sense. | | I was wondering if anybody could give an estimated cost of equipment maintenance per year for a complete SMT line for | | a medium volume facility? | | | Equipment maintenance falls distinctly into two categories. | 1. Preventative maintenance. | 2. Failure / repair maintenance | My assumption is you are interested in info on PM's. as Failure maintenance is difficult to predict 9aka predictive maintenance). | Also, a "complete " smt line can mean different things to different people. Example: would you include wave and wash equipment? Some shops use glue machines some print epoxy. | You get the point? | I'll give you a scenario. Three distinct business models | High volume 1 to 2 million placements per week (40 hours). | medium volume, high mix, high complexity, 500k to 1million parts per week (40hrs) | low volume, prototypes, box-o-parts build, high to low complexity up to 500k parts per week. | PM time per high vol. line is 8 hours per month | PM time per medium volume is 8 hours per month | PM time per low vol. line is 5 hours per month. | | Repair / failure maintenance varies per line ( as does the equipment brands). Some are better than others (and I'll leave it at that as litigation is pending...just kidding!) | | Some high volume shops perform NO PM's and run them til they drop, then swap them out and repair offline! Maby once a year or 18 months give 'em and overhall and off you go again. Unfortunately as an EMS shop we can't get away with that mentality. | | Dean |

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