Printed Circuit Board Assembly & PCB Design SMT Electronics Assembly Manufacturing Forum

Printed Circuit Board Assembly & PCB Design Forum

SMT electronics assembly manufacturing forum.


Machine Utililaztion

CFraser

#19957

Machine Utililaztion | 17 May, 2002

Does anyone know what the industry standards are for machine utilazation on a SMT line or across a shop floor? I am looking for a percentage.

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Bob

#19995

Machine Utililaztion | 21 May, 2002

If you are comparing the machine utilization to the manufacturers best speed generally it is less than 20%.

i.e. Fuji CP6 max manufacturers speed = 40000 placements per hour. When you add in downtime, breaks, maint, set-up, feeder replenishment etc etc etc you will be looking at less than 20% of this figure.

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CFraser

#19997

Machine Utililaztion | 21 May, 2002

Currently, we are using Siemens Siplac machines with a CFM line that includes in circuit test.

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Mark Susol

#20081

Machine Utililaztion | 28 May, 2002

Maybe we should better define the type of line and the expected utlization? Are you a contract mfg. or is this your own product line? Are you hi/low mix - hi/low volume?

I have a hi-mix/low volume Siemens line (S23/F5) that I am able to get 40-60% utilization on. The nature of my schedule really controls the utilization I can expect. I have a second set of feeder tables but not enough feeders to completely setup my next load list offline in parallel. So there still is lost time for unloading feeders to move to next table setup.

Even with several people working on this I average over 60 minutes per "pit stop".

During operation I see 80%+ performance.

Now..how to get to 80% utilization?

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JohnW

#20090

Machine Utililaztion | 28 May, 2002

There is alway's squabbles when people talk about utilization and then there's the fabled effective utilization, which rumour has it is differnt. Most of the time as you say the benchmark's aren't really there and as Mark point's out it depend's on what type of market your in and the product mix as to how good yoru utilization will be. If yoru runnign a real hi volume phone line then you'd expect to be up in the mid to hi 90's, low volume hi mix and you could be as low as 10% depending on the sixe / complexity of the PCB and the number of feed changes. Don't even take into account how good yoru purchasing dept is at buying the right size of reel's....10K?, na easier to by 5K's and let you do more feed changes to slow the lines down....a little pet peav of mines. 1st off you have to decide if your utilization caculation is going to be based on the time the machein is avalable for production i.e. 7*24 and so forth or only the amount of time it's scheduled to run ...see the rub? the true calculation (for me anyway) is the time it's actually doing something devided by the time it's available to dosomething (i.e. 7*24) *100 to get the percentage. the other calculation time yoru placing / time scheduled to be placing is effectivity i.e. how well your using the macheins rather than how much and you need yoru scheduled rates and so forth to make real sense of it. In term's of fixing a base line the equipment manufactures will quote 40,000 placements per hour but that's from 1 feeder in the middle of the table that doesn't need a feed change, not real life. measurign soemthing is only usefull if your going to use it to improve soemthing.... so I guess the next question is why do you want to measure it and is it the right measure to use?.....

JohnW

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Roger

#20124

Machine Utililaztion | 29 May, 2002

This is just a simplistic suggestion but why don't you invest in additional feeders so that you can do a 'complete' feeder setup offline? How much money is 1 hour of downtime costing your operation? If you can reduce the pit stop from 60 minutes to 20 minutes would that not easily pay for the investment in additional feeders?

Everybody wants to step over dollars to pick up pennies. No wonder most of our higher volume manufacturing is moving to China.

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TheConsultant

#20172

Machine Utililaztion | 31 May, 2002

If you provide some information regarding the number of different products you are running per line and typical lot sizes I will provide you with some typical numbers.

TheConsultant

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Ken Bliss

#20291

Machine Utilization | 10 June, 2002

In response to the original question, �Does anyone know what the industry standards are for machine utilization on a SMT line or across a shop floor?�

Ceeris International published a report showing an industry average of 52% utilization of staffed shift. For reference, I DO NOT RECOMMEND using the industry average as your benchmark! There is no excuse why this number should be so low.

The bottleneck of an SMT line is (and should always be) the pick-and-place machine(s). Keeping this bottleneck running as many hours during a staffed shift as possible is mandatory for maximum plant efficiency. Making every effort to minimize downtime during product changeovers, feeder exhausts, maintenance and programming is the foremost critical step to ensuring your bottleneck is kept running. Considering all mandatory downtime on an SMT line, the percentage of uptime should be closer to 75% - 80% of a staffed day. For more information on how to increase your SMT line efficiencies, download the following white paper on Profit-Driven Manufacturing. http://www.blissindustries.com/profit-drivenmanufacturing and be sure to calculate the economic returns of recapturing this capacity at http://www.blissindustries.com/calculator.

This should answer your question and the white paper will definitely help focus your efforts on the areas of the line that count the most.

If you�d like to speak with me directly, please call 510-490-8401.

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Tired of Ken Bliss

#20301

Machine Utilization | 11 June, 2002

How many times are you going to cut and paste the same tired marketing pitch to us?

Leave it alone.

Doug

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Ken Bliss

#20303

Machine Utilization | 11 June, 2002

To respond to your message that you are tired of Ken Bliss, obviously you are entitled to your opinion on any subject on this forum, that is what the forum is about. I offer facts on how to make PC board assemly factories work better and more profitability. I also am proud to post my real name and stand behind what I offer for information unlike yourself. I offer all the information on how to fix factories like yours to run the way they should be for free. If they use my products great and if they use someone elses, that is what makes America great. I am unaware of anyone or any company offering anything equal to what we offer to meet the single one goal of evey company, "profit" it is the only reason your company is in business. With that said lets get on with worthwhile questions and comments that help companies meet that goal.

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Daan Terstegge

#20380

Machine Utilization | 15 June, 2002

I'm sure that Ken has commercial goals, but after reading his whitepaper I'm sure that many manufacturers could benefit from it. It's just to easy for a management to save costs on feeders, without really having an idea of how it affects the amount of boards that can be produced.

Daan Terstegge http://www.smtinfo.net

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CFraser

#20388

Machine Utilization | 17 June, 2002

I agree totaly and would like to thank Mr. Bliss for his reply. I would also suggest that anyone who is serious about SMT manufacturing, read the "White Pages" on the Bliss Tech. site. The concepts are very basic but still good. Thanks to all of you for your advice and suggestions.

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DL

#20396

Machine Utililaztion | 17 June, 2002

I've seen where companies (in the U.S.) are unhappy with the quality of certain china manufactures, and are in process of aquring pick and place equipment and do the boards in house.

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