Siplace PnP

It doesn't really matter which PnP machine you use. The correct way to cut down the variety is to use the same mfg p/n part for the whole time. Some would try to cheap by increasing the part size tolerance, but that's not the right way to do it. To your question, 1) With correct dimensions there shouldn't be alignment issues. 2) Protects you from loading the wrong size part onto the board. Lastly, a good operator would know it's best practice to measure the part before the 1st article run and always remeasure the part again if different mfg part(reel) to be used as refills.

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My experience is that capacitors cause more problem as resistors. Mostly the problem is that the solder legs not flat, more like a surface with radius.

If you use smaller nozzle which can catch the capitors between the two legs, the placement accuracy and production fails will be better - but you need better accuracy on both machine, feeder. Make different GF for capacitors and resistors, try nozzle which was/were made for 0201, 01005.

Nozzle material can be also a weak point. If it isnt a ceramic nozzle it will deform really fast, tooling changover is requested after a quantity - depends on your experience on the line.

The effective solution to use bigger parts if possible - in design, in price.

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Just make more specific shapes/packages for these size parts and decide on a naming convention that's easy to decipher then stick with it.

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