After the automation transformation of the reflow soldering production line, the production efficiency has generally increased by 20% to 45%, and the specific extent is directly determined by the matching degree between the transformation module and the original production line foundation.
1, Core Efficiency Gain Module and Contribution
(1) Loading and Unloading Automation System
Replace manual insertion and removal of PCBs/carriers, eliminate the ineffective action of manual back and forth to workstations, and shorten the circulation time of a single batch production line by more than 30%
To avoid rework/adjustment caused by manual insertion and offset, and reduce the time loss caused by defective products occupying production capacity
(2) Automatic closed-loop control of welding parameters
By real-time collection of temperature curves and algorithm calibration, the time required for manual parameter adjustment after order replacement is reduced from 2-4 hours per time to 10-15 minutes per time, thereby reducing the downtime of order replacement
Avoiding parameter deviations in manual operations, reducing welding failure rates by 10% to 15%, and reducing the production capacity occupied by repairs
(3) Online AOI linkage closed-loop
Automatically intercept defective boards and trigger tagging/rework, replacing the lagging process of manual screening, and increasing the overall line pace by about 15%
Synchronize defect data to the production management system to achieve equipment failure warning and reduce unplanned downtime
2, Boundary conditions that affect the improvement effect (I): The automation foundation of the original production line
The production line with partially automated units (such as automatic loading machines) has been configured, and the efficiency has been improved by 15% to 25% after the transformation; The improvement rate of fully manual production line can reach 35%~45%
(2) Adaptability for renovation
The modification module needs to match the PCB size, carrier specifications, and welding process requirements. If the matching degree is low, the efficiency improvement will be offset by 5% to 10%
After the renovation, corresponding operation and maintenance training is required. If personnel are not proficient in operation, it is easy to cause downtime and reduce actual efficiency
