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September 2014 • SMT Magazine 51 SMT: Does your company have actual ex- periences regarding automating your produc- tion/assembly processes? Howell: Yes, we have implemented several hands-off, fully automated system assembly lines over the past eight years. We work with OEMs and product designers along with several automation equipment providers to create the most cost-effective and reliable automation so- lutions possible. Due to the complexity of manufacturing platforms and industry best-practice require- ments, automation solution providers tend to specialize in discrete market segments, such as consumer, medical or automotive. These pro- viders then will typically have a core competen- cy or be able to demonstrate greater experience in an area such as the following: • Challenging operating environments such as Class 8 clean rooms • Niche skills such as plastics, odd-form mechatronic assembly, electronic testing, and final packaging • Integration of advanced technologies such as vision systems, precision screwing, dispensing and curing • Laser systems suitable for high throughput and precise material handling, welding, cutting and marking products, especially for the assembly of miniature components, within the medical device and pharmaceutical industries SMT: Why does implementing an automat- ed assembly line take so much time? Howell: Automation requires custom tool- ing, additional design features in certain com- ponents and often some custom equipment— one size does not fit all. It can take from six months to three years to develop, implement and validate complex automated processes and equipment for system assembly and test. This investment can pay off. Once running, prod- ucts can be produced at lower costs, and often the same automated production equipment can be used for the next generation of products. SMT: Why don't companies jump straight into automated assembly? Howell: Automation can and does save money, but there are risks involved and finan- cial and time commitments required to make automation successful. And certainly, not all products benefit from manufacturing automa- tion. Basic considerations include both a time to market and financial analysis. That is, is there enough time to implement automation and will it pay off based on product complexity, volumes, the availability of suitable automation cells (that can be customized) and other factors? Another factor for successful assembly auto- mation is designing the product for automation. Involving equipment builders in the early design phase of a new product offers the greatest oppor- tunity and flexibility to include design features in the product and components so that assem- bly automation can be kept as simple as possible. This investment in time and effort will pay off when closing in on the product launch date. Products that have been designed in accor- dance with DFAA (design for automated assem- bly) and DFT (design for testability) principles enable the engineering team to identify and eliminate unforeseen issues, which would later result in efficiency or quality issues during the volume manufacturing phase. SMT: What are some of the pros and cons of robotics replacing human workers in an as- sembly line? Howell: Images of futuristic-looking robots rapidly and efficiently assembling products per- meate modern advertising. And, the reality is that automated assembly can save money and improve quality for a growing number of prod- uct types. This is an area that will continue to advance. On the other hand, there is a signifi- cant number of complex, high-mix, low-vol- ume products such as large format printers, in- dustrial and complex medical equipment where the lower volumes and high complexity do not justify a fully automated solution. Smt richard Ayes is an editor with I-Connect007. feATure SANmINA: AUtOmAtION IN prODUCtION LINeS continues