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May 2016 • The PCB Magazine 15 For the remaining process steps or for prod- ucts that must be individually handled in panel formats such as multilayer FPCs, coverlay, or rigid-flex circuits, robotic stack handler sys- tems can be used to increase the level of au- tomation. Standardized and custom solutions cover almost all segments of the processing flow, thus making it possible to accommodate a wide range of product-specific requirements and sizes. When does it make sense to automate? Many factors can spur FPC manufacturers to consider automating parts or all of a production line. Key considerations include: • Yield loss due to operator material handling, material contamination, and operator errors • Low equipment efficiency due to high levels of operator interaction, variability, standby, and non-scheduled equipment time • Continuously-shifting bottlenecks in a production line due to cycle time variability • High operator labor costs that could be alleviated through handler automation In general, low-mix, high-volume manufac- turers tend to get the most value from automa- tion with the least amount of investment. For such manufacturers, investments in web han- dling automation can often provide sufficient increases in throughput, uptime and yield on existing process machines to obviate the need for additional investment in capacity. However, even high-mix, low-volume man- ufacturers are finding that the cost-benefit anal- ysis is beginning to favor automation technolo- gy as wages rise globally, materials become more susceptible to damage from manual handling, and accuracy and quality requirements become more stringent. And, as noted above, the macro trends in wearables, medical devices and other electronics devices point to greater use of thin- ner, more fragile materials, which can only be processed cost-effectively with automated web handling solutions. Automation: The Low-Hanging Fruit? The move to automated web handling sys- tems, while not trivial, often proves to be rela- tively easy to implement for many of the pro- cessing tools used in most FPC manufacturing operations around the world. This is especially true for tools such as laser-based processing systems that incorporate communications in- terfaces capable of supporting integrated han- dlers. In such cases, the resulting gains in yield, throughput, and efficiency lead to rapid returns on capital equipment investments. Of course, the ideal scenario for rapid ROI is a turnkey au- tomated process solution, such as when setting up a new or expanded process. As materials become thinner and more sensi- tive, it becomes more and more difficult to pre- vent material damage from occurring during the normal course of manual material handling op- erations. As damage problems and risks mount, significant yield improvements can be realized from the use of web handlers with automated positioning and automated tensioning control that virtually eliminate damage and wear to flex materials during the manufacturing process. Let's take a look at some of the problems with manual panel-based processes with mod- ern flex materials. Panel Damage Moving the panels is a challenge since the slightest bend or uneven tension applied to ma- terials can result in permanently bent edges and wrinkled substrates. Operator Handling Even the slightest physical contact with the material surface can cause scratches or surface contamination, as all too frequently occurs dur- ing the course of manual panel handling by op- erators. Machine Calibration Manual operator material handling requires significant user-machine interaction. Each in- teraction presents an opportunity for errors to be introduced. With web automation, closed- loop feedback can assure that error tolerances are not accumulated through the processing of even a large roll of production material. automate to innovate in flex proCessinG