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22 SMT007 MAGAZINE I DECEMBER 2025 tighter thermal control and improved integration for line-level data. Reliability in the form of a long service life doesn't automatically equal competitiveness. If your line can't handle current-generation package sizes or lacks the speed, flexibility, and integration capabil- ities that customers expect, that reliability is only preserving obsolescence. The Connectivity Gap Modern SMT equipment isn't just about through- put; it's also about efficiency and communication. The newest machines share data across the line, communicate with MES systems, and provide real- time OEE and process visibility. Older machines often operate as data silos. They might still perform well mechanically, but they cannot be integrated into modern traceability or analytics systems. That gap can significantly limit yield improvement efforts and slow down trouble- shooting. Retrofits and middleware solutions can serve as a temporary solution for some of this, but they have limitations. A system that can't communicate is a system that can't improve, and in today's data- focused production environment, that's a serious limitation. When Is it Time to Explore Upgrading? Deciding when to replace equipment rarely comes down to any single factor I've mentioned. It's usually a combination of factors that build over time, including: • Ongoing maintenance hours and downtime cut into production • End of OEM support, making repairs unpre- dictable • Technology gaps are limiting the jobs your line can take on • Connectivity limits are limiting your visibility and efficiency When two or more of these issues converge, it's time to consider modernization. That doesn't mean every line needs a complete overhaul; targeted upgrades, such as replacing the pick-and-place system while keeping the printer and oven, often make the most sense. The goal is to maintain conti- nuity while removing the weakest link. Planning for Modernization Replacing equipment proactively is easier than doing so reactively. Planned modernization enables budget allocation, operator training, and seamless integration. It also prevents line-down surprises that can occur when a machine eventually fails and there are no parts available to repair it. Today's equipment manufacturers often design their equipment with modernization in mind. Many vendors have standardized critical hard- ware and software across generations, allowing a new machine to integrate into an existing line with minimal disruption, while also providing immediate benefits. Maintenance and Modernization Go Hand in Hand Preventive maintenance and modernization are part of the same lifecycle. Maintenance ensures equip- ment reliability, and modernization ensures that this reliability continues to serve current production goals. The best manufacturers don't wait for a cata- strophic failure to make a change; they recognize when uptime, capability, and connectivity diverge. Maintenance ensures stability, but modernization keeps companies competitive. Reliability Is Only Half the Equation Good maintenance keeps a machine running, but when it can't keep up with your workload, communi- cate with your systems, or support your next custom- er's design, consider replacement, not repair. It's not about abandoning equipment that's served you well; it's about ensuring your line continues to serve your busi- ness. SMT007 Josh Casper is a regional sales manager for Horizon Sales. To read past columns, click here. S M A RT AU TO M AT I O N