Issue link: https://iconnect007.uberflip.com/i/661282
54 SMT Magazine • April 2016 calculations are based on the following repre- sentative numbers: • Automatic profiling is saving at least 15 minutes per changeover • $190 per hour cost of downtime ($90 labor, $100 machine time) • Average three changeovers per day on seven lines. • 10x3x7= 315 minutes per day • 315/60*$190= $997.50 per day savings Another benefit is that during the produc- tion run, every PCB is profiled automatically, and adherence to the relevant process window is verified. John Siemens stated that there are op- portunities for the oven to drift out of spec dur- ing a given production run. One example may be an upstream stoppage that leads to a tempo- rary empty oven followed by a wave of tightly spaced PCBs. Such thermal loading may lead to changes in the PCB profile. Other opportunities for profile variations during production may in- clude facility exhaust system changes, human error and more. Now, the reflow quality becomes consistent and free of operator influence. This is an example of a win-win situation where the client is ensured a high-quality prod- uct (from the thermal process perspective) and full thermal process traceability, while the new reflow technology reduces cost in scrap, rework, production downtime and even electricity use. (Case studies indicate a 15% elec- tricity use reduction opportunity for each reflow oven with the use of oven setup software.) The same investment in Lean manufacturing and smart oven technology also supports Siemens' other core strategy characterized by an intense focus on customer sup- port. Clients appreciate flexibility, quick response time and fast time to market. The reflow oven predic- tion software enables a faster NPI and the automatic system offers process documentation, traceability and peace of mind. The company is even setting up a factory in Mexico, not motivated by reducing produc- tion cost, but by being able to better serve its many clients who now are located in Mexico. Running a Lean and flexible factory offers an opportunity to accept projects that few other contract manufacturers can handle. According to Sales Manager Lisa Boland, the flexibility al- lows the company to react faster and to take on different sized projects, all the way down to small client. As a result, Siemens has won sever- al contracts over the years with little to no com- petition due to the difficulty in accommodating clients' requirements while staying profitable. Conclusion The intensely competitive EMS industry makes the following adage unacceptable: "There is never enough time to do it right, but there is always enough time to do it twice." Defects are simply too expensive and "doing it right the first time" is the new strategy. Investing in the right technology and strategy can lead to the best of both worlds: happy customers and higher profits. SMT Bjorn Dahle is the president of KIC Thermal. Figure 3: Smart reflow oven. bEnEfiTs of imProvinG rEfloW and scrEEn PrinTinG ProcEssEs