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Pick-and-Place: Users & Vendors Speak Out
December 31, 1969 |Estimated reading time: 13 minutes
SMT surveyed EMS providers to learn about their placement needs. Following are their responses.
By Gail Flower, editor-in-chief, SMT
How do you compare pick-and-place machines?“For us, it’s a cost-to-value comparison,” says Tom Chapo of ATS, who determines how much money the company has to spend on new equipment, and then evaluates features, technology updates including software, and placement rate vs. cost. “There are many machines that could do the job, but many are more expensive than would fit our budget. Several would come with more capabilities than we could justify for the work to be done, so we must weigh functionality vs. cost. At some point, we settled on using Philips/Assembléon machines.”
Most EMS companies set up a matrix of what they need, and then make a decision based on equipment that matches those needs. José Ruiz of Madrid-based Amper Programas looks at technical service and desired software. Bob Qian of Benchmark Electronics’ Suzhou, China, facility looks at versatility, including the capability to handle a variety of components - from 0201s to large-scale BGAs and odd-form components. Qian considers the number of slots for feeders and placement accuracy. Jack Yeung of Guangzhou, China-based Jabil Circuits (Figure 1) notes Cpk, scalability, price, and robustness. Presently, the facility uses equipment from Fuji and Universal Instruments. Sergio Ilescas of Tijuana-based C-COR looks at how the machine impacts throughput, flexibility, maintenance, report capability, and machine specifications.
Location and support are important to Clive Kellow of Young Control Systems (Underwood, Australia). Mike Berry, of Toronto-based Celestica, uses a dual-source strategy. “We treat our suppliers as partners. We have an investment in their equipment, feeders, software, and support. We’d prefer to work with our approved vendor list (AVL) of suppliers, rather than switch to another company,” Berry adds.
“Speed in set-up and changeover weigh almost equally with placement speed,” says Scott Mauldin of Tampa, Fla.-based Genesis Manufacturing, a high-mix EMS provider. In this agile environment, it is necessary to re-configure an SMT line quickly to fit a particular requirement. Mauldin also looks for manufacturers with wide distribution of equipment and a solid service infrastructure.
How often do you update equipment? Do you buy or lease?
Responses ranged from 4-10 years, with most agreeing that today’s equipment lasts longer and is more robust than it was prior to 2000. Whether this is due to necessity after a market downturn or to improve equipment and support is unclear. Generally, updates occur when capability, speed, and reliability are needed for expansion.
Each EMS provider bought pick-and-place equipment. “We do both,” says Berry. “Most of our equipment is bought, but leasing can be used when equipment needs refreshing within a few years as a means of managing cash.” Chapo added that his firm purchased equipment more often than not, but many times they finance through various companies specializing in leasing and purchases. When they expand, they upgrade and often combine several pieces of equipment under one financial umbrella.
What does ROI or cost of ownership mean?
To most providers, this means the bottom line or the time it takes to pay for equipment. Berry added that it includes all costs, not just the capital needed to purchase equipment. The cost of quality, downtime, efficiency, staffing, support, and floor space must be considered. “Many people use a criteria and weighting system to evaluate machines. For example, they would list 20 different things about equipment (price, speed, quality, support, maintenance, ease of use, etc.), and then put a weighting system against each item. They would score each section for a total weighted score,” adds Berry. “I’m not really a big fan of that approach, since there is subjectivity in the weighting and scoring system. I prefer to relate everything in terms of dollars (Figure 2). For example, what would my maintenance costs be per year?”
What placement speed (CPH) do you require?
Most EMS suppliers want 10,000 to 35,000 CPH - mid-range speed for flexible, modular platforms. “Our pick-and-place machines are arranged in multiple machine lines,” says Chapo, who looks at the throughput capability of a given line, not necessarily CPH placement of one machine. “We consider various machine options and calculate the impact for those machines on the overall functionality of the line.” While Chapo’s lines are considered mid-range, he adds, “We do see CPH increasing as the years go by; this mirrors the needs of our customers, along with the functionality per dollar for the equipment today vs. what was available years ago.”
In the past, Celestica had many lines with one turret machine and one fine-pitch system, a layout that worked well. “Today we replaced these lines with modular machines with twice the speed,” Berry notes. “In this case, we may have high-mix lines with 1,000 CPH. High-volume lines can be upward of 450,000 CPH.”
Will you purchase more placement equipment? How do you calibrate?
All providers surveyed said they do plan to purchase more equipment as part of expansion. Some of Celestica’s sites have the capability to calibrate machines, while others have to place a service call. After calibration, Berry says, it’s desirable to measure placement accuracy with a coordinate measurement machine. At Jabil, Yeung uses the CeTaQ calibration system. Genesis Manufacturing uses a daily software-based, auto-verification and auto-correction system, said Mauldin. However, if major maintenance is needed, they use a special glass calibration plate. Other firms use local service and support. Chapo uses factory-trained maintenance personnel, but they also have a contract with the manufacturer for regular calibration and maintenance.
Figure 1. Jabil Circuits in Guangzhou, China, has more than one type of pick-and-place equipment.
Are you loyal to one equipment supplier or do you use different ones? Most providers said they use a single supplier for placement equipment. Two use two suppliers; one uses three; and one has several different systems on the line, due to acquisitions. Eventually, the acquired company will transition over to the preferred suppliers of the purchasing company. Having one or few suppliers seems to be the avenue of choice.
SMT surveyed top global placement-system manufacturers to learn about equipment capabilities and the future of pick-and-place. Following are their responses.
Are customers more interested in accuracy or speed?
According to John Perrotta of Europlacer and Steve Pollack of ESSEMTEC, accuracy is key. However, most equipment makers said that both are important - and reliability is also part of the picture. “Customers want better accuracy to reduce rework at the end of the line, and many customers require increasing throughput,” says Skip Beighey of Assembléon America, Inc.
Figure 2. Factors that create total cost of ownership.
Location of the EMS provider also plays a part. “In the U.S. and Canada, customers seem to be equally interested in accuracy and efficiency, not necessarily on machine speed. Yet in Mexico, China, and other parts of Asia, the primary focus is on raw machine speed,” says Dynatech/Samsung’s Mike Foster. “A high-volume electronics manufacturer in China building 50,000 cell phones a day is looking for speed,” says Scott Wischoffer of Fuji America. Yet a provider manufacturing hearing aids in Minnesota emphasizes accuracy. In North America, rated accuracy of most machines is better than users require; speed is not generally an issue either, adds Wischoffer. Price, delivery, proximity to service and parts, changeover time, cost of ownership, and equipment reliability are common drivers of purchasing decisions.
“There is constant pressure to improve production speeds,” says Brian Duffey of MYDATA automation. Instead of focusing exclusively on CPH, MYDATA concentrates on changeovers per day; i.e. actual throughput. The company prioritizes innovations that improve speed, set-ups, and changeovers with products such as the Agilis Stick Magazine, which is designed to handle a range of SMT components (Figure 3), from small TSSOPs to large PLCCs and connectors; all sizes of components can be fed simultaneously into the same magazine.
Panasonic Factory Solutions Company of America’s CM401-M is a modular, high-speed machine with capabilities of placing 30,000 CPH at ±35-µm accuracy. Siemens Electronics Assembly Systems’ Guenter Lauber adds that both accuracy and speed are prerequisites for customers worldwide. “Customers with low-volume/high-mix production environments focus more on accuracy than speed, whereas high-volume/low-mix customers focus on speed. Siplace D Series meets the requirements of standard, high-performance applications, while the Siplace X Series suits high-speed high-performance applications.”
Savvy customers are interested in both speed and accuracy, according to Bob Black of Juki Automation Systems. “What is not so easily compiled, but just as important as the speed of equipment, is the measure of machine uptime provided by each manufacturer.” Vera Chang of Sony Manufacturing Systems America, Inc., notes that speed often is the first requirement, but accuracy is equally important. Depending on the application, Sony’s pick-and-place machines are designed to be calibrated as needed. At Cencorp Corp., Israel Ayala says that their customers are looking for high-accuracy in thru-hole component insertion, while increasing speed on the line. Cencorp’s solution is to ensure both using an automated odd-form insertion process with a variety of feeder solutions
How are placement requirements different in China than the rest of the world (ROW)?
The idea that China is only high-volume/low-mix assembly has been replaced with one reflecting a more mature market. Sony’s Chang notes that cost-per-placement is key, as is on-time delivery. Pollack of ESSEMTEC emphasizes that price and speed are major concerns in China. Siemens’ Lauber agrees with these assessments, adding, “In a recent global customer survey conducted at our Munich headquarters, customers in China have clearly expressed their need for extremely flexible machine solutions with a good cost-of-ownership ratio.”
The differences are nominal, and narrowing each month, says Brad Bennett of Universal Instruments. “Today’s environment still has lower demands for hyperfast, labor-heavy change areas, and odd-form and advanced-package handling, but that is changing quickly.” Duffey of MYDATA adds, “Electronics assembly in China has shown a tremendous growth over the last couple of years, and has thus far been focused on large-volume production, i.e. large batches and few changeovers. NPI and high-mix manufacturing is less common compared to manufacturing in Europe and North America, but this might change as the market evolves.”
Black of Juki has noticed that, even in China, batch sizes are shrinking and the requirement is for highly flexible, quick-changeover machines. Perrotta of Europlacer disagrees, saying that lot size is the biggest difference between PCBs assembled in China vs. the ROW. Lot sizes or quantities of PCBs assembled per run are much higher in China due to end markets (consumer electronics) and price pressures. Lot sizes in the west typically are 10-200 vs. 1,000-20,000 in China. Ease of changeover, capability, and flexibility are critically important.
Figure 3. The Agilis Stick Magazine is designed to handle a wide range of SMT components.
Beighey of Assembléon says that China comprises three regions - all of which require different things. Northern China is high-volume manufacture of simpler boards; South China is driving to higher technology with requirements that run closer to Eastern Europe and Mexico; and Central China is in the middle, requiring a little of both.
What is your company?s strength in pick-and-place systems?
Each manufacturer emphasized their system’s exceptional features. For instance, Sony’s dual-head pick-and-place with its 1.2-meter-wide footprint with speeds of up to 45,000 CPH represented their best feature (Pages 12-13). APS Novastar mentioned system value, based on cost-effective solutions with high reliability and accuracy. Panasonic Factory Solutions Company of America listed a range of choices, flexibility with interchangeable platforms, high-speed multifunctional heads, ease of operation, and the ability to place with accuracy. Hitachi pointed out speed of operation; direct drive technology used in turret-style chipshooters, and miniaturization of their modular flexible GXH mounters. Cencorp also talked about flexibility and high-quality automation for thru-hole component insertion.
Siemens noted accuracy, flexibility, modularity, design, and performance, as well as the company’s 10-year track record. “Our global alignment as well as global thinking and inter-culturally oriented employees gives us a competitive advantage,” says Lauber. Samsung’s traditional strength has been value, where product and service quality are high when compared to investment. “Our systems have strong technical appeal to more sophisticated users, and our service philosophy and process expertise is second to none,” says Foster.
Universal Instruments has been recognized for being a multi-function provider since the inception of its GSM, says Bennett. “Today, our AdVantis and Genesis platform solutions deliver high-mix, production-based flexibility with incremental capacity.” The Lightning head enables users to change the program without a hardware change during product changeovers.
“Fuji is best known for our high-speed chip placer - the CP,” says Wischoffer. Three years ago, the company introduced the NXT, noted for advancements in modularity, flexibility, and low cost of ownership. Juki’s Black also mentions low cost of ownership, “which simply means that our combination of speed, accuracy, and high reliability allows customers to build their products at the lowest possible cost.”
Europlacer noted integrated intelligence, rapid changeover, and optimum productivity for manufacturing environments that depend on processing multiple jobs during each shift. Their machines “flawlessly and simply perform the critical steps required for set-up and verification,” notes Perrotta.
Assembléon believes that it is most known for award-winning service and support. “We have won numerous awards recognizing the high standard of customer support,” says Beighey. They also are known for a broad product portfolio - from 5,000 to 150,000 CPH, and from low- to high-technology products.
MYDATA mentioned a flexible platform and smart feeder system, with fast changeover times. The company believes that no other machine can handle such a variety of components and boards. ESSEMTEC has become known as a specialist for low-volume and prototype placement equipment.
SMT also spoke with an industry market research firm to uncover their views of where the pick-and-place market is heading. ITM Marketing conducted research on the pick-and-place sector and end-user perceptions of major mid-range suppliers in early 2007. This study indicates that the North American market for mid-range placement equipment is increasing at a rate higher than the industry average, due to NPIs and prototype requirements. ITM’s Bob Klenke notes, “Flexibility holds the key to this market, users value equipment suppliers who offer maximum organic growth to meet unanticipated future requirements.” The equipment must also be flexible when odd-form variations of component sizes (0201, 0105 and 01005, etc.), and ultra-fine pitch are considered. How quickly each machine places chips may be measured in CPH following the IPC-9858 standard; however, the ability to change over quickly from one type of board to another is more important to mid-range users. The study offers a unique perspective from the end-user, and is based on extensive research, first-person interviews, and consulting practices. The report also offers a comparison of mid-range pick-and-place equipment specifications based on features and options, price/performance benchmarks, supplier perception ratings, and user comments.
Conclusion
Manufacturers looking to buy new equipment should first consider their production needs, and then determine what is available to match those needs within a certain price range. A matrix comparison of available options should also be used. When looking at actual machine speed, find the spec speed in components placed per hour, the Surface Mount Placement Equipment Characterization (IPC-9858) speed, and actual production speed, while simulating product cycle times for each project using a supplier’s programming software. Goals of using software, a topic to be discussed in future articles, should include finding programs that do not require debugging, and that are simple to use and set up. Many users lean toward single vendor lines because they can use OEM software, rather than third-party offerings.
EMS providers noted that placement machines are only as good as their feeders, and there have been several feeder advancements recently. Other information can be gleaned by comparing products online, in magazine articles, and through consultant research studies. But a decision shouldn’t be made until talking to other professionals - ask respected colleagues, compare products at conferences, and ask vendors for assistance on a particular problem. Many companies have trained technical staff available globally. With the right resources, you won’t need a weatherman to know which way the wind blows.
Gail Flower, editor-in-chief, SMT: (603) 891-9325; gailf@pennwell.com.
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