The second part of our blog series "PAILOT for electronics production" focused on assembly planning and the personnel factor. We showed how APS systems (Advanced Planning & Scheduling) take detailed scheduling in electronics production to a new level - by realistically mapping shift models, qualifications and available capacities, thereby significantly improving adherence to schedules and resource utilization. The practical example of STARTEAM Global made it clear how intelligent, networked planning can increase capacity utilization and reduce delays.
In the third part, we now turn our attention to the next central building block of networked production planning: SMT and THT - and how APS tools such as PAILOT help to minimize set-up times, avoid bottlenecks and thus further increase efficiency in electronics production.
Efficient SMT and THT planning: How APS tools avoid set-up times and bottlenecks
Electronics production is characterized by a high number of variants and complex process chains. Particularly in the area of SMT (Surface Mount Technology) and THT (Through Hole Technology) production, planning is crucial for efficiency, on-time delivery and throughput times. However, this is precisely where bottlenecks often occur. Be it due to long set-up times in SMT or process steps in THT that only need to be run through for some products. Modern APS systems (Advanced Planning & Scheduling) such as PAILOT offer the solution: they make detailed scheduling transparent and production processes flexibly controllable.
SMT: Setup time optimization in complex scenarios
1. double-sided assembly and what this means for detailed scheduling
Today, many assemblies are assembled on both sides. This creates dependencies between the production of both sides. For example, due to joint set-up processes, material availability or priorities in the line. An APS system automatically recognizes these relationships and takes them into account in planning, regardless of whether side A and side B are produced directly one after the other or at different times. This keeps the overall plan flexible, but at the same time coordinated and efficient.
2. challenge of set-up times in high-mix, low-volume environments
In high-mix, low-volume production, products and variants change frequently. Set-up processes are therefore one of the biggest time factors. Without smart planning, machines quickly come to a standstill. The aim is to design the production sequence in such a way that products with similar set-up requirements are produced one after the other, thereby reducing material changes to a minimum.
3. two planning variants and their limitations
1. planning with manufacturer software: Many SMT system manufacturers supply tools for setup optimization. If they are in use, it is possible to work with general set-up time values. However, these systems usually have a purely area-related focus - consistent PCBA planning is not included. --> Risk of silo planning.
2. no software available: This is the reality in many production facilities: Setup sequences are maintained in Excel or decided "in the head" by experienced employees. This may work with a small variety of products, but with increasing complexity, deviations from the plan and bottlenecks are inevitable. This is where the introduction of an APS system offers the opportunity to eliminate these weak points.
4. role of APS in SMT planning
An APS system links order priorities, material, personnel and set-up times in a dynamic model. This allows scenarios to be simulated and bottlenecks to be avoided at the planning stage. This means less manual readjustment, higher output and more realistic delivery dates.
5. practical example: How PAILOT implements setup optimization
PAILOT automatically analyzes all orders and creates setup groups based on common product characteristics. For example, identical placement sides, component families or line assignments. Within these groups, orders are arranged in such a way that the overall setup effort is minimized. At the same time, planning remains flexible enough to introduce rush orders without the overall system coming to a standstill.
THT: Flexibility in integration
1. THT as part of the overall PCBA (Printed Circuit Board Assembly) process
THT production is a central component of the PCBA process chain. It usually follows SMT and directly influences throughput times and on-time delivery. Isolated planning is therefore not enough - THT must be closely integrated into the overall plan.
2. special features of THT production
Processes such as wave soldering or selective soldering have their own requirements. Different assemblies require different process steps, which makes planning more complex.
3. why THT must be scheduled flexibly
While SMT is strongly characterized by set-up times, THT production requires flexibility. Additional steps such as re-soldering or selective soldering can have a major impact on throughput times. A static plan rarely takes this into account. As a result, delays and bottlenecks often occur.
4. optional steps as a bottleneck factor and how APS avoids them
It is often process steps that not every product has to go through that can bring a production line to a standstill: Special tests, coatings or reworking. An APS system such as PAILOT recognizes such dependencies at an early stage and simulates alternatives: Orders can be rerouted, sequences adjusted or resources prioritized differently. In this way, bottlenecks can be identified and eliminated before they even arise.
Conclusion
SMT and THT are two central production technologies in the PCBA process. Both have their own challenges that are difficult to master without modern planning. While SMT planning is strongly characterized by setup time optimization and sequence dependencies, THT production requires a high degree of flexibility in process steps that do not have to be run through by every product.
PAILOT combines both: we integrate SMT and THT into a holistic APS plan, reduce set-up times, avoid bottlenecks and ensure realistic delivery dates and high adherence to deadlines. The result: less manual intervention, more transparency and production that is both reliable and flexible.
