Professional Documents
Culture Documents
Whats Online
A PCB defects guide
www.ee.globalsources.com/ART_ 8800009494_499505,499513.HTM
www.ee.globalsources.com
applications monitor line activity and provide machine reports that optimize maintenance and reel loading. For example, rather than stopping the line to replace a single reel after it runs out of components, an SFLM application can recommend that several other reels should be replaced since their component supplies are low.
Quarter
1 2 3 4 5 6
Costs
$22,000.00 $ 500.00 $ 500.00 $ 500.00 $ 500.00 $ 500.00
Benefits
$12,236.88 $12,236.88 $12,236.88 $12,236.88 $12,236.88 $12,236.88
Net
-$9,763.12 $11,736.88 $11,736.88 $11,736.88 $11,736.88 $11,736.88
PC1
$1,500.00 $500.00 3,739 3,627 97.00% $433.77 $191,559.22 $4,672.18
In the variables presented, the process yield is equal to the number of boards shipped divided by the number of boards that entered the PCB manufacturing process.
Table 2 2: The SFLM optimizes component loading schedules that decrease machine downtime.
solder joints have been shorted on five out of 100 boards, there is a reasonable chance that a process variable needs to be adjusted. Therefore, the SFLM system can immediately alert you via a page when this rule has been violated, and the process engineer on duty can respond to the situation. The process engineer can view process line throughput and individual cycle times for each process step through the SFLM system. The engineer can quickly identify any fluctuations in individual cycle times that may impede the throughput of the process line. This can be seen in figure 1. Before a value can be placed on the SFLM application, the baseline costs for current data collection and analysis, rework, scrap and an inactive line must be assessed. The following equation can be used to calculate the gross profit per shippable PCB based on the manufacturing costs and selling price. If the per unit profit equation is multiplied by total quantity produced, the total expected gross profit can be calculated. This approach is based on a real-time costing method so that individual cost components can be 4 Electronics Engineer June 2000
itemized and changed to understand the effects on profitability. p = qs * [R - (fPCB + fcomp + vlabor + vmach + vrent + vrework + vcons)/y] In the equation, bareboard and component costs are identified as fixed costs, while non-material costs are described as variable costs. It can be assumed that the purchasing department has already procured the PCBs and components at a set price per unit. The variables included in the equation are as follows: p - profit qs - total quantity shipped and sold R - revenue per saleable unit produced fPCB - cost of the bareboard (fixed) fcomp - cost of materials and components (fixed) vlabor - direct labor costs vmach - amortized cost of capital machinery vrent rent vrework - amortized rework costs vcons - cost of consumables y - final process yield
We can use the formula previously discussed and arrive at a profit value equivalent to US$66.33/unit.
You may e-mail your comments on this article to Kyle Klatka at klatkak @ genrad.com; or fax: 1-978-5892050.
www.globalsources.com