Cycle Time Optimization in PCBA Manufacturing

In PCBA (Printed Circuit Board Assembly) manufacturing, cycle time refers to the time it takes to complete a production cycle, from the moment a PCB board enters the production line to the time it takes to when it is tested and shipped. Cycle time optimization is essential for manufacturers looking to improve their efficiency and reduce costs ­– and is commonly one of the top concerns electronics manufacturers want to tackle when exploring our products.

In this blog post, we will discuss some of the ways in which cycle time can be optimized in PCBA manufacturing. We’ll look at everything from traditional methods of standardizing processes and systems to newer options with Artificial Intelligence and machine-learning systems.

Standardizing processes is one of the simplest and most effective ways to optimize cycle time. In the PCBA industry, the IPC has over 300+ active standards covering every stage of the production process. Those standards are well-known, and more than 3,000 professionals participate in their development. Adhering to these standards can help reduce the amount of time it takes to complete each production cycle, as well as improve quality by minimizing both errors and defects.

Optimizing equipment is another way to reduce cycle time in PCBA manufacturing. This is one of the things our IIoT.Edge solution can be used for. By using our trained Artificial Intelligence (AI) algorithm, you’ll be able to improve your productivity through continuous improvement of each machine’s cycle time (CT).

Even though the whole AI thing can seem daunting, the process can be summarized and simplified accordingly:

1. Our AI algorithm uses machine learning (ML) capabilities to learn a baseline pattern for each product on each machine over time.
2. Then, it will automatically detect/predict CT anomalies and issue alerts.
3. These alerts will give you the chance to quickly identify bottlenecks so you can take corrective action on the root cause and quickly clear identified bottleneck.

This results in reduced time responding to problems, as well as a proactive problem-solving methodology.

Changeover time refers to the time it takes to switch from one production run to another. This can be a significant source of cycle time in PCBA manufacturing, especially for high-mix manufacturers. By optimizing changeover time, manufacturers can minimize the time it takes to switch from one production run to another, reducing the overall cycle time. Over the years, Cogiscan’s kitting control and offline setup validation
solutions have been widely adopted to achieve this goal.

Inspection and quality control are critical steps in PCBA manufacturing. Despite the advancements in automated optical inspection (AOI) machine technology, most common AOI machines still experience a false call ratio between 30% and 50%, forcing manufacturers to have an operator to sit in front of the machine and provide verification feedback. This added step leads to an overall lower cycle time. AI solutions are now available to help address this issue by automatically dismissing calls it knows with a high degree of confidence are false. In some cases, the IIoT.Edge platform has helped PCBA manufacturers reduce their AOI false calls by up to 60%, while also increasing throughput on the line.

In conclusion, cycle time optimization is essential for manufacturers looking to improve their efficiency and reduce costs in PCBA manufacturing. Whether you’re looking to implement one of these options or all of them, you should be able to see a direct impact on your factory’s cycle time.