capacity expansion through additional line with the latest technology

capacity expansion through additional line with the latest technology

The growing demand for printed circuit board assemblies (pcba's) answers tbp electronics (EMS) with the investment in an additional state-of-the-art production line. Since October, this has been operational at the main location in Dirksland. At the same time, the entire production process has been further optimized thanks to smart improvements.

The new line 5 is identical to production lines 1 and 2, but the latest technologies ensure a modern machine park and an even more efficient process. Thanks to the efforts of many tbp colleagues and the machine partners, the new line was built in a very short time and put into use with two shifts. The capacity has been significantly expanded as a result. In combination with other adjustments, tbp can continue to offer the same high delivery reliability, despite the growing demand. A look behind the scenes.

flexibility in paste printing

The new paste jetter (MY700) can, like the previous generation, apply the solder paste in multiple layer thicknesses to the PCBs (3D paste printing). By adding an extra jet head, paste and glue can be combined in one production step. The arrangement of the paste jetter and screen printer also offers a lot of flexibility. A larger jet head and a smaller machine surface are other improvements.

continuous production flow

A buffer tower after the solder paste inspection machine (SPI) provides storage for the jetted and/or screened boards. This allows jetting and screen printing to continue, even when the pick & place machines are at a standstill. In addition, you can convert the screen printer for a subsequent product, while the production of the previous product can continue with the buffer stock. The assembly of components is therefore uninterrupted. The new machines and smart software also make it possible to optimize machine planning and 'family kits'. Family kits are loads for multiple (similar) projects that have a component overlap.

precise assembly with digital positioning

In the latest generation of pick & place machines (MY300), the mechanical centering mechanism with electrical verification unit has been removed, making the machine shorter. The optical verification unit (now part of the y-table) completely takes over the control of correct components. After a short transition period to adjust the database to this, placing components will be even more accurate and faster.

software optimization

Communication between the machines is crucial for the production process. Ronald de Jong, as technical application manager, prepared the software for the new line. 'That is to say: all available links between the machines and the control processes around them. We wrote a program to automatically compare the component information, so that we can use previously matching information bundles instead of constantly creating new ones. We expect to receive these digital packages from our suppliers in the future.' The technical application managers also write the software to preset the entire control process per product in one go, so that this no longer has to be done per machine. The new generation of machines makes this possible.

even more accurate inspection

The 3D solder paste inspection machine (SPI) checks immediately after applying the paste whether the correct amount has been applied correctly. The 3D automatic optical inspection machine (AOI) checks before soldering whether the correct components are in the correct place (pre-reflow) and after soldering also checks whether the soldering process has been completed correctly (post-reflow). 'Inspections by the latest generation of machines are even more accurate due to the higher camera resolution', explains Raymond Hokke. He is a test operator at tbp. 'If the communication between the AOIs and the SPI develops further (with the software tool K-SMART), we can continue to fine-tune the inspection process for maximum product reliability.'

 space for the new line

To make room for the extra production line, lines 3 and 4 for small series and prototypes have been moved to the tbp branch on the same business park 'De Watertoren'. The upper floor is where complete housings are manufactured. Depending on demand, we install the pcba's in modules and cabinets or take care of the entire box building. This includes cables, connections, card readers, batteries, plating, manuals and possibly software. Custom work.

The temporary release of the production floor was used, among other things, for the reorganisation of the test department. This was recently expanded with an additional flying probe tester and three additional base stations (now six) for the extended boundary scan test solution. This is the most effective and efficient option that we have developed ourselves for the automatic detection of possible deviations on a pcba. We advise clients on the best test strategy as part of our early supplier involvement with which we help perfect their pcba design (Design for eXcellence, DfX.)

plug & play

Senior maintenance engineer Ronald Willemse had been busy for weeks installing, rerouting and expanding connections for electricity, data and air. 'Workplaces had to be temporarily moved to access them, but everyone was very flexible. Lines 1 and 2 were able to continue operating without interruption and lines 3 and 4 were only out of service for a few days. All machines could be connected immediately, that's how well we had prepared. With these kinds of jobs, I feel like a fish in water.'