How to maintain Auto Insertion and SMT machine — ESD Cleaning and Testing Procedures

Procedures and Adjustments

CAUTION

The following procedures explain how to properly clean and test an ESD surface.

Clean an ESD Surface

Do not use abrasive or highly alkaline cleaners on polycarbonate. Never scrape polycarbonate with squeegees, razor blades, or other sharp instruments. Benzene, gasoline, acetone, or carbon tetra chloride should never be used on polycarbonate. Do not clean polycarbonate in the hot sun or at elevated temperatures.

  1. Using a sponge or soft cloth, wash the ESD-protected surface with either a mild detergent or Windex product and lukewarm water.
  2. After washing, rinse with water and dry thoroughly with a chamois or moist cellulose sponge to prevent water spots.
  3. To protect the ESD surface after rinsing and drying,  recommends applying Kleenmaster Brillianize®. This application helps to maintain the static dissipative coating and reduce the accumulation of dust.

Test Static Dissipative Covers

Periodically and after maintenance, check the machine covers to determine if the dissipative qualities of the cover have changed. The following procedure ensures that static dissipative covers are in fact dissipative.

Tooling

Surface resistance meter (such as 3M 701 Surface Resistance meter and probe).

Comments

The surface resistance should be less than 109 ohms in all areas. If the cover package is no longer dissipative, contact you Universal Instruments Corporation sales representative.

Procedure

  1. Clean the static dissipative covers using the Clean ESD Surface procedure to ensure the accuracy of the test.
  2. Using the surface resistance meter, follow the instructions provided by the manufacturer to measure the surface resistance of both the inside and outside of the covers. Measure the resistance at all four corners and at several areas in the middle of the cover. This test checks the integrity of the ESD coating.
  3. Connect the ground path resistance probe to the meter and chassis ground.

The path to the ground should not be higher than the surface resistance. If it is, clean the frame connections, repair loose or corroded fasteners and ground straps, and check tracks for dirt and/or corrosion.

4. Measure the ground path from the covers to the chassis ground. Take this measurement from both surfaces and all four corners of each cover.

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How to invest future – Auto Insertion and SMT equipment ROI calculation

Fill in “Green Areas” on Summary Sheet Below & Production Need Sheet

Calculations in “Blue” or “White” and should not be changed

INPUTS
Financial Machine Price Depreciation Time (Years)

Electricity Cost ($/kWHr)

US$ 205,000

5

US$ 0.1200
Machine Data Configuration Pass Thru / Non Pass Thru

Spec Speed

Sm Triple Span (2.5/5.0/7.5) Pass Thru (Automatic BDH)

22,000

Labor Rates / Hour Machine Operator Maintenance
US$ 10.00 US$ 15.00
Factory Work Time

Hours / Day

Days / Week

Weeks / Year

20

6

50

Hand Labor

Hand Labor Rate

Insertion Rate / Hour

US$ 6.00

250

OUTPUTS
Production Data
Insertions Needed   4,900,000 Annual Component Insertion
Machine Work Time
Machine Time

613

Hours to MFG
Hours in Year

6000

Machine Utilization

10.22%

Machine Yearly Costs
Depreciation US$ 41,000 Straight Line Depreciation
Utilities US$ 155 Electricity for Machine & Air
Maintenance US$ 900 Parts & Labor for Machine
Operator US$ 6,132 Operator Time @ machine
Total Yearly Costs US$ 48,186 Sum of all costs
Hand Labor Equivalents
Labor Hours   19,600
Labor Costs US$ 117,600
MACHINE DRIVEN SAVINGS
Hand Placement Cost US$ 117,600 Per Year
Machine Placement Cost US$ 48,186 Per Year
Annual Savings US$ 69,414 Per Year

 

Price

Unit

Notes

Machine Cost

US$ 205,000

$

Machine Costs

Depreciation Time

5

Years

Straight Line Assumed

Yearly Deprciation Expense

US$ 41,000

Result

Work Days per Week

6

Days

Hours Per Day

20

Hours

Weeks per year

50

Weeks

Hours per Year Available

6,000

Hrs/Year

Work Hours per Year

PM  Hours per 100 Hrs

12

Hours

Maintenance

Machine Working Hours

522

Hours

Total Production Hours

Maintenance Intervals

5

Periods

Maintenance Times

Maintenance Time

60

Hours

Maintenance Times

Maintenance Labor Cost

US$ 900

Costs

Labor Hours x Rate

Production Hours Needed

522

Hours

Machine Production Time

Intrinsic Availability

94.00%

Uptime

Downtime (Increased based on Age)

Lost Hours

31

Hours/Yr

Downtime

Machine Hours To Produce

553

Hours

Production Hours

Guide Jaw / Clinch Costs

US$3,000

Cost

Per Unit

Tooling Replacement

6,000,000

Cycles

Cycles per replacement

Tooling Replacements / Yr

0

Replacements

Replacements Needed

Yearly Replacement Costs

US$0.00

Costs

Total Yearly Tooling Costs

Chain Clip Replacments

US$780

Cost

Cost Per Replacement

Tooling Replacement

15,000,000

Cycles

Cycles per replacement

Tooling Replacements / Yr

0

Replacements

Replacements in a Year

Yearly Replacement Costs

US$0.00

Costs

Total Yearly Chain Costs

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