-
- News
- Books
Featured Books
- smt007 Magazine
Latest Issues
Current IssueComing to Terms With AI
In this issue, we examine the profound effect artificial intelligence and machine learning are having on manufacturing and business processes. We follow technology, innovation, and money as automation becomes the new key indicator of growth in our industry.
Box Build
One trend is to add box build and final assembly to your product offering. In this issue, we explore the opportunities and risks of adding system assembly to your service portfolio.
IPC APEX EXPO 2024 Pre-show
This month’s issue devotes its pages to a comprehensive preview of the IPC APEX EXPO 2024 event. Whether your role is technical or business, if you're new-to-the-industry or seasoned veteran, you'll find value throughout this program.
- Articles
- Columns
Search Console
- Links
- Events
||| MENU - smt007 Magazine
Detachable Tape-and-Reel
December 31, 1969 |Estimated reading time: 3 minutes
Low-volume/high-mix manufacturers face an increase in tape-and-reel splitting. In LVHM, it is estimated that 20 to 30% of these reels need to be split into two or more reels. A detachable tape-and-reel can be used as one reel (in continuation) or separated into two or more sub-reels.
By Henry Lourdes John
Low-volume/high-mix (LVHM) is a manufacturing environment in which multiple assemblies in small-build lots are run on the same equipment in a manufacturing cell or work center. Ideally, if a manufacturing facility could produce in lots of one and supply these units directly to the end-user, this would be the ultimate supply-chain solution. In reality, there are many challenges manufacturers need to overcome.
Many techniques, tools and methods are used in high-mix manufacturing environments to confer competitive advantage in cost, quality, delivery, responsiveness, technology and service. Every effort should be used to reduce costs, achieving profitable LVHM manufacturing.
Tape-and-Reel Splitting
As high-mix environments become standardized among manufacturers and assemblers, more value is placed on component kitting, slowing machine-changeover and setup processes. With the number of components per board growing, those tasks are further complicated. One of the problems LVHM manufacturers face is the increase in tape-and-reel splitting. A large portion of production materials comes in tape-and-reel form. In LVHM manufacturing, it is estimated that 20 to 30% of these reels need to be split into two or more reels.
Figure 1. Standard Reel
There are two main reasons for splitting a reel. The first reason is to feed two or more pick-and-place machines running parallel, using the same component. The second reason is to cater to small lots or work orders.
Setbacks of Reel Splitting
Additional headcount/manpower is needed to carry out the split process, which includes counting, attaching barcode labels and scanning. These processes also are time consuming.
Because of many reels splitting, counting machine capacity will be tight and may require the purchase of additional machines to carry out this process. There also is the possibility of adhering an incorrect component or label, increasing the rework cost. Because of this, component value check may be required. This is an additional process implemented to prevent incorrect components from being mounted onto boards. Other problems, such as the need for additional empty reels and space for kitting and storage, need to be taken into consideration.
Detachable Tape-and-Reels
This reel has two or more reels attached back-to-back. It can be used as one reel (in continuation) or separated into two or more sub-reels. For example, three sub-reels carrying 1,000 components each are attached together to make one standard reel of 3,000 components. During this process, the reel can be separated into two or more reels by cutting off each attached reel. Figures 1-3 show the prototype of a reel, divided into two sub-reels.
Figure 2. Reel Splitting
null
Advantages of Detachable Tape-and-Reels
- Flexibility - this type of reel can be used as one reel or split reels. Therefore, it can be used in all environments (high, medium and low volume).
- Reduction in the reel-splitting process - an estimated reduction of about 30 to 40% of the total quantity can reduce machine time, headcount, time and space without additional processes.
- Faster turnaround
- Reduced splitting - each individual reel has a supplier barcode attached to it. This not only helps with splitting, but also can help in tracing the reels.
- No counting - because the reel has been divided into the specific quantity needed, there is no counting required.
- Reduced rework costs - fewer reel-splitting processes will reduce rework costs due to wrong components at the user sites.
Concerns with Detachable Tape-and-Reel
Despite the benefits to equipment manufacturers, there also are concerns with detachable tape-and-reel. There is an increase in product cost due to additional processes and materials costs such as tooling and plastic reel materials. Manufacturers also could encounter errors when splitting the reels on the production floor. This often occurs because the part number or barcode label required may not have been created in-house.
Figure 3. Two Split Reels
null
Conclusion
Detachable tape-and-reel technology targets chip components, such as resistors and capacitors. It provides equipment manufacturers and assemblers with a fast, traceable and reliable reel-splitting process. While there are increases in product cost, the advantages are such that this has little impact when compared to the savings it provides. Detachable tape-and-reel is not going to solve 100% of reel splitting issues, however, it will reduce reel-splitting quantities by more than 30%.
Henry Lourdes John, quality engineer, Jabil Circuit Sdn Bhd, may be contacted at 670305-07-5269; e-mail: henry_lourdes @jabil.com.