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The Printed Circuit Assembler's Guide to... ™
Factory Analytics

by: Julie Cliche-Dubois, Cogiscan

Using and understanding factory analytics is the future for electronics manufacturers. Those who strategically prioritize analytics and properly leverage the insights generated throughout their entire operation systematically will stand the test of time. In this fast-changing, deeply competitive, and margin-tight industry, factory analytics can be the key to unlocking untapped improvements to guarantee a thriving business.



ISBN: 978-1-959894-08-7
ISBN: 978-1-959894-12-4 Print-on-demand

Julie Cliche-Dubois
Product Manager Analytics & Connectivity, Cogiscan

Julie Cliche-Dubois leads all product management efforts at Cogiscan. She received her bachelor’s degree in computer science and a postgraduate diploma in business information technology, both from the University of Sherbrooke in Québec Canada. Julie has extensive experience providing product management to software development companies in the high-technology hub of Montréal.

With a combined tenure of 11 years spent at Cogiscan, Julie has worked in a variety of roles from development to applications support to product management. She has extensive technical knowledge of the complete Cogiscan portfolio and leverages those insights to develop new features and products that are relevant both to Cogiscan’s technology and target market. Her empathetic nature, coupled with her technical expertise, makes her the ideal person to lead Cogiscan’s product management efforts, and she is focused on improving the user experience of the company’s products overall.

When not developing solutions to improve the manufacturing process, Julie can be found running along the streets of Montréal, Canada (typically chasing after her two young children) or enjoying a good book.

Cogiscan was founded in Québec, Canada in 1999 by three manufacturing engineers. The company was established to fulfill the vision of creating a smart factory that seamlessly integrates all manufacturing processes, including machines, materials, people, and software systems, using information technology. More than two decades later, Cogiscan continues to provide modular smart factory solutions that are tailored specifically for PCB assembly in high-reliability industry sectors.

Cogiscan's applications enable machine connectivity, process control and traceability, and data-driven analytics—from the shop floor all the way to the enterprise level, including parent company iTAC Software AG’s Gartner-recognized MES/MOM suite. As subsidiaries of Dürr Systems AG, both Cogiscan and iTAC Software are part of Dürr’s Digital Factory. The Dürr Group is one of the world’s leading mechanical and plant engineering firms with particular expertise in the technology fields of automation, digitalization, and energy efficiency. Its products, systems, and services enable highly efficient and sustainable manufacturing processes.

After 25 years focused solely on electronics manufacturing, Cogiscan has helped transform manufacturing operations all over the world with installations in over 800 factories. To understand how Cogiscan can guide you along your smart factory journey, please visit Cogiscan.

This book has been technically reviewed by the following experts:

Jason Sciberras President, Saline Lectronics Division of Emerald Technologies

For the last two decades, he has worked in a wide variety of roles at Saline, touching every element of the organization from sales and program management to quality control and manufacturing operations. He finds collaborating with new talent to be extremely rewarding and has enjoyed watching these [...]

Alejandro Carrillo Founder/General Manager, InterLatin

Alejandro Carrillo is a distinguished Mexican professional and entrepreneur. He holds a Bachelor’s Degree in electronics engineering from the Institute of Technology in Juarez, Mexico, earned an MBA from the prestigious IMD in Lausanne, Switzerland, and also did graduate studies in the Japanese [...]

Chapter Summaries

  • Chapter 1

    Getting and Processing Factory Data

    This chapter discusses the challenges faced by electronics manufacturers in obtaining and processing data from the factory floor. It highlights the complexities of dealing with multiple machine types, output formats, licensing requirements, and the need for effective data normalization.

  • Chapter 2

    SMT Process: A Treasure Trove of Data

    Chapter 2 highlights the importance of analytics for key machines like screen printers, solder paste inspection machines, and placement machines. The author discusses the different perspectives and needs of line operators, manufacturing engineers, and quality managers, offering insights into maximizing efficiency, quality control, and performance evaluation within the SMT process.

  • Chapter 3

    SMT Data Analytics: Oven to AOI

    Chapter 3 delves into the critical aspects of the SMT process, focusing on the reflow oven and automated optical inspection (AOI) machine. Highlighted are the key roles of the line operator, manufacturing engineer, and quality manager in maintaining efficient operations and high-quality PCBAs.

  • Chapter 4

    Data Analytics: Beyond SMT

    In this chapter, readers will learn the importance of efficiency in post-SMT processes such as rework and testing. Key KPIs are discussed, along with the need to reduce rework time, improve first-pass yield, maintain testers, and monitor defect rates. By optimizing these processes, manufacturers can enhance product quality, reduce costs associated with defects, and ensure customer satisfaction.

  • Chapter 5

    Measuring and Monitoring Global Factory Health

    Chapter 5 discusses the importance of measuring factory health through Overall Equipment Effectiveness (OEE). How do analytics at the line and factory level provide insights for continuous improvement? The role of OEE is critical in identifying bottlenecks, improving performance, and ensuring quality.

  • Chapter 6

    Driving Meaningful Action

    Chapter 6 emphasizes the importance of normalizing and labeling shop-floor data for analytics tools in PCBA manufacturing. Contextualized data is crucial for precise KPI calculations. Integrating factory analytics with production control systems can drive meaningful improvements in manufacturing operations by identifying issues, reducing errors, and maximizing production efficiency.

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Jason Sciberras For the last two decades, he has worked in a wide variety of roles at Saline, touching every element of the organization from sales and program management to quality control and manufacturing operations. He finds collaborating with new talent to be extremely rewarding and has enjoyed watching these "green" team members flourish into key team members who drive a meaningful difference in the electronics manufacturing industry.

Alejandro Carrillo Alejandro Carrillo is a distinguished Mexican professional and entrepreneur. He holds a Bachelor’s Degree in electronics engineering from the Institute of Technology in Juarez, Mexico, earned an MBA from the prestigious IMD in Lausanne, Switzerland, and also did graduate studies in the Japanese University of Scientifics and Engineers under a scholarship from the Japanese government.