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For Australian and New Zealand electronics manufacturers, bringing PCB assembly in-house can provide greater control over production, quality, lead times and intellectual property.
Whether you are reshoring electronics manufacturing previously outsourced overseas or considering setting up an in-house PCB assembly line for the first time, there is more to consider than simply purchasing a pick-and-place machine.
Components, utilities, skilled operators, inspection, traceability and ongoing technical support all need to form part of the decision when planning an SMT production line.
Outsourcing PCB assembly can provide flexibility, but establishing your own electronics production capability can give manufacturers greater visibility and control over how and when products are produced.
Depending on your production requirements, bringing PCBA production in-house may help you:
For businesses considering the move, the first step is understanding the equipment, infrastructure, people and processes required to establish an SMT production line.
A modern PCB assembly production line incorporates several interconnected processes rather than one individual machine.
A typical SMT production process can include:
Additional equipment may also be required for component storage, feeder preparation, PCB handling, traceability, rework and inspection.
Hawker Richardson supplies complete SMT production line solutions using electronic production equipment from leading manufacturers including Yamaha, Heller, Nutek, Saki and Scienscope.
The exact configuration depends on your products, production volumes, component range, required throughput and the level of automation you want to achieve.
Ensuring you have the right components available when they are required can be just as important as selecting the SMT equipment itself.
Many electronic components are manufactured overseas, so bringing PCB assembly in-house does not automatically remove supply-chain considerations. Stock levels, component availability, production schedules and changing product requirements all need to be considered when planning the move.
Increasing component stock may provide greater production security, but holding too much inventory can create additional cost and waste if products or board designs change.
Component storage systems and intelligent software can help manufacturers manage this more effectively, tracking materials and components through the SMT production process and potentially integrating production requirements with existing ERP systems.
When setting up an SMT production line, the infrastructure required to operate the equipment should be considered from the beginning.
Power, compressed air, extraction, factory layout and available floor space can all influence the design of the line.
Energy efficiency should also form part of the equipment selection process. Reflow ovens are typically one of the more energy-intensive elements of an SMT production line, so comparing operating requirements as well as initial equipment costs can make a considerable difference over the lifetime of the system.
Planning the complete production environment rather than evaluating each machine independently can help create a more efficient and practical PCB assembly operation.
Once the hardware is in place, attention shifts to operating and optimising the production line.
It is one thing to have a team capable of operating the equipment day to day; it is another to develop the skills and processes required to get the most from an integrated SMT production environment.
Experienced production management can help coordinate departments, production schedules, materials and operators to ensure the right boards are being produced in the right quantities and at the right time.
Training and ongoing technical support should therefore be considered as part of the initial equipment investment.
There will also be occasions when equipment requires servicing, maintenance, technical assistance or replacement parts beyond the scope of the internal production team. Choosing an SMT equipment supplier with local Australian and New Zealand support can help minimise unnecessary production downtime.
Greater control over quality is one of the major reasons manufacturers consider bringing PCB assembly production in-house.
Rather than identifying problems after completed boards have been received from an external supplier, inspection can be incorporated directly into the production process.
An Automated Optical Inspection (AOI) system can inspect assembled PCBs for production defects and provide feedback within the manufacturing process.
Solder Paste Inspection (SPI) can be positioned after solder paste printing and before component placement to inspect paste deposits and identify potential problems before additional value is added to the board.
Integrating SPI and AOI into the SMT line provides manufacturers with greater visibility of production quality and can help reduce rework, waste and the continued production of defective boards.
The pick-and-place machine sits at the heart of automated SMT assembly, accurately positioning electronic components onto the PCB before reflow.
The appropriate machine depends on factors including production volume, component range, PCB complexity, product mix and required throughput.
Hawker Richardson supplies a range of pick-and-place machines, including Yamaha SMT mounters such as the Yamaha YRM20, allowing the placement solution to be configured around actual production requirements rather than taking a one-size-fits-all approach.
Modern PCB assembly extends beyond the individual machines.
Production software can connect processes across the SMT line, manage production programs and schedules, monitor performance and provide traceability throughout PCB assembly.
For manufacturers looking beyond simply bringing production in-house, integrating hardware, software and automation can create an increasingly connected production environment and provide a platform for future growth.
Explore SMT production optimisation and connected manufacturing ā
For manufacturers currently outsourcing PCB assembly, bringing production closer to home can provide benefits extending beyond cost alone.
Greater production control, shorter response times, quality management, supply-chain resilience and protection of intellectual property can all form part of the business case.
It can also support a broader commitment to local manufacturing and give businesses greater visibility over the environmental and operational impact of their production.
The important point is to look at the project as a complete PCB assembly production environment rather than simply a collection of machines.
Hawker Richardson works with electronics manufacturers throughout Australia and New Zealand to configure PCB assembly equipment and complete SMT production lines, from individual production machines through to integrated and automated manufacturing environments.
See it in practice: Discover how Philips Dynalite brought PCB assembly production in-house with a complete SMT production line.
Already considering the equipment required? Explore equipment for reshoring an SMT production line.
A typical automated SMT line may include a solder paste printer, SPI system, pick-and-place machine, reflow oven, AOI and PCB handling equipment. Component storage, feeder preparation, traceability and production software may also form part of the complete production environment.
Yes. Manufacturers can establish their own PCB assembly capability for prototyping, production or both. The appropriate solution depends on factors including production volumes, product mix, investment requirements, staffing and the level of automation required.
PCB manufacturing can refer to fabrication of the bare printed circuit board itself. PCB assembly (PCBA) refers to mounting and soldering electronic components onto that board. Hawker Richardson supplies equipment primarily for PCB assembly and electronic production.
In addition to the SMT equipment itself, manufacturers should consider factory space, utilities, component storage and management, operators, programming, inspection, traceability, training and ongoing technical support.
Hawker Richardson supplies electronic production equipment and integrated SMT production solutions for manufacturers across Australia and New Zealand, including printing, component placement, reflow, inspection, PCB handling, component management and production software.
