How do you envision technological progressions influencing the future of manufacturing operations? Get informed from Electronics for You’s Akanksha while in dialogue with Bejoy George of Chipmax Designs Private Limited.
Q. How do electronic manufacturing innovations benefit mid- and small-scale manufacturers?
A. We offer flexible and scalable solutions altered for mid- and small-scale electronics manufacturers. Our approach allows these manufacturers to enhance their production without the high costs associated with large systems. The latest trends in manufacturing elevate our efficiency, product quality, and speed to market, while allowing more customisation. This helps us meet varied client needs and stay ahead in the market.
Q. What new software helps improve the latest manufacturing machines?
A. Our software innovations use modern analytics, real-time monitoring, AI for predictive maintenance, and automation to enhance operations. These tools improve decision-making, reduce downtime, and significantly increase efficiency.
Q. What problems do they face, and how do their innovations help with making things smaller, simpler, and integrated?
A. The key challenges in adding new equipment to existing systems include ensuring compatibility with old technology, integrating data across platforms, optimising workflows, and training staff on new technology and processes. Other issues encompass complex supply chains and cybersecurity risks. However, innovations in precision manufacturing, latest robotics, and new materials are helping to overcome miniaturisation and complexity challenges, leading to better performance and reliability in electronic assemblies.
Q. What materials do you make and how are they beneficial?
A. We use refined materials and technologies to improve production efficiency and quality. We use brushless direct current (BLDC) motors for precise control, high-speed HD cameras for quality checks, low-power high-speed processors for computing, AI for smart decisions, linear encoders for accurate positioning, Linux for system management, and laser windows for safety. These help us work faster, better, and more efficiently.
Q. How are IoT, smart tech, and automation changing small electronics manufacturing?
A. IoT and smart tech change electronic manufacturing by collecting data in real-time, monitoring remotely, predicting maintenance needs, and improving connectivity. This enhances production efficiency, cuts downtime, and helps with quick decisions, transforming how things are made. Automation and robotics change electronics manufacturing by simplifying repetitive tasks, speeding up production, and improving accuracy in placing parts. They cut labor costs and make scaling up easier and more reliable, even for smaller operations.
Q. What sensors does your new equipment use, and how do they help?
A. Critical sensors, including proximity sensors, air pressure sensors, limit sensors, position sensing linear encoders, and HD visual sensors for quality inspection, elevate operational performance by ensuring precise measurement, control, safety, and quality assurance throughout our manufacturing processes.
Q. How is new SMT equipment making manufacturing better and faster?
A. Better surface mount technology (SMT) equipment improves precision, speed, part compatibility, and soldering techniques, which results in higher quality, faster production, and more reliable electronics.
Q. What new thermal profiling features do SMT reflow ovens have that help with PNP machines and stencil printers?
A. Our latest thermal profiling for SMT reflow ovens sets new industry standards with advanced temperature control, multi-zone heating, and real-time monitoring. Using nichrome-aluminum alloy for heating ensures precise temperature control and lower power consumption. These innovations improve soldering quality, reduce defects, and enhance energy efficiency. Additionally, our equipment includes eco-friendly features like a smoke carbon filter and an inbuilt temperature profiler for real-time PCB temperature monitoring. These advancements enhance efficiency, reliability, and environmental sustainability, making our SMT reflow ovens as leaders in thermal profiling technology.
Q. How have new SMT machines become more accurate, faster, and energy-efficient?
A. Recent advances in SMT pick-and-place machines and reflow ovens are transforming the industry. They feature better vision systems, faster processing, ingenious motion control, quicker cycles, and energy-efficient operations. Collectively, these improvements deliver higher accuracy, speed, and efficiency in placing smaller components, aligning perfectly with the trend towards miniaturisation.
Q. How are new software and AI improving SMT systems?
A. Progressive software and AI improve SMT systems by optimising component placement and using machine learning to enhance defect detection. Predictive maintenance ensures proactive equipment management, fostering production yields, reducing scrap rates, and enhancing overall equipment effectiveness (OEE). These innovations set new standards for efficiency and precision.
Q. How do new SMT tools make setup faster, changeover quicker, and maintenance easier for high-mix production?
A. Advances in SMT equipment are setting new industry standards with intuitive user interfaces, automated calibration routines, and tool-less changeover mechanisms. These innovations slash changeover times, minimise downtime, and enable rapid responses to production demands in high-mix environments, ensuring efficiency and adaptability.
Q. How do real-time monitoring, analytics, and AI improve traceability, quality control, and logistics?
A. Real-time monitoring, analytics, and AI integration revolutionise traceability, quality control, and logistics in SMT production. By tracking production data from raw materials to finished products, these technologies enhance traceability, employ predictive defect detection for superior quality control, and streamline material flow with intelligent routing decisions. Ancillary equipment like PCB auto loaders and linkage conveyors further increase production quality and speed by minimising human interference. These advancements ensure higher product quality, reduce rework, and significantly improve supply chain efficiency.
Q. How do you manage your equipment’s life cycle and plan for upgrades?
A. We improve equipment management with proactive maintenance, ongoing performance monitoring, and strategic upgrades based on lifecycle analysis. Using data-driven insights, we time upgrades and replacements perfectly to balance cost-effectiveness with production needs.
Q. How do you keep data secure with more connectivity in manufacturing?
A. To safeguard against cyber threats and unauthorised access in our highly connected manufacturing operations, we implement robust data encryption, network segmentation, access control mechanisms, intrusion detection systems, and regular security audits. These measures ensure the highest levels of data security and integrity.
Q. How does your new equipment handle errors and what fail-safes are included?
A. Our equipment is equipped with built-in diagnostics, automated recovery processes, redundant critical systems, and fail-safe mechanisms to prevent major failures. These features increase reliability, reduce downtime, and maintain peak equipment performance.
Q. Can you give an example of new equipment improving production or quality?
A. A prime example is the deployment of automated assembly lines equipped with the latest robotics and AI-driven quality control systems. This led to a 30% rise in production throughput, a 20% reduction in defects, and a 15% drop in production costs within the first year for a small to mid-sized electronics manufacturing firm.
Q. How have recent upgrades improved product quality and consistency?
A. Recent equipment upgrades have significantly enhanced product quality and consistency. Enhancements include improved process repeatability, reduced production variability, advanced inspection capabilities, tighter component placement and soldering process tolerances.
Q. How is sustainability included in your equipment design and operation?
A. We promote sustainability through energy-efficient technology, recyclable materials, waste reduction, and strict environmental compliance. These efforts foster eco-friendly manufacturing, cut environmental impact, and support sustainable development goals.
Q. How do you manage the cost of new manufacturing technology investments?
A. We strategically manage manufacturing equipment costs through partnerships, efficient resource use, and process optimisation. We offer flexible financing, including subsidies, to minimise initial expenses. For Small to mid-sized businesses, we consider total cost, ROI, budgeting, financing, and savings from efficiency and quality improvements.
Q. What measures ensure product quality with new manufacturing equipment?
A. Adopting progressive manufacturing equipment brings new metrics and standards, such as first-pass yield rates, defect rates, equipment uptime, cycle time, throughput, and overall equipment effectiveness. These metrics offer insights into production performance, highlight areas for improvement, and drive continuous optimisation efforts.
Q. How do you measure new equipment performance?
A. We ensure our equipment meets industry standards through CE certification by TUV NORD, guaranteeing compliance with safety and quality requirements. Additionally, we develop customised metrics to meet our production goals and customer needs, enabling precise performance evaluation and continuous improvement.
Q. What are your upcoming investments in manufacturing equipment, and what trends or innovations are you considering?
A. We are planning significant investments in advanced robotics for automation, AI-driven predictive maintenance, smart sensors for real-time monitoring, and software platforms for data analytics and process optimisation. These innovations promise substantial improvements in operational efficiency, quality control, and market responsiveness.
Q. Can you talk about your current R&D projects in manufacturing and what you expect from them?
A. We are advancing R&D projects to develop modular assembly lines with adaptive robotics, AI-driven defect detection for quality assurance, and sustainable manufacturing practices. These initiatives aim to magnify production efficiency, enhance product quality, and reduce environmental impact.
