Totally Focused on Efficiency |
Laser Focused on SMT
EYES captures and analyses SMT equipment data to pinpoint the causes of production loss. It makes the losses visible, the causes traceable and will prescribe corrective actions. Without clear data, effective action isn’t possible. EYES makes every second of machine data an opportunity to drive efficiency.
EYES is the fastest improvement path for SMT based plants to increase their EBIT.
SMT lines using EYES will cut downtime, speed up production and unlock extra capacity. The result is a significant boost in OEE and profitability. A modest 10% OEE gain — from 60% to 70% — can raise EBIT by 3.4%, while a 20% gain can lift it by nearly 6%.
Loss Measurement
and Analysis
Losses are inevitable even with automated SMT lines, though the extent of loss can vary. Among these losses, micro-stops — intermittent, short-duration stoppages in Pick and Place machines — are highly underestimated and frequently invisible. Plants do not get to see what truly affects their OEE.
EYES automates the data collection and analysis process. EYES’ proprietary algorithms analyse machine data to accurately map losses to their root causes.
Major losses in SMT lines are concentrated at the Pick-and-Place machine. Over a full production run, the cumulative effect of micro-stops can result in 10% to 40% of lost output. A powerful capability of EYES is to track micro-stops and help eliminate them.
| Label | Machine 1 | Machine 2 | Machine 3 | Machine 4 | Machine 5 | Machine 6 |
|---|---|---|---|---|---|---|
| Count | 190 | 220 | 220 | 192 | 191 | 220 |
| Min | 46 | 43 | 42 | 39 | 45 | 38 |
| Max | 532 | 607 | 658 | 487 | 525 | 672 |
| Mean | 62.91 | 65.96 | 66.32 | 62.13 | 62.54 | 67.03 |
| Mode | 50 | 44 | 44 | 46 | 48 | 43 |
| Median | 49 | 46 | 45 | 47 | 48 | 44 |
| Ideal Cycle Time | 46 | 44 | 43 | 41 | 45.5 | 38 |
| Cycles with microstops | 16.42% | 30% | 34.09% | 21.35% | 17.28% | 27.27% |
| Performance Loss (Mode) | 21.86% | 32.55% | 35.62% | 24.47% | 24.73% | 32.83% |
| Performance Loss (Median) | 21.86% | 32.55% | 32.62% | 24.47% | 23.13% | 32.83% |
| Performance Loss (Standard Time) | 23.04% | 27.65% | 27.73% | 22.44% | 22.71% | 27.96% |
| Performance Loss (Ideal CT) | 26.65% | 37.04% | 35.62% | 34.11% | 27.14% | 43.28% |
EYES automates the data collection and analysis process. EYES’ proprietary algorithms analyse machine data to accurately map losses to their root causes.
Major losses in SMT lines are concentrated at the Pick-and-Place machine. Over a full production run, the cumulative effect of micro-stops can result in 10% to 40% of lost output. A powerful capability of EYES is to track micro-stops and help eliminate them.
Actionable Insights and Continuous Improvement
EYES can help address various SMT problems. As an example, for the Pick and Place machines, EYES will continually monitor problems/ related to feeders, nozzles, components, vision/component recognition issues and more. EYES converts its analysis into regular micro-maintenance plans to keep production consistently efficient.
Immediate Fixes to Long-Term Actions
- Immediate action on critical blockers (e.g., cleaning, calibration).
- Early identification of issues through PPM (Parts Per Million) trend analysis
Intelligent Micro-Maintenance Schedule:
- Optimized scheduling of preventive maintenance activities.
- Data-driven, condition-based maintenance: targeted cleaning, calibration, and part replacement (e.g., feeders, nozzles).
- Identification of recurring component issues → enables informed vendor
feedback and smarter component selection. - Visibility into chronic manpower gaps → enables balancing cost of staffing vs. hidden production losses.
