Background
Automotive electronics PCBAs have the following characteristics:
- Extremely strict product quality requirements
- Post-insertion small-batch directional inspection required
- Need to avoid quality risks from secondary handling
Under traditional manual insertion, 4 operators per shift handled 8 insertion positions with hourly output of about 200 pcs and daily output of 4,000 pcs.
Solution
The goal is to achieve inline automated insertion with direct packaging per customer requirements, eliminating secondary handling. Automated equipment ensures insertion quality consistency, meeting the strict quality standards of the automotive electronics industry.
Automation Comparison
| Item | Staff/Shift | Insertions | Hourly Output | Hours/Day | Output/Shift (PCS) | Daily Output (PCS) |
|---|---|---|---|---|---|---|
| Manual | 4 | 8 | 200 | 20 | 2,000 | 4,000 |
| Automated | 0.5 | 8 | 243 | 22 | 2,673 | 5,346 |
Key Benefits
- Staff reduction: From 4 to 0.5 per shift, saving over 85% labor costs
- Output increase: Daily output from 4,000 to 5,346 pcs, 34% improvement
- Quality assurance: Guaranteed product quality with zero missed insertions
- No secondary handling: Inline insertion with direct packaging eliminates handling risks
- Meets strict standards: Meets automotive industry quality and traceability requirements
Summary
After automation, product quality is guaranteed with zero missed insertions, significantly improved production efficiency, zero floating or electrical short issues, reduced labor costs, and downstream repair expenses.