|
Throughput Revenue gained per Factory
Due to the advanced heat transfer control possible with stationary reflow, TOWER can perform a four minute thermal proflile 15% faster than in-line ovens (3.4 minutes).
Throughput Speed Calcuation:
(Thoughput Revenue Gained per Day per Factory) = 15% * (Revenue per Day per Line) * (Lines in Factory)
(Revenue per Day per Line) = (Revenue per Board) * (Boards per Day per Line)
(Boards per Day per Line) = (Production Seconds per Day) / (Cycle Time for a Board in Seconds)
(Production Seconds per Day) = (Production Hours per Day) * (60 min/hr) * (60 sec/min)
(Throughput Revenue gained per Factory per day with TOWER)
= 15% * (Lines per Factory) * (Revenue per Board) * (Production Hours per Day) * (60 min/hr) * (60 sec/min) / (Cycle Time)
(Throughput Revenue gained per Factory per Year with TOWER)
= (Production Days per Year) * (Throughput Revenue gained per Factory per Day with TOWER)
Floor Space Revenue gained per Factory
With the typical reflow cycle taking less than four and a half minutes, forced convection oven length is determined by the desired throughput the user desires to achieve. The longer the oven the higher the volume of PCB assemblies processed. TOWER changes that equation by stacking 8 individual reflow ovens capable of high-speed board processing. The result is the production speed of a 20+ foot horizontal reflow ovens in only 7 feet (TOWER is 13 feet shorter).
Floor Space Savings Calculation:
(Floor Space Revenue Gained Per Factory per Day) = (Gain in Floor Length with TOWER) * (Cost of Line Length Per Day per Line) * (Lines in Factory)
(Gain in Floor Length) = (13 feet)
(Cost of Line Length per Day per Line) = (Revenue per Day per Line) / (Line Length)
(Revenue per Day per Line) = (Revenue per Board) * (Boards per Day per Line)
(Boards per Day per Line) = (Production Seconds per Day) / (Cycle Time for a Board in Seconds)
(Production Seconds per Day) = (Production Hours per Day) * (60 min/hr) * (60 sec/min)
(Floorspace Revenue gained per Factory per Day with TOWER)
= (13 feet) * (Lines in Factory) * (Revenue per Board) * (Production Hours per Day) * (60 min/hr) * (60 sec/min) / [(Cycle Time in Seconds) * (Line Length in Feet)]
(Floorspace Revenue gained per Factory per Year with TOWER)
= (Production Days per Year) * (Floorspace Revenue gained per Factory per Day with TOWER)
Changeover Cost saved per Factory
In-line ovens are the bottleneck to convert from high-volume to high-mix assembly. TOWER accommodates both types of assembly jobs without line changeover downtime. Any or all of the modules can be running entirely distinct PCBA profiles simultaneously. In fact, some can be reflow profiles while others are curing. Each profile is generated instantly with no need for chambers to warm-up or cool down during line changeover. Whereas heater failure in a conveyorized oven shuts the line down, modular reflow means that if a single chamber goes down, the line continues to operate using one fewer module.
TOWER essentially eliminates lost production downtime to convert from one profile to another.
Line Changeover Calcuation:
(Changeover Cost per Factory per Day) = (Lots per Line per Day) * (Cost of Lost Production per Lot) * (Lines in Factory)
(Lots per Line per Day) = (Production Seconds Per Day) / (Time per Lot in Seconds)
(Production Seconds per Day) = (Production Hours per Day) * (60 min/hr) * (60 sec/min)
(Time per Lot in Seconds) = (Cycle Time Per Board in Seconds) * (Boards per Lot)
(Cost of Lost Production per Lot) = (Revenue per Second) * (Time per Changeover in Seconds)
(Revenue per Second) = (Revenue per Board) / (Cycle Time per Board in Seconds)
(Time per Changeover in Seconds) = (Time per Changeover in Minutes) * (60 sec/min)
(Changeover Cost per Day per Factory)
= (Lines in Factory) * (Time per Changeover in Minutes) * (60 sec/min) * (Production Hours per Day) * (60 min/hr) * (60 sec/min) * (Board Revenue) / [(Cycle Time per Board in Seconds) * (Cycle Time per Board in Seconds) * (Boards per Lot)]
(Changeover Cost per Year per Factory)
= (Production Hours per Year) * (Changeover Cost per Day per Factory)
Line Downtime Cost per Profile per Factory
The "Holy Grail" of reflow has always been a self-profiling oven. TOWER uses an off-line profiling station which automatically creates the optimal board profile. The profiling station means that the production line TOWER continues the current production run while a new board is being profiled – eliminating line downtime required for profiling. Since the board is stationary through the reflow process and does not travel through heating zones set to varying temperatures, Research International control software generates the time/temperature curve to create the profile - the belt speed variable is eliminated. With reflow parameters entered into the software, the profiling station will cycle until those parameters are met. TOWER then monitors board temperature to verify the profile settings are accurate.
TOWER can profile without assembly line downtime and does not need a trained engineer to optimize the profile.
Reduced Downtime Savings Calcuation:
(Line Downtime Cost per Profile per Factory) = (Profile Creation Time in Seconds) * (Revenue per Second Lost) * (Lines in Factory)
(Profile Creation Time in Seconds) = (Profile Creation Time in Hours) * (60 min/hr) * (60 sec/min)
(Revenue per Second Lost) = (Revenue per Board) / (Cycle Time per Board)
(Line Downtime Cost per Profile per Factory)
= (Profile Creation Time in Hours) * (60 min/hr) * (60 sec/min) * (Revenue per Board) * (Lines in Factory) / (Cycle Time in Seconds)
(Line Downtime Profile Cost per Year per Factory)
= (New Profiles per Line per Year) * (Line Downtime Cost per Profile per Factory)
Electrical Savings per Factory
Reflow ovens only have boards in them about 40% of the time. The remaining 60% of the time it is idle, yet it still uses electricity. TOWER does not power the heaters when idle, providing a 60% reduction in electrical power use.
Electrical Power Savings Calcuation (Assumption: Average Oven Power Use = 45 kW):
(Electrical Savings per Factory per Day) = (60%) * (45 kW) * (Cost of Electricity per Hour) * (Production Hours per Day) * (Lines in Factory)
(Electrical Savings per Factory per Year)
= (Production Days per Year) * (Electrical Savings per Factory per Day)
Modularity gained per Factory
Placement gear modularity is limited by the fact that the reflow oven needs to be long enough to handle the highest throughput rating. This means that even though modular placement gear can make the front of the line shorter, the back of the line is longer since you need to maintain a large in-line reflow oven. This defeats the purpose of using modular placement gear to shorten the line.
TOWER is designed for factory modularity, since the oven delivers instant line changeover capability (calculated in this model under "Changeover Cost Saved") and allows multiple board types to reflow in a single oven (for creating a "mass customization"-based factory).
TOWER's modularity means you can fit a minimum of 25% more SMT lines (placement gear) into the same floor space. The revenue generated from getting more boards out of the same factory is the gain possible using TOWER.
TOWER can run multiple lines into a single oven if the cycle time of each line is greater than 45 seconds.
Note: TOWER is designed for a 30 second cycle with a 4 minute profile (120 boards/hr) loading 1 board per chamber. The 45-60 seconds for 2 lines assumes addition transport and handling time for routing boards from different lines.
This link provides a paper on Using a Modular Reflow Oven
Profitability Improvement due to Modularity Calcuation (More lines in the same factory):
(Modularity gained per Day per Factory) = (Revenue per Day per Line) * (Percent of Revenue gained due to Modularity) * (Lines in Factory)
(Revenue per Day per Line) = (Revenue per Board) * (Boards per Day)
(Boards per Day) = (Production Seconds per Day) / (Cycle Time for a Board in Seconds)
(Production Seconds per Day) = (Production Hours per Day) * (60 min/hr) * (60 sec/min)
(Percent of Revenue gained due to Modularity) = 25%
(Modularity gained per Day per Factory) = (25%) * (Lines per Factory) * (Revenue per Board) * (Production Hours per Day) * (60 min/hr) * (60 sec/min) / (Cycle Time per Board in Seconds)
(Modularity gained per Year per Factory) = (Production Days per Year) * (Modularity gained per Day per Factory)
Total Revenue gained per Factory
This is the sum of all the individual savings obtained by converting your factory from in-line reflow ovens to TOWER.
Summary Calcuation:
(Total Revenue gained per Factory per Day) = (Throughput Revenue per Day per Factory gained) + (Floor Space Revenue per Day per Factory gained) + (Changeover Cost saved per Day per Factory) + (Electric Savings per Day per Factory gained) + (Modularity gained per Day per Factory)
(Total Revenue gained per Factory per Year) = (Throughput Revenue per Year per Factory gained) + (Floor Space Revenue per Year per Factory gained) + (Changeover Cost saved per Year per Factory) + (Line Downtime Profile Cost per Year per Factory) + (Electric Savings per Year per Factory gained) + (Modularity gained per Year per Factory)
|
