Improving SMT component alignment by transferring to an existing, upgraded production line

Abstract

High reject rates caused by misaligned SMT components were negatively impacting quality and efficiency at the Collins Aerospace manufacturing site in Santa Isabel. These defects were traced to limitations in an aging pick-and-place machine used in PCB assembly for aerospace and military applications. This project aimed to improve alignment accuracy and increase throughput by transferring operations to an upgraded production line featuring a high-speed pickand-place machine and an integrated automated optical inspection system. A structured approach was used to assess the current process, implement the transition, and validate results through quality checks and performance monitoring. After implementation, misalignment defects decreased by 90%, while productivity improved by 35–40%. The results confirm that modernizing SMT equipment can deliver substantial gains in quality and efficiency without compromising compliance with strict industry standards.