Analysis of printed wiring assembly manufacturing systems

Abstract

This dissertation presents a cost and performance model of manufacturing systems used in the printed wiring assembly (PWA) industry. The model is evaluated in the context of the requirements of a "World Class" manufacturing factory. The model describes the performance of atypical, in-line manufacturing system for the batch production of PWA's. The cost model has three main components: inventory cost, assembly cost, and test, diagnosis, and rework cost. The model is used to account for the direct cost elements associated with each of the three cost components. The behavior of the typical manufacturing system is described in a modular, station by station manner. The model is implemented on a Lotus 1-2-3 spreadsheet. A variety of different manufacturing systems can be modelled using combinations of the modular elements. In this way it is possible to evaluate alternate manufacturing system configurations at the system definition phase and to evaluate the cost of manufacturing alternative PWA design candidates on an existing manufacturing system. The model is used to evaluate alternative rework strategies and to determine the economic benefit associated with a conceptual, automated rework facility. The model is applied to a series of five actual PWA manufacturing systems. The resulting case studies are used to draw general conclusions about the current PWA manufacturing environment.