The challenges faced by the production of PCBA with multiple varieties and small batches.
I. Challenges in Production Mode
l High Difficulty in Mixed Production Scheduling: There is a large variety of products with small batch sizes, leading to frequent production line switching and adjustments, which makes mixed production scheduling complex and hard to optimize.
l Extended Production Cycle: Frequent product changeovers and debugging prolong the production cycle, affecting delivery times and customer satisfaction.
l Unstable Delivery Time: There are more uncertainties during production, such as equipment failures and material shortages, making it difficult to stably control the delivery time. Overtime work is often required to meet deadlines.
II. Challenges in Quality Management
l High Scrap Rate during Debugging: When products are changed over and debugged, operations like modifying equipment parameters and replacing fixtures are complex and error-prone, resulting in a relatively high scrap rate.
l Difficulty in Implementing Total Quality Management: Different products have different quality control requirements, and there are numerous variables in the production process, increasing the difficulty of implementing a quality management system.
l Limitations of Sampling Inspection Mode: The commonly used sampling inspection mode fails to comprehensively reflect the product quality status, and the ability to trace quality is limited.
III. Challenges in Supply Chain Management
l Complex Material Management: More refined and flexible material management is needed as the material demand and supply cycle vary for different products.
l Difficult Inventory Control: With a large variety of products and small batch sizes, inventory control is complex and hard to optimize, prone to overstocking or material shortages.
IV. Challenges in Technical Complexity
l High Requirements for Process Control: Different products have different production processes and parameters, demanding more precise and stable process control.
l Equipment Compatibility Issues: Producing different products may require different production equipment or fixtures, leading to more equipment compatibility problems.
V. Other Challenges
l Personnel Training and Management: Employees need to possess higher skills and flexibility to cope with frequent product and process changeovers. Personnel training and management thus become more complex.
l Pressure of Cost Control: The increase in production uncertainties makes cost control more difficult. It is necessary to reduce costs while ensuring quality to enhance competitiveness.