Pick and place machines come in various configurations, with two primary types being inline (with a conveyor system) and batch (with a fixed board holder). Deciding which is best for you depends on factors like production volume, board complexity, feeder capacity, and available floor space. Let's explore the benefits and drawbacks of each option to help you make an informed decision.

 

Inline Pick and Place

Inline pick and place machines are conveyorized, typically found in high-volume SMT assembly lines. These systems seamlessly integrate with other equipment, such as inline stencil printers and reflow ovens, minimizing manual handling and increasing operational efficiency. Once a board enters the system, components are automatically placed, and the board moves on to the next stage in the process without interruption.

As you can see below, this inline MC388 Pick and Place machine easily integrates with an inline stencil printer, reflow oven, and several conveyors to maximize efficiency. With an open space free from obstructions, this type of setup works very well:

While high production volume is the most common reason for choosing inline systems, they're also beneficial in low-placement applications. For instance, even if only a single component like a BGA or QFP needs to be placed, the continuous board flow reduces operator intervention. Efficiency can further be enhanced by adding automatic loaders and unloaders to the system.

Interestingly, you can also operate an inline machine as a batch system. This setup allows you to take advantage of the machines 3-board staging capability, which reduces the need to open and close the machine's hood between each board. By using the staging system, you avoid having to press start repeatedly, streamlining the process even further.

Advantages of Inline Pick and Place

• Best for high-volume production
• Minimizes manual handling between machines
• Can improve overall throughput and reduce downtime
• Streamlines the entire SMT process by directly integrating with other machines
• **Can be used in batch mode** with a 3-board staging system, eliminating manual start/stop actions and hood opening

 

Batch Pick and Place

Batch pick and place machines are ideal for lower-volume, high-mix environments where frequent changeovers are necessary. These machines require manual loading, as operators place the board inside the machine, close the cover, and start the assembly process. Batch machines allow for greater flexibility in handling different board designs and smaller production runs.

One major advantage of batch systems is the potential for increased feeder capacity. Without the need for a conveyor, additional feeder bases can be installed on both sides of the machine, boosting capacity by 50-100%.

Due to the tight floor space of this production room (above), this MC388 is ideal as a batch pick and place.

Advantages of Batch Pick and Place

• Ideal for low-volume or high-mix production
• Higher feeder capacity due to the lack of conveyor space
• Requires significantly less floor space, making it suitable for smaller labs or offices

 

Floor Space and Layout Considerations

Inline systems require more floor space, typically needing 30-40 linear feet (or more) for a medium-volume SMT line. Batch systems, on the other hand, can be set up in much smaller spaces, including small labs or offices. There are also hybrid setups where a batch machine is combined with inline systems. For example, a batch stencil printer might be used with an inline pick and place that feeds into an inline oven.

 

Choosing the Right Setup for You

Ultimately, the decision between inline and batch pick and place systems depends on your specific needs:

• High-Volume Production: Inline machines offer greater efficiency.
• Low-Volume or High-Mix Production: Batch machines provide flexibility and increased feeder capacity.
• Available Floor Space: Inline systems need more space, while batch systems are more compact.

Inline Machine Setup

With a PCB loader, inline stencil printer, two conveyors, two inline pick and place machines, a reflow oven, and an unloader, this SMT line is over 41 feet long! When floor space is no issue, inline machine setups are highly efficient.

Batch Machine Setup

If your floor space is smaller, like this 12'x14' example, you can still have a full equipment line, but a batch machine setup is better to suit your needs.

Check out this layout for an MC1400 automatic stencil printer, an MC385 batch pick and place machine, and an MC302 benchtop reflow oven. All three machines fit in the compact space with room to spare. 

 

By carefully evaluating your production volume, board complexity, and floor space, you can choose the pick and place configuration that best suits your needs.

If you are considering a new SMT line and would like help with machine configurations and the best equipment for your production needs, please contact us at sales@manncorp.com. You can also reach our sales managers directly, by emailing Ed Stone at estone@manncorp.com and Chris Ellis at cellis@manncorp.com.