What is Component Kitting?

Component kitting, also known as CompKitFeedPrep, is the process of organizing and preparing electronic components for use in the assembly of printed circuit boards (PCBs). Kitting involves grouping together all the necessary components required for a specific PCB Assembly job and ensuring they are ready for the automated pick-and-place machines or manual assembly processes.

The main objectives of component kitting are:

1. Streamlining the PCB assembly process
2. Reducing the risk of component shortages or misplacements
3. Improving overall production efficiency

The Importance of Proper Component Kitting

Proper component kitting is crucial for the smooth operation of any PCB assembly line. By organizing components in advance, manufacturers can:

• Reduce setup times between different assembly jobs
• Minimize the risk of human error during component placement
• Ensure the correct components are used for each PCB
• Optimize inventory management and storage space utilization

Benefits of Effective Component Kitting

Benefit	Description
Increased Efficiency	Properly kitted components allow for faster changeovers between assembly jobs, reducing downtime and increasing overall production output.
Improved Quality	By ensuring the correct components are used for each PCB, the risk of assembly errors is minimized, leading to higher quality end products.
Better Inventory Management	Kitting helps manufacturers maintain accurate inventory levels and reduces the likelihood of component shortages or excess stock.
Cost Savings	Streamlined assembly processes and reduced errors translate to cost savings through increased productivity and fewer defective products.

The Kitting Process

The component kitting process typically involves the following steps:

1. Bill of Materials (BOM) Review: The first step is to review the BOM for the PCB assembly job. The BOM lists all the required components, their quantities, and specifications.

2. Component Procurement: Once the BOM is verified, the necessary components are procured from suppliers or retrieved from existing inventory.

3. Component Inspection: Received components are inspected to ensure they meet the required specifications and are free from defects. This may involve visual inspections, electrical testing, or other quality control measures.

4. Component Grouping: Components are grouped together based on the BOM requirements for each specific PCB assembly job. This may involve sorting components by type, value, or package size.

5. Packaging and Labeling: Kitted components are packaged in appropriate containers, such as trays, tubes, or tape and reel, and labeled with relevant information, such as part numbers, quantities, and job-specific identifiers.

Kitting Techniques

Several techniques can be employed to optimize the component kitting process:

• Barcoding: Using barcodes to label kitted components and track them throughout the assembly process can help improve accuracy and efficiency.
• Automated Storage and Retrieval Systems (ASRS): Implementing ASRS can streamline the kitting process by automatically storing and retrieving components as needed, reducing manual handling and the risk of errors.
• Lean Manufacturing Principles: Applying lean manufacturing principles, such as 5S (Sort, Set in Order, Shine, Standardize, Sustain), can help optimize the kitting process by eliminating waste, improving organization, and standardizing procedures.

Feeder Preparation

Feeder preparation is an essential aspect of component kitting, specifically for automated PCB assembly using pick-and-place machines. Feeders are the mechanisms that hold and dispense components onto the PCB during the assembly process.

Types of Feeders

There are several types of feeders used in PCB assembly, each designed to accommodate different component packages and sizes:

• Tape and Reel Feeders: These feeders use tape and reel packaging, which consists of components stored in pockets on a continuous tape wound onto a reel. Tape and reel feeders are commonly used for small, lightweight components.

• Stick Feeders: Stick feeders are used for components packaged in tubes or sticks, such as through-hole components or larger surface-mount devices (SMDs).

• Tray Feeders: Tray feeders are designed for components that are supplied in trays, such as bulk SMDs or oddly shaped components that cannot be easily packaged in tape and reel or stick form.

• Vibratory Feeders: Vibratory feeders use vibration to orient and feed loose components to the pick-and-place machine. They are often used for larger, more robust components that can withstand the vibration without damage.

Feeder Setup and Maintenance

Proper feeder setup and maintenance are critical for ensuring the smooth operation of the pick-and-place machine and minimizing component placement errors. Some key considerations include:

• Feeder Positioning: Feeders must be correctly positioned in the pick-and-place machine according to the machine’s program and the specific PCB assembly job requirements.
• Component Alignment: Components in the feeders must be properly aligned and oriented to ensure accurate pickup by the machine’s nozzles.
• Feeder Calibration: Feeders may require calibration to ensure the correct component pitch and pickup position, particularly when using tape and reel feeders.
• Regular Cleaning and Maintenance: Feeders should be regularly cleaned and maintained to prevent component misfeeds, jams, or damage to the pick-and-place machine.

Frequently Asked Questions (FAQ)

1. Q: What is the difference between component kitting and feeder preparation?
   A: Component kitting refers to the process of organizing and grouping components required for a specific PCB assembly job, while feeder preparation involves setting up and maintaining the feeders that hold and dispense components in the pick-and-place machine.

2. Q: Why is component kitting important in PCB assembly?
   A: Component kitting is essential for streamlining the PCB assembly process, reducing the risk of component shortages or misplacements, and improving overall production efficiency.

3. Q: What are the most common types of feeders used in PCB assembly?
   A: The most common types of feeders used in PCB assembly are tape and reel feeders, stick feeders, tray feeders, and vibratory feeders. Each type is designed to accommodate different component packages and sizes.

4. Q: How can lean manufacturing principles be applied to the component kitting process?
   A: Lean manufacturing principles, such as 5S (Sort, Set in Order, Shine, Standardize, Sustain), can help optimize the kitting process by eliminating waste, improving organization, and standardizing procedures.

5. Q: What are the benefits of using automated storage and retrieval systems (ASRS) in component kitting?
   A: Implementing ASRS can streamline the kitting process by automatically storing and retrieving components as needed, reducing manual handling and the risk of errors, ultimately improving efficiency and accuracy in the PCB assembly process.

Conclusion

Component kitting and feeder preparation are vital aspects of the PCB assembly process, directly impacting production efficiency, quality, and cost. By properly organizing and preparing components for assembly, manufacturers can streamline their operations, reduce the risk of errors, and improve overall product quality.

Implementing best practices in component kitting and feeder preparation, such as using barcoding, automated storage and retrieval systems, and applying lean manufacturing principles, can further optimize the process and lead to significant benefits for PCB assembly operations.

As the electronics industry continues to evolve and demand for high-quality, cost-effective PCBs grows, the importance of efficient component kitting and feeder preparation will only increase. By staying up-to-date with the latest techniques and technologies in this area, PCB assembly manufacturers can remain competitive and meet the ever-changing needs of their customers.