This page aims to provide actionable steps to maximize production efficiency.
The True Cost of a Bad Splice
Splice yield is the percentage of component reels spliced successfully on the first attempt without machine fault. A low yield drains profitability through component scrap and downtime.
This guide outlines the five most effective, proven techniques to dramatically increase your SMT splice yield and move toward a continuous production environment.
Technique 1: Standardize on Precision Splicing Tools
- Utilize specialized SMT crimp tools for consistent, measurable pressure
- Calibrate tools regularly to maintain performance
- Use alignment jigs to ensure a perfect butt-splice alignment
Technique 2: Master Operator Training and Certification
- Implement a single, documented, standardized operating procedure (SOP) for all splicing
- Train operators to visually check for full coverage and clean crimp marks after every splice
- Institute a mandatory Splice Certification program for all line operators
Technique 3: Select the Right SMT Splice Tape Material
- Use a tape with adhesive strength optimized for both paper and plastic carrier tapes
- Ensure the tape’s color provides high contrast for sensor visibility (Feeder-Safe)
- Prioritize thin, high-quality tape to reduce friction and jamming risk
Technique 4: Implement a Leader Tape Extender Program
- Use extenders on partial reels to provide sufficient tape length for the machine to load automatically
- Extenders ensure the cover tape remains continuously engaged with the stripping mechanism
Technique 5: Proper Storage and Shelf-Life Management
- Store all tape rolls in a climate-controlled area (cool, dry conditions)
- Enforce a strict First-In, First-Out (FIFO) inventory system to prevent using tape with degraded adhesive
