Analyzing printed circuit board assembly lines using a PCB assembly template

PCB assembly lines are characterized by asynchronous transfer of parts resulting from variability in terms of random processing, failure, repair, exhaust, and replenishment times. The throughput for such manufacturing systems depends upon simultaneous availability of resources; namely, machines, material, and operators. Further, random breakdowns along with the capacitated buffers cause blocking and starving which affects the throughput. Analytical models for such system require simplifying assumptions, hence simulation modeling is the popular choice. For simulation models to be successful, capturing the impact of operator interference is important. This paper describes a methodology developed for simulation modeling and analysis of PCB manufacturing lines, capturing the complex interactions between its components. A custom-developed PCB assembly template is used for modeling purposes. Though the analysis described in this paper pertains to PCB assembly lines, it is equally applicable to general class of serial production lines with capacitated buffers.