Use of simulation to improve the kitting process at an EMS provider´s facility

In an electronics manufacturing service (EMS) provider´s environment, smooth and continuous manufacturing flow is extremely desirable. The kitting stage is of critical importance in a streamlined surface mount technology (SMT) assembly process. Based on historical data, the kitting process at the EMS provider where this research was conducted was identified as a focus for continuous improvement. This paper discusses the research undertaken to improve the kitting process at a medium volume, medium to high mix EMS provider´s environment. The process improvement effort was based on a six-sigma approach with simulation being used as an analysis tool. At present, three of the five phases of the six-sigma approach have been completed with encouraging positive results. This paper discusses problems at the kitting stage of a printed circuit board (PCB) assembly process and the use of simulation to improve the process by reducing discrepancies.