Italy LED Full Production Line
Flexible SMT Line Solution for High-Mix, Low-Volume Production
Customer Background
The customer is an Italian LED lighting manufacturer, focusing on:
- Industrial LED lighting
- Commercial lighting modules
- Customized LED boards for different projects
Production Characteristics
|
Feature |
Situation |
|
Order type |
Small batch, many models |
|
PCB size |
Large LED boards |
|
Product changeover |
Very frequent |
|
Process stability requirement |
High (LED brightness consistency critical) |
|
Automation expectation |
Semi-auto to full line integration |
The customer needed a line that is flexible, stable, and easy to switch models, rather than a pure high-speed mass-production line.
Customer Challenges
High-Mix, Low-Volume
- Dozens of LED board types
- Frequent program and feeder change
Large PCB Handling
- Long boards
- Risk of board bending during transfer
Process Control for LED
- Solder volume consistency affects LED brightness
- Reflow profile stability is critical
Limited Factory Space
- Needed compact layout but complete process control
Our Complete SMT Line Configuration
Based on their products and process needs, we provided a full SMT line:
|
No. |
Machine |
Function |
|
1 |
Vacuum Suction Loader |
Stable loading of large PCBs |
|
2 |
Solder Paste Printer |
High-precision paste printing |
|
3 |
SPI |
3D solder paste inspection |
|
4 |
Conveyor |
Buffer & transfer |
|
5–6 |
Pick & Place Machines (2 sets) |
LED + driver IC + components mounting |
|
7 |
Folding Conveyor |
Line connection & space saving |
|
8 |
Reflow Oven |
Stable thermal profile for LED boards |
|
9 |
Conveyor |
Cooling transfer |
|
10 |
Tester (Reserved) |
Functional test preparation |
|
11 |
Conveyor |
Line balancing |
|
12 |
OK/NG Unloader |
Auto separation of good & NG boards |
Key Solution Highlights
Designed for Large LED Boards
- Vacuum suction loading to avoid PCB bending
- Stable rail support across the whole line
- Smooth transfer between machines
01
Perfect for High-Mix Production
- Fast program switching on pick & place
- SPI feedback improves first-pass yield
- Suitable for frequent model changes
02
LED Process Quality Control
- SPI ensures stable solder volume
- Reflow oven with uniform heating zones
- Reduced LED color deviation caused by solder issues
03
Flexible & Compact Line Layout
- Folding conveyor helps optimize factory space
- Modular structure for future expansion
04
Results After Installation
After running the line:
▲ Production efficiency increased compared to manual or semi-auto processes
▲ Yield rate improved significantly due to SPI + stable reflow
▲ Faster model changeover, ideal for customized LED orders
▲ Reduced operator dependence
The customer now uses this line as their main production line for various LED products.
Why This Case Matters
This project proves that our solution is ideal for:
✔ LED manufacturers
✔ High-mix, low-volume factories
✔ Large PCB production
✔ Customers who need flexibility + stability, not just speed