Mexico SMT Production Line Upgrade Case

The customer is an electronics manufacturer in Mexico. The SMT production line had been running for many years.

While the line was still functional, several limitations had become critical:

• Aging machines with increasing failure rate
• Outdated AOI system with limited detection capability
• Old conveyor system with poor stability and low compatibility
• Difficult to integrate with modern factory automation
• Rising maintenance cost

The customer aimed to upgrade the existing line, instead of investing in a completely new production line.

• Replace old equipment while keeping the original line layout
• Upgrade inspection capability
• Replace the old PCB conveyor system with a more stable and flexible solution
• Prepare the line for AGV-based smart logistics
• Minimize production downtime

We delivered a production line modernization solution, focusing on key process and handling upgrades.

✅ 1. Key Machine Replacement

Old unstable machines were replaced with new-generation equipment featuring:

Higher operational stability

Lower breakdown rate

Easier maintenance

Better process consistency

This improved performance without rebuilding the entire line.

✅ 2. AOI System Upgrade

The original AOI was replaced with a new system offering:

Higher resolution

Improved defect recognition

Lower false call rate

Better inspection data traceability

This upgrade significantly enhanced quality control.

✅ 3. New Intelligent Conveyor System (Core Upgrade)

The entire old conveyor system was removed and replaced with a new modular PCB handling solution.

Improvements include:

More stable board transfer

Reduced vibration and board misalignment

Standardized interface height and communication protocol

Modular structure for future line expansion

★ Smart Factory Ready Design

The new conveyor system is designed with AGV docking compatibility, enabling:

Direct connection with AGV for magazine transportation

Reduced manual logistics

Preparation for unmanned material flow

Seamless integration into smart factory planning

This turns the production line from a traditional setup into a future-ready automated line.

The line had been in operation for many years → interface differences between old and new equipment

Limited shutdown window

Need to keep part of the production running during replacement

Our team carried out:

• Detailed site measurement
• Interface customization
• Phased replacement planning
• Result: Smooth upgrade with minimal production interruption

After the upgrade, the customer achieved:

✔ Improved line stability
✔ Higher inspection reliability
✔ Lower maintenance cost
✔ More stable PCB flow
✔ AGV-ready logistics system
✔ Extended lifetime of the production line

The customer successfully transformed an aging line into a modern, automation-ready SMT production line through a cost-effective upgrade strategy.