Thursday 2023-08-03

The assembly of printed circuit boards is an essential, indispensable step in the production of electronic components. In this process, electronic components are placed directly on the PCB and then mounted; this production step is called Surface Mount Technology (SMT). There are some 130 such SMT lines in the global FORVIA network, around 80 at HELLA, and another 50 on the Faurecia Clarion Electronics side. Each year, they are placing almost 30 billion electrical components on the printed circuit boards, which are used in electronic control units, radar sensors or battery management systems.

SMT lines are production lines over 30 metres long, where the countless drums and reels are lined up, looking a little like old film reels from the cinema. "SMT assembly is very important for both HELLA and Faurecia. In this respect, a close cooperation was obvious from the very beginning," says Markus Eschhaus, Head of Operations Industrialization Electronics at HELLA.

The aim is to define a uniform standard for SMT production in the global FORVIA network, that means to gradually source the SMT lines only from one manufacturer. "The advantages are obvious: together we can call up larger quantities, procure at lower prices and simplify maintenance and servicing immensely. At the same time, we can draw on a larger pool of potential suppliers who could be considered as the new standard supplier. After all, we work with manufacturers with whom Faurecia has no experience, and vice versa," says Eschhaus.

A project team consisting of four employees each from Faurecia and HELLA has set itself a timeline of a total of one year, starting in spring 2022. In order to define a uniform set-up for SMT production, the best three manufacturers were initially included in a short list and evaluated: What is the reliability, how high are the acquisition and production costs, how is the connection to the Manufacturing Execution System?

And: The lines were tested in real operation; at the HELLA plant in Recklinghausen they assembled several hundred printed circuit boards for different electronic products from HELLA and Faurecia, for example for control units, daytime running lights and door handles. "This was the first time we manufactured Faurecia products in a HELLA plant," says Stefan Kraft, project manager for the Equipment Benchmark at HELLA.

The decision was made a few days ago: FUJI, a Japanese manufacturer won the race and will supply the SMT systems for FORVIA in the future. Already by the end of 2025, this will lead to savings in the mid-single-digit million euro range, because systems can be purchased at lower costs and further discounts have been negotiated for service, maintenance and spare parts. "The commercial aspect is one positive aspect. The other is the extremely good cooperation between the teams throughout the benchmark period," says Tim Li, project manager for the Equipment Benchmark at Faurecia.

The first production line, following the new standard, was already ordered for the new electronic production plant of HELLA in Timisoara. Further orders will follow soon.