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Core PCBA Process Know-how Digitalization

Digital transformation solution for stencil printing
Digital Knowledge Base for Process Engineering

Vayo-Stencil Designer is a core SMT process (Stencil) know-how digitalization tool. The software can intelligently recognize, read, and integrate existing stencil aperture data from the enterprise, digitalizing past experience and quickly establishing a digitalized know-how database. For new product aperture design, the software can intelligently match and create from the batabase. For aperture designs not found in the batabase, the software offers over 30 built-in stencil aperture templates, which can be quickly completed with simple parametric adjustments based on the templates. Additionally, the software provides 60+ comprehensive validation rules, integrating industry and expert experience. Before design output, detailed digital process validations are conducted to identify design omissions in a timely manner, ensuring high-quality stencil designs and driving zero-defect SMT soldering.

Vayo Stencil Designer Solution Empowers Digital Transformation

Stencil printing is the core process in Surface Mount Technology (SMT) manufacturing and plays a crucial role in ensuring soldering quality reliability. However, traditional stencil design and process management face significant challenges: difficulty in transferring and sharing expertise, digitalizing standards and requirements, reusing valuable stencil knowledge, high levels of manual involvement, and outdated management practices. These issues undermine quality stability and hinder the digitalization of critical know-how, affecting a factory's ability to rapidly respond to new product introductions (NPI) and meet delivery schedules. Our Stencil Designer addresses these challenges by building a centralized corporate know-how database. It significantly reduces human error, enhances design and management precision and efficiency, ensures of stencil process quality stability, enables timely and effective NPI demands, and consolidate and leverage expertise for a competitive advantage.

Screen Printing Issues Mostly Originate from Human Errors

Stencil is the core process of the entire PCBA, as we have found that 70% of issues originate from the stencil. This is because every aperture on each stencil represents a potential risk. Therefore, if we can address stencil-related issues effectively, we can define the overall quality of the entire PCBA.

Revolution: Core PCBA Process (Printing/Stencil) Know-how Digitalization

Vayo's Stencil solution can digitalize factory’s past know-how and engineers' experience into your digitalized know-how database, enabling quick reuse in new NPIs. This not only saves time but also benefits engineers at every site, facilitating efficient collaboration and knowledge sharing.

Know-how Digitalization: Stencil Requirements Preparation

When new product comes into production, SMT process engineers will be able to obtain apertures automatically for those packages available in the library. This automatic know-how reuse approach spare engineers from repetitive operations; most importantly, engineers without such experience or deep knowledge will reach consistent result.

Know-how Digitalization: Enable Continuous Improvement

Vayo’s solution only allow senior engineers to manage the centralized knowledge base, all other engineers just apply them for new products . The manufacturing team can review top n defects, and make continuous improvement related to stencil apertures.

Know-how Digitalization: Worldwide Process Standardization

For big organizations with worldwide sites/factories, global deployment with centralized management team allows you to manage best practice for worldwide manufacturing sites; it not only minimizes business risks, but also enables business expansion.

Extra Function: Powerful/Comprehensive Validation

Vayo solution converts traditional human inspection of aperture design (from external suppliers) to intelligent/automatic way with powerful checks, which not only increase work efficiency of SMT process engineers, but also guarantee high quality design to stencil apertures.

Extra Function: Process Consistency Audit

Vayo’s solution can check the difference with the past aperture design automatically to ensure consistency of core PCBA process, save lots of time and maintain high quality.

Extra Function: Stencil Aperture Traceability

Vayo solution records aperture usage for every product, it allows you to trace all applied products if there is a risky aperture, like job name, PN, package, project… you can track aperture usage on every products and query by aperture ID, product, date, engineer.

Extra Function: Easy New Aperture Creation

Stencil Designer comes with flexible aperture pattern creation function, it contains plenty of pattern templates and allow end-users to select & fine-tine them easily; more over it support DXF graphic import/export for special aperture design.

Extra Function: Automatic Processing & Optimization

Stencil Designer comes with automatic processing & optimization approaches for special pads (thermal, common shared, test points …), safe distance to via holes, step generation & etc.

Extra Function: Pin-in-paste/Th-reflow Process Preparation

Pin-in-paste is a common concern in stencil production, and Vayo solution offers a specialized set of formulas to help you calculate the filling rate and determine the required solder paste volume. This enables you to identify the best solution for your specific needs efficiently.

As Is Vs. To Be

In contrast to the manual preparation of stencils and the management of processes and teams, Vayo's stencil designer presents numerous clear benefits.

Business Benefits for OEM (Outsourcing)

For OEM companies (outsourcing PCBA to external EMS), you could extract process experience for products built in the past (critical package, key process), achieve
process traceability for existing EMS suppliers; then automatic recommend such best practice for new products (NPI), and quickly verify the process consistency.

Core PCBA Process Know-how Digitalization

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