2.2 Program Creation & Tuning

A pick-and-place machinemachine's performance is onlygoverned as good asby the program that drives it. From the moment CAD data is imported, everydecisions decision—howregarding rotations are defined, howrotations, vision isteaching, taught,feeder howlayout, feedersand areplacement laidsequence out—shapesdetermine whether the line runsachieves smoothlymaximum throughput or stumblessuffers intofrom delays.constant Goodstoppages. programmingDisciplined turnsprogram chaoscreation intoensures consistency:consistency machinesacross recognizeshifts, partsminimizes instantly,setup nozzles travel efficiently,time, and operators seemaintains the samemaximum “truth”theoretical shiftComponents afterPer shift.Hour With disciplined setup and verification, programs transform from fragile one-offs into stable, reusable assets that sustain both speed and quality.(CPH).

2.2.1 StartData withIntegrity: cleanStandardized inputs (CAD/centroid → program)Inputs

Before youplacing placethe first part, the foundation must be built on clean, consistent data. Errors here force time-consuming manual fixes later.

• Input Standardization: All data imports must use consistent units (mm), a single part,origin makefor the data boringtop and consistent:
  bottom

  What you import (and freeze):

  • Units & origin: mm, one origin for topsides, and bottom, and θ defined CCW. rotation convention.
  • SidePart &Library rotation:Match: explicitAll “Top/Bottom”imported per refdes, rotation as seen from top view (bottom side mirrored in software).
  • Package names & heights: match your PnP librarypackage names and Z-heights—noheights one-offmust aliases.
  • Polarity/pin-1 & fiducials:strictly match the assemblyPnP drawing,machine withlibrary globalnames. +Avoid using one-off aliases that require translation.
  • Fiducials: Global and local fiducials listed.must be clearly defined in the data package and used consistently for board alignment and large component correction.
  • Golden Data Pack: The final, verified set of placement data, machine offsets, and rotation tables must be archived as the single source of truth for the entire run.

  Audit Tell:Put theseIf rulesa inprogram requires bulk rotation or coordinate offsets after import, the Goldenlibrary Data Packconventions so every line loadsor the sameCAD truth.

  output

  Quickare tell:misaligned. ifThis yourmust firstbe importfixed needs bulk “+90°” fixes, your rotation convention isn’t aligned—fixat the library,source, not in the program.

  
  

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  2.2.2 Vision teachingand (makeComponent Definition

  Component recognition effortless)must

  Buildbe librariesrobust thatand theinstantaneous camerato can’tprevent misread:vision retries and slowdowns.

  • ClearTeaching features:and Locking: useDefine packagesand withlock obviousone golden image per package family in the machine library. This image must feature clear pin-1/polarity markers and body edges (your land-patterns and silks did this back in 3.2–3.3). Teach one good part per package, then lock it.edges.
  • Nozzle/pickPick point:Point Consistency: centerThe nozzle pick-up point must be centered on flat,the flattest, most repeatable surfaces;surface avoidof the component. Areas with embossed logos or domes.irregular domes must be avoided.
  • Lighting/algorithms:Algorithm Selection: pickChoose the simplest vision algorithm that passes—fastachieves beatsstable recognition. Stability and speed are prioritized over high-fancy whenrecognition it’salgorithms stable.that may be sensitive to slight component variation.
  • Golden images: keep a small photo set per package so night shift can compare “good vs weird” quickly.
    

  
  

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  2.2.3 RotationFeeder sanityOptimization: (catchMinimizing 0/90/180/270° traps early)Travel

  DoThe aphysical arrangement of feeders is the primary driver of machine speed. rotationFeeder auditoptimization beforeaims to minimize the firsttravel panel:

  distance
  • Buildof a one-page rotation table per package family (what “0°” looks like on top, and how bottom is mirrored).
  • Dry-runthe placement on screen and print a “rotation heat-map” (count of 0/90/180/270). Spikes at 90/270 on parts that “should be 0°” = library drift.
  • On the bench, check pin-1/A1 for BGAs/QFNs and polarity for diodes/LEDs on your First Article routine (see 8.5).
    

  
  

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  2.2.4 Feeder optimization (travel less, place more)

  Your program is only as fast as its feeder map:head.

  • Permanent banks:Banks: park high-High-runner passivescomponents (e.g.,01005 01005–0603)– in0603 passives) should be assigned to fixed feeder slots across productsall soproduct changeoversprograms. don’tThis touchmassively them.reduces changeover time.
  • Shortest paths:Paths: place theThe highest-hit parts frommust feedersbe placed in feeder slots closest to the head’head's home position; cluster(or bythe nozzlecenter familyof tothe cutplacement swaps.area).
  • Splice-friendlyNozzle lanes:Grouping: assignFeeders high-runnershould reelsbe toclustered feedersby youthe canrequired splicenozzle insize/type. place;This avoid starvingminimizes the constraintnumber machine.of (Morerequired intool 8.3.)changes during the placement sequence, improving efficiency.
  • Tray parts last:Management: bigLarge BGAs/QFNsBGAs, QFNs, and odd-form parts (sourced from traystrays) costrequire time—sequencemore time and head travel. Sequence them afterlast chipto storms soensure the headhigh-speed isn’tplacement joggingof acrosschips is not interrupted.

  2.2.4 Path Sequencing and Load Balancing

  The sequence of placement determines the worldcycle mid-run.
  

time

and whether parallel machines operate efficiently.

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2.2.5 Path & sequencing (seconds live here)

• Zones,Placement then details:Order: The general rule is to place chips first (dense chip fields first (short headfield moves), then ICs,ICs, thenand finally tall/odd-form last.components that might interfere with head travel.
• SideLoad strategy:Balancing in Tandem: ifIf yourunning run tandem mounters (Chapter 2.1), the placement program must be split byto effortensure (chips vs ICs) sothe cycle times matchof both machines are balanced (within ~±10%—otherwise). oneThe machinesplit idles.must be by effort (8.1e.g., coversfast load-leveling.)chips on PnP A, slow ICs on PnP B) to avoid bottlenecks.
  

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2.2.65 First Article steps(FA) (and Program Freeze

The First Article procedure is a short, scripted audit used to prove the program,program's thenintegrity freeze)before

Runproduction a quick, scripted FA on the first panel:release.

1. Alignment Check: Teach three fiducials; confirmand verify the global X/Y/θ.θ alignment.
2. Witness Placement: Place witness parts for each package family near a board edge;edge. checkInspect these parts under a microscope to confirm orientation/orientation, polarity, heights,height, offsetsand offset underare correct.
3. Log Audit: Review machine pickup logs. Any high rate of misses/retries indicates a vision or nozzle parameter issue that must be fixed.
4. Recipe Freeze: After successful verification, the scope.
3. Review pickup logs (miss/retry rates) and tweak vision/nozzle for the worst offender.
4. Save themachine recipe and generateprogram themust be locked and a Golden Board photo set forcaptured. thisThis revfreeze (usedprevents againunauthorized inchanges 8.5).that could compromise production.
   

2.2.6

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Key Performance Metrics

These

2.2.7metrics Metricsmust be monitored on the machine dashboard to watchtrack (keepefficiency tuningand small)

flag drift.

• Placement timeTime perPer boardBoard: The time consumed for the placement routine (ex-excluding conveyor/buffer travel). andThis is the key measure of program efficiency.CPH vs spec
• PickupMiss/Retry missesRates: /The count of vision retriesfailures or pickup errors, tracked by part familyfamily. This directly indicates a feeder or vision library problem.
• Nozzle swapsSwaps Per Board: perMeasures boardthe (aimefficiency low—groupof partsthe byfeeder nozzlegrouping. size)Higher numbers indicate poor clustering and wasted time.
• StarvationCPH eventsvs. Theoretical: (countThe ofachieved “noComponents part”Per waits;Hour splicemust earlierbe iftracked rising)against the machine's maximum theoretical CPH to calculate overall utilization.

Program Setup Checklist

Phase	Non-Negotiable Item
Data & Library	TieProgram thesebased to youron OEEGolden dashboardData later so planners see the real constraint, not guesses. 2.2.8 Pocket checklists Before import Units mm, shared origin, θ CCWPack; top/bottomcomponent flaggedlibrary names match the PnP system. Library names/heights match; fiducials listed
Vision & rotationRotation	One taughtGolden partImage per package; golden images saved Rotation tableSanity built;Check performed on bottom-side mirroring verifiedmirroring.
FeedersFeeder & sequenceOptimization	High-runnersrunner onparts assigned to permanentPermanent banksFeeder Banks; splice-friendlyfeeders lanesclustered setby Nozzle Type.
Sequencing	Chips first, trays last; tandem programsprogram cycle times balanced (±10%)
First Article	Witness PartsFiducials OK;verified witnessfor partspolarity/offset; passmachine orientation/polarity/height/offset Logslogs confirmed clean (miss/retry); recipe frozen;program Golden Boardfrozen captured.

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By standardizing inputs, tuning vision and rotations, and optimizing feeders, placement programs become predictable tools instead of firefights. The payoff is faster startups, fewer errors, and lines that run at speed with minimal intervention.