Setup Grouping & Changeover Minimization in Contract Electronics
A high-mix Contract Electronics Manufacturer (CEM) operating 12 Surface Mount Technology (SMT) lines producing PCBA boards for automotive and industrial IoT clients.
Run on Niyojan · Production Planning & Scheduling
The challenge
Frequent order changeovers between custom customer PCBA jobs consumed 35% of total line operating hours in setup downtime (re-reeling component feeders, changing solder stencils).
Planners scheduled orders strictly by customer priority date, causing excessive machine changeovers between jobs sharing identical component reels.
SMT machine line efficiency (OEE) dropped to 52% due to setup downtime.
How Niyojan solves it
BOM Component Similarity Grouping
Niyojan analyzes active work order BOMs, automatically identifying jobs that share high percentages of identical SMT component reels.
Optimal Setup Sequence Generation
Sequences production jobs to group shared component reels together, minimizing feeder re-reeling downtime between runs.
Stencil & Feeder Changeover Minimization
Calculates exact changeover time penalties for alternative sequencing options, selecting the sequence that maximizes net machine run-time.
Customer SLA Compliance Checking
Ensures setup grouping optimization never violates customer delivery lead times or contract SLA windows.
Operator Changeover Instruction Generation
Dispatches detailed feeder setup change instructions to SMT line operators.
The outcome
- machine changeover setup downtime reduced
- 0%machine changeover setup downtime reduced
- SMT line Overall Equipment Effectiveness (OEE) increased
- 0%SMT line Overall Equipment Effectiveness (OEE) increased
Machine changeover setup downtime reduced by 58%, unlocking 14 hours of hidden line capacity weekly per SMT line.
SMT line Overall Equipment Effectiveness (OEE) increased from 52% to 74%.
Increased plant throughput by 22% without purchasing additional capital machinery.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
More from Niyojan
Operations
Global 60+ Plant Capacity Balancing & Workload Re- Allocation
A multinational industrial equipment manufacturer operating 60+ production facilities across 4 continents, producing custom hydraulic pumps, valves, and heavy gearboxes.
Operations
Dynamic Resequencing Following Unplanned Primary Line Failure
A high-volume automotive stamping and welding plant producing body panels for 3 concurrent vehicle assembly platforms.
Operations
Order SLA Protection & Overtime Minimization During Demand Spikes
A commercial HVAC equipment manufacturer producing custom rooftop air handling units with high seasonal demand surges during pre-summer months.
Bring us the version of this that you actually have.
Every engagement is fixed-scope and outcome-guaranteed. The scoping conversation starts with your systems, not with a template.