A Simulation-Based Approach: Optimizing PCB Assembly Lines with ARENA®

We present a simulation-based approach to increase throughput and resource utilization of Printed Circuit Board (PCB) assembly lines. We use ARENA to simulate and optimize production, ultimately reducing overall costs and maximizing throughput and resource utilization. A multifaceted simulation approach is used to assess different alternatives, providing insights into critical production parameters. Using ARENA to produce real-time simulations has proven to be an excellent, cost-effective approach for studying industrial supply chains, and the impact of various control parameters. For over a decade, Printed Circuit Board (PCB) assembly lines have been providing solutions, developing new technologies, and pioneering advancements in the semiconductor industry. Through more efficient resource allocation, production line reconfigurations, and long-term throughput analysis, PCB assembly lines can further enhance production processes and reduce costs through long-run simulations, “what-if” and uncertainty analysis. Simulation-based modeling using ARENA (by Rockwell Automation) provides invaluable insight into entire production lines from raw materials through assembly and quality control. This approach determines the root causes of downtimes, seamlessly identifying bottlenecks, and various forms waste and delays. The simulation model is also used to understand the effect of changes in operational plans, machine breakdown and downtime occurrences, resource allocation, as well as other production line disruptions. PCB assembly lines are always focused on continuous improvement, maintaining a lean supply chain, and optimizing its production lines without relying on simulations. We show that through a simulation-based approach, PCB assembly lines can redesign production schedules and resource allocation by re-evaluating production processes, increasing PCB availability and production throughput, and reducing costs and defect rates.