Nonstop production, no matter the volume.

In the fast-paced world of surface-mount technology (SMT), every second matters. As demand rises for quickturn prototypes, smaller lot sizes and just-in-time manufacturing, businesses face increasing pressure to reduce downtime and minimize waste. In this environment, reel splicing kits have evolved from a niche accessory into an essential tool for optimizing SMT operations.

Whether running high-mix, low-volume builds or driving 24/7 production on high-volume lines, reel splicing kits remain one of the most cost-effective solutions to enhance feeder setup, streamline changeover and improve inventory efficiency.

The hidden cost of setup waste. SMT feeders operate on the same basic principle: components arrive in a carrier tape sealed with cover tape, precisely indexed for pick-and-place machines. But setting up a reel, even with today’s semiautomated feeder loaders, inevitably results in scrap. The first 12" to 18" of peeled cover tape usually means scrapped components, especially if they can’t be reintroduced into the feeder. For high-value or limited-supply parts, this isn’t just inconvenient – it’s expensive.

Now, imagine doing that setup 20, 30 or even 50 times in a single shift across multiple lines. That amounts to hours of cumulative downtime, hundreds of wasted components and a significant reduction in production efficiency.

Keep the line moving. Reel splicing allows operators to join two reels together without interrupting production. Operators can quickly create a seamless transition between reels using a splicing kit that includes alignment shims, crimping tools and adhesive cover tape connectors. This process results in zero machine stoppage.

Modern SMT lines, especially in high-volume EMS factories, rely on continuous uptime to maintain profitability. Stopping machines for even a few minutes to change reels adds up fast. With a well-trained operator, and a quality splicing kit, a new reel can be spliced in before the old one runs out, keeping the pick-and-place machine running at full speed.

Splicing carts have become standard equipment on SMT floors. Stocked with everything from cover tape extenders to universal shims and crimpers, they give operators mobile access to all necessary tools and reduce the time needed to perform splices at the machine.

High-mix builds. While high-volume manufacturers splice to keep lines running, high-mix assemblers rely on cover tape extenders to preserve component inventory. Frequent reel changeovers in short production runs mean increased scrap, and in many cases, no spare components are there to lose.

Tape extenders add 20" or more of usable leader to a reel, enabling proper setup without sacrificing pickable components (Figure 1). For contract manufacturers working with consigned kits or exact part counts, tape extenders are often the difference between hitting or missing a delivery window.

Figure 1. Tape extenders add several feet of of usable leader to a reel, aiding ongoing production.

As industries such as aerospace, medical and advanced prototyping increasingly shift toward low-volume, high-variability production, this straightforward solution has emerged as a best practice.

Regardless of production volume, the benefits of reel splicing and tape extenders are clear:

• High-volume lines minimize downtime and maximize machine utilization with continuous reel splicing.
• High-mix/low-volume lines reduce component scrap, improve kitting efficiency, and maintain momentum with tape extenders.
• Hybrid operations gain flexibility to support both modes with a small investment in universal splicing tools.

Additionally, the universal compatibility of certain kits, which supports feeder tapes from 8mm to 56mm across all SMT platforms, makes the return on investment (ROI) evident and hard to overlook.

As SMT manufacturing evolves, achieving success hinges on the ability to build more quickly, intelligently and with reduced waste. Reel splicing kits and tape extenders offer a low-cost, high-impact solution for any assembly line.

Rob Sierra is owner and president of Sierra Electronics and founder of Sierra Electronics (tapesplice.com); rob@tapesplice.com.

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