How to Reduce Material Loss Caused by Splicing Tape? | Shenzhen Kanghongjin Electronics Co., Ltd.

Materials
03 Jun

How to Reduce Material Loss Caused by Splicing Tape?

In SMT (Surface Mount Technology) production, improper operation of splicing tape is one of the main causes of material loss.

Key Methods to Reduce Material Loss Caused by Splicing Tape

1. Standardized Operation Comes First

- Follow Standard Operating Procedures (SOP): Splicing must strictly adhere to company-defined guidelines to avoid human error.
- Accurate Splice Positioning: The joint between old and new tape must be precisely aligned to prevent feeding issues.
- Control the Length of Peeled Tape: Avoid peeling off too much tape, which can lead to unnecessary component loss.
- Correct Pressing Technique: Do not apply excessive force, as it can deform the carrier tape or cause misalignment, resulting in identification errors.

2. Improve Operator Skills

Employee Training: Enhance operator proficiency in feeder structure, splicing tape application, and tension judgment.
Practical Drills: Conduct hands-on training and assessments to reduce splicing mistakes.

3. Feeder Management and Maintenance

Check Feeder Springs and Gears for Wear: Aging or loosened parts may cause poor feeding.
Calibrate Feeder Tension Consistently: Both overly tight and overly loose tension can lead to uneven pulling or slippage.
Test Feeder Status Before Splicing: Use a tester or inspection window before mounting to ensure normal feeding.

4. Choose the Right Splicing Tape

Use High-Quality Tape and Splice Tabs: Low-quality adhesive may fall off or fail to bond securely.
Match Splicing Tape to Carrier Material: For example, use anti-static splicing tape for anti-static carrier tapes.
Use Reinforced Double-Sided Tape for Odd-Shaped Components to prevent them from rolling off or shifting.

5. Visual and Smart Monitoring of the Splicing Process

Use the Tape Sensing Function of the Pick-and-Place Machine to monitor feed status.
Enable Splice Alerts or Pre-Warning Functions on compatible equipment to minimize downtime during material changes.

Common Splicing Errors That Lead to Material Waste (Avoid These!)

Error Examples:

Excessively long peeled tape — wastes multiple components
Misaligned splice — causes pick errors, misplacement, or offset
Feeder not locked — leads to no feeding and empty runs
Uneven tape tension
Carrier tape breakage or slippage
Wrong tape type used — incompatible splice
Insufficient adhesive strength — tape detaches during production

Summary Recommendation:

Reducing material waste = Standardized Process + Skilled Operation + Proper Tools + Equipment Maintenance

If you'd like me to help customize an SMT splicing operation optimization plan, feel free to share your machine model and main material types.

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