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How to Program In-House, Part II

Nov 9, 2020 | Case Study, How To | 0 comments

Previously, we discussed how to use Device Search and Device Request. In this article, first, we’ll cover Benchmarking to determine which system you need to program in-house. Next, we’ll do a capacity analysis. Finally, we’ll do a real-world ROI (return on investment) calculation (hint: Device programming in-house starts making money in weeks, not years).

Example of Programming In-House

In reviewing our example, we’ve got two programmable devices on our board: a TSOP and a QFP programmable device. The TSOP has 1200 Kilobytes of data; the QFP has 1 Gigabyte (which makes in-line or on-board programming a bad option).

6 Ways to Program Devices (and Why Off-Line Programming may be an option)

Our initial device search revealed one of the devices is supported (the QFP), but the other is not (the TSOP). If we’re early in the process, it’s possible to find a similar device that is supported. If not, you can always request support for the device. Depending on the complexity (is it in a “family” of devices that have support, does it require a custom socket, etc.) BPM will provide a support proposal with cost and lead time.

Device Semi House Code Socket Qty/Year File Size Bench-mark
QFP Renesas

R5F100GXXX

FVE4ASMR48LQFPG 1,200,000 1 GB ?
TSOP Renesas HN58VXXXX Custom Dev 1,200,000 1 MB ?

Now that we have an idea of support, the next step is to determine which system is the best fit.

APS Rule of Thumb

A good rule of thumb regarding when a programming project is a good candidate for Automated Programming is if quantities are in excess of 50,000 parts per year (there are some other things that could factor in, such as laser marking, 3D inspection, etc.). In our example, we will need 2.4 million devices per year, so that makes Automated Programming an easy choice.

Benchmarking

Benchmarking is what determines how the system is configured. Typically, the longer the programming times, the more sites needed. You start with the number of programmed devices needed (in our example it’s about 3 million per year). BPM can provide the programming time for the device. After that, it’s just math…

Device Device SKU Socket Qty/Year File Size Benchmark Recommended Sites/Sockets
QFP R5F100GXXX FVE4ASMR48LQFPG 1.2 mil 1 GB 150 seconds ?
TSOP HN58VXXXX Custom Dev 1.2 mil 1 MB 24 seconds ?

The QFP socket is a four-up (each site can program 4 devices concurrently) but has a long programming time (150 seconds in our example). BPM utilizes concurrent programming, so it can load fast and start programming as soon as the site is filled. Each site can program approximately 96 devices per hour ( 4 sockets per site x 3600 seconds / 150).

in addition, the 3928 Automated Programmer can be configured with up to 7 programming sites with up to 28 sockets.

For instance, if we max out the 3928 Automated Programmer (7 sites, 28 sockets) we can get approximately 650 Devices Per Hour (DPH), or approximately 4550 per shift (650 x 7 hours). Dividing that out into the total quantity of devices needed, we would need 1846 hours for just that one device.

Don’t forget, we have another device we need to program as well. The benchmark is 24 seconds; we can get by with just 3 sites (12 sockets) which will yield approximately 1200 devices per hour. The TSOP device requires about 1000 hours to produce.

  • Total Volume per year: 2,400,000
  • Theoretical Machine Hours Required: 2,846
  • Utilization Rate: 85%
  • Estimated Machine Hours Required: 3348
  • Changeover Hours per year: 88.4
  • Total Shift Hours Required: 3437
  • Shift Hours Available per year*: 3640
  • Equipment Shift Capacity: 94%

*2 Shifts per day

Above all, BPM Automated Programmers are built to run 3 shifts at a utilization rate of 85% (conservatively). The 2-shift scenario is tight (94% utilization rate) but doable. You can instantly add a third more capacity by adding a third shift or authorize some overtime to make up any shorts.

Device Device SKU Socket Qty/Year File Size Benchmark Recommended Sites/Sockets
QFP R5F100GXXX FVE4ASMR48LQFPG 1.2 mil 1 GB 150 seconds 7 sites (28 sockets)
TSOP HN58VXXXX Custom Dev 1.2 mil 1 MB 24 seconds 3 sites (12 sockets)

In developing the system configuration, your line needs the devices on a tape/reel, so you’ll need a tape-out peripheral.

Total system:

  • 3928 with 7 sites
  • TM-50 Tape Out
  • Tape Input (2 sizes)
  • 28 FX4ASMR100QFPZR Sockets
  • 12 New Dev Sockets for TSOP HN58VXXXX
  • Full spares kit (includes spare site)

Pays for itself

To determine the total cost, please contact us. You would also need to factor in replacements for sockets (regular sockets are rated for approximately 5-10K total insertions; many of our sockets modules include a receptacle that allows you to replace the consumable socket as required on the board).

ROI Calculator

In this real-world example, we’ll break down the numbers to bring device programming in-house:

COST PER DEVICE ANALYSIS 3928 System
Shift Hours per Day 16
Theoretical Machine Hours Required 2,846
Machine Utilization Rate 85%
Changeover Hours 88
Estimated Total Burdened Hours Required 3,436
Years Amortized 5
Burdened Labor Rate $15.00
Cost per Device (Outsourced) $0.25
Total Solution Price $225,000
Devices per year 2,400,000
Estimated Devices per hour 698
Total cost per year $96,540
Estimated Consumable Cost Per Device $0.015
Cost per device = Equipment, Overhead + Consumables $0.055
Cost Per 1000 $55.23
Cost per 1,000,000 $55,225
   
SYSTEM PAYBACK CALCULATION 3928 System
Total Solution Price $225,000
Device per day (260 days/yr) 9,231
Savings per device $0.195
Savings per day $1,797.92
Days to payback 125.1

Payback in About 4 Months

Therefore, it would take a little under 18 weeks (not years) to make device programming in-house a profit center! Once paid for, it’s almost all profit. Many customers use these systems for 10+ years and achieve 5-10X ROI.

We can help!

In conclusion, we provide an ROI Calculation based on your configuration. Depending on your requirements, you can start producing positive ROI in months, not years. Contact us for a Business Review.

Some variables to factor in:

  • Security of not having your Intellectual Property possibly compromised
  • Speed of making updates
  • Reduced time-to-market
  • Quality Control
  • Faster, reduced inventory turns
  • Just-in-time productions supplies what the line needs today
  • Ability to adjust production by adding shifts and/or outsourcing
  • Faster, more accurate set-ups on BPM automated equipment (see WhisperTeach™);
  • See article on OEE here.

Intrigued?

Learn more about BPM Microsystem's Automated Programming Systems Deliver ROI

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