How to Program In-House, Part II
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.