SMT technology upgrade amplifies production by 500%

RØDE Microphones is an Australian-owned and -operated audio company with offices in Sydney, Los Angeles, New York and Hong Kong. It specialises in the design and manufacture of a range of microphones and other audio accessories, selling them into markets around the world.

In mid-2014, RØDE was busy planning the launch of a new wireless microphone. Having received some large pre-orders for the product, and with mid- to long-term forecasts showing strong demand, it was apparent RØDE’s SMT line had to dramatically increase its production capacity to satisfy the market.

After running preproduction samples on the existing YAMAHA YS100 line, it became apparent that although the line could offer accuracy and reliability, it would not meet the hotly anticipated production numbers required. RØDE needed to upgrade its SMT capabilities and fast. Any upgrade to its existing set-up also had to handle the pressures of business growth for the next five to 10 years.

Having conducted some initial research into possible solutions, RØDE consulted with SMT supply specialist Hawker Richardson. After initial discussions and analysis of sales and marketing forecasts, it was agreed RØDE needed to retain its existing SMT set-up and invest in a complete new line. It was suggested that the new line should ideally have YAMAHA machines at its core as RØDE was happy with the ease of use of the YAMAHA operating software.

Having used DEK printers and Heller Reflow curing ovens in the past, RØDE wanted to use the latest models in its new line. For its pick-and-place machine, a YAMAHA model called the Z:LEX YSM20 looked to be suitable and, after testing in Japan, was the chosen solution.

In its entirety, RØDE’s new SMT line consisted of the following:

• One Nutek triple magazine line loader
• One bare board loader
• One DEK Horizon stencil printer
• Two YAMAHA Z:LEX YSM20 pick-and-place machines
• One Heller 1809 Mark III Series oven
• One Nutek triple magazine line unloader
• Nutek conveyors
• SMS International SMT software

Hawker Richardson project-managed the entire logistics, installation and commissioning process, and had the line fully operational within seven days of the machines arriving on-site at RØDE. The company also developed and delivered a full training program that was conducted by experienced Hawker Richardson staff, YAMAHA engineers from Japan and SMS engineers from New Zealand.

Since going live in mid-2015, RØDE’s SMT line has increased production capacity by 500%. While RØDE still has its existing line that delivers 10,000 components per hour (CPH) for lower volume products, the new line provides up to 50,000 CPH thanks to the new YAMAHA Z:LEX YSM20 pick-and-place machines. The other upgraded machines have proved more than capable of keeping up with the increase in pick-and-place speed and will ensure RØDE has the ability to continue to innovate and grow in the medium to long term.

“The new line has allowed us to dramatically increase the quantity of boards that we can make and allows us to match the demands for our global markets,” said Peter Freedman, managing director of RØDE Microphones. “It’s an investment we simply had to make to ensure the ongoing growth of our company and worldwide customers.”