Every PCB monitored. Every process traceable.
How KIC supports an advanced automotive SMT factory, from profiling and optimization to reflow process monitoring, MES integration and audit-ready traceability.
At the former ZF Poland operation, now part of Capri, a highly automated SMT production environment combines multiple inspection and process-control steps to manufacture automotive electronics. For Piotr, who developed from an assembly-line operator into an engineering role, KIC has become part of both the learning process and the daily control of reflow production. The system supports new-product profiling, recipe optimization, continuous monitoring of every PCB, long-term traceability, MES-based production validation and customer audits.
At a Glance
Q: Piotr, can you tell us about your experience at ZF?
I have been working at the ZF facility for around four years. I started as an operator on the assembly line and then began working together with our engineers. Today I work in an engineering role and support the manufacturing process. ZF was also my first experience with an SMT line, so a large part of my knowledge has been built directly in this production environment.
That progression has given me a practical view of the complete process, from what happens on the line to the engineering decisions behind it. Reflow is an important part of my daily work, but I also support other equipment and processes when needed.
Q: What does the SMT line at ZF / Capri Poland look like?
The production line is highly automated and includes several process and inspection stages. The flow starts with laser marking, followed by solder paste printing and SPI to verify that the paste has been correctly deposited on the pads. The line then includes multiple pick-and-place stages for component placement before the PCB reaches the reflow oven.
After reflow, inspection continues with AOI and operator verification of detected issues. X-ray inspection is also used, particularly where internal solder joints such as BGA connections need to be evaluated. On some of the more demanding products, the inspection requirements can be extensive.
For us, KIC fits into this environment as the thermal process-control and monitoring layer around reflow. It adds continuous process information to a line that is already built around automation, inspection and traceability.
Q: How does KIC support your daily production?
The biggest benefit is that KIC monitors every single board we produce through the reflow process. We manufacture important automotive products, so knowing that the thermal process is continuously monitored gives me confidence in production.
Once a profile is approved, monitoring does not stop at the qualification stage. KIC continues to evaluate production, board after board. This means we are not relying only on a profile measured at one point in time; we have ongoing visibility of the process during actual manufacturing.
Q: How does KIC help with new products and profile optimization?
We do not currently have a very high number of new products, but when we need to measure something new, KIC is very helpful. For example, if there is a new or critical component, I can attach a thermocouple directly to that component and measure what is actually happening to it inside the oven.
I also use the prediction functionality when working on recipes. I normally make my own assessment and then use prediction to check whether my thinking is correct and to evaluate small changes. Sometimes I use automatic prediction, but manual prediction has been particularly valuable because it helped me understand how the reflow process works and how changes to oven settings influence the thermal profile.
That was very useful while I was learning, and today it still helps me whenever I need to create a new profile or modify an existing one.
Q: How do you evaluate whether a process change is really successful?
We work within defined process windows prepared for our production requirements, taking into account the solder paste and the specifications of the components used in our factories. When I make a change, I record it and then evaluate the result over a meaningful amount of production.
For example, rather than judging a change from only one or five boards, we can look at the results after a much larger production quantity, such as around 1,000 PCBs, and combine the reflow information with feedback from downstream inspection. X-ray results can then help confirm whether issues such as BGA bridging are present or whether the process is performing as expected.
This gives us a much stronger basis for deciding whether an optimization is genuinely successful in production.
Q: What value does KIC provide for traceability and customer claims?
Traceability is one of the strongest benefits. We can locate an individual board produced years ago and retrieve the corresponding oven profile. If a customer reports an issue, we can go back to the production history and show what happened during the reflow process for that specific PCB.
This is very important because it gives us objective evidence. If the thermal process was correct, we can demonstrate that to the customer and then the investigation can continue in other areas. Instead of relying on assumptions, we have historical process data connected to the manufactured board.
Q: How is KIC connected with the wider manufacturing system?
KIC is integrated with our MES environment, and the communication works reliably. This is important because reflow control is not isolated from the rest of the line. Information and status from previous manufacturing stages can be validated before the PCB is allowed to enter the oven.
For example, we have a defined maximum time after solder paste printing. Our standard is eight hours, although the rule can be changed when required. If the board exceeds the permitted time, it can be interlocked before entering the oven. The system can also validate information from previous stations and confirm that the product and recipe are correct.
The important point is that the board does not simply enter the oven because it has physically arrived at the conveyor. The required manufacturing conditions have to be fulfilled first. KIC therefore contributes not only to thermal monitoring, but also to enforcing the production rules around the reflow process.
Q: Does the integration depend on a specific oven platform?
From the production point of view, the control concept can work across the different reflow equipment used in the factory. KIC communicates within the manufacturing environment and supports the required validations and interlocks around the oven process. This gives us a consistent approach to process control even when different oven platforms are present.
Q: How does KIC support audits?
Sometimes auditors are not familiar with KIC when they first see the system. But when I show them what we measure, that every single board is monitored and that we can retrieve the relevant production information, they immediately see the value.
For me, this makes audits easier because I can show the information they ask for. We have transparency of the reflow process and evidence behind it, rather than only saying that the process was under control.
Q: How would you describe the technical support?
I am really happy with the cooperation. I work with the KIC team and with the local support in Poland, and whenever I have an issue I know I can contact them. Even when I need help directly by phone, the team supports me whenever possible.
For production, that relationship matters. The technology is important, but it is also important to know that there are people available who understand the application and can help when needed.
I can show everything the auditors ask me.
Piotr Pisula, ZF / Capri Poland sp. z o.o.