manufacturing
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Setup Grouping & Changeover Minimization in Contract Electronics

A high-mix Contract Electronics Manufacturer (CEM) operating 12 Surface Mount Technology (SMT) lines producing PCBA boards for automotive and industrial IoT clients.

Runs onNiyojan

machine changeover setup downtime reduced: 58%machine changeover setup downtime reduced
SMT line Overall Equipment Effectiveness (OEE) increased: 52%SMT line Overall Equipment Effectiveness (OEE) increased

How the work runs

The pressure that made this worth automating, the steps the system runs, and what came out the other side.

Pressure & Trigger Points

Frequent order changeovers between custom customer PCBA jobs consumed 35% of total line operating hours in setup downtime (re-reeling component feeders, changing solder stencils).
Planners scheduled orders strictly by customer priority date, causing excessive machine changeovers between jobs sharing identical component reels.
SMT machine line efficiency (OEE) dropped to 52% due to setup downtime.

The run · 5 operational steps

Click any step to inspect telemetry signals, model reasoning, and governance gates.

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BOM Component Similarity Grouping

Niyojan analyzes active work order BOMs, automatically identifying jobs that share high percentages of identical SMT component reels.

Input Signal:

Real-time operational telemetry & queue

Reasoning Pattern:

MCP grounded vector inference

Governance Gate:

Policy constrained with audit write-back

Verified Business Outcomes

Machine changeover setup downtime reduced by 58%, unlocking 14 hours of hidden line capacity weekly per SMT line.
SMT line Overall Equipment Effectiveness (OEE) increased from 52% to 74%.
Increased plant throughput by 22% without purchasing additional capital machinery.

Capabilities this relies on

constraint solving
system connectors
forecasting
scenario simulation
workflow orchestration

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