Now, what do you think? It is long, but it is interesting
Regards,
Executive Summary
After completion of the first two phases of this project, it is our recommendation that the JBC Advanced Series soldering iron is more capable than the current vendor Metcal. JBC has outperformed Metcal and all other vendors in nearly every evaluation category. It is our recommendation to purchase two JBC Advanced Series units to complete an extended tip life study, as well as a complete cost justification analysis to prove a cost benefit. This would allow the last two phases of the project to be completed.
Project Overview
This project evaluates new vendors of soldering iron/rework units. The scope is to purchase units from the vendor of choice for future buys for all locations or replace existing irons when minimum capabilities cannot be met. At the least, the vendor of choice should be allowed on the approved vendor list for rework/repair situations that our current vendor cannot support. Recommendations will be based on results of the evaluation.
Purpose for Evaluation
Improvement effort for Repair UG
* Capability and technology of soldering irons
* Flexibility of workstation
* Tip life and cost comparison
* Want better control of Solder/Repair operations
* Future purchases of irons
Vendors Evaluated
* Metcal
* JBC
* Hakko
* Pace
* ERSA (only evaluated on the thermal load testing)
Equipment Used
*Hakko FM-202 Soldering Station
*Pace TW100 Soldering Station
*JBC AD4200 Soldering Station
*Metcal MX- 500S-11 Soldering Station
*ERSA PT Soldering Station (only in thermal load testing)
*Pace Process Monitor
*Wahl ST2100 Solder Iron Tester
*ERSA Thermal Load Tester
Limitations of Current Metcal Irons
* Short tip life (some last 2 weeks)
* Expensive Tips (twice as much as most competition)
* 3 tips required for varying temperatures
* No 0402 or 0201 capability
* Ground plane repairs difficult (PTH and SMT)
* IC-shaped tips are not effective
* Additional flux needed to achieve hole fill
* Process Controls
Assumptions
* Test equipment used is repeatable.
* Decision matrix scoring is objective.
Phases of Evaluation
* Phase 1: Paper evaluation
-Reduce to 2 vendors (Weighted Decision Matrix)
* Phase 2: Demo units (1-2 months)
-Performance based evaluation
-Thermal performance based tests
* Phase 3: Cost justification
-Tip life/cost and added capability
* Phase 4: Implementation
Phase 1: Paper Evaluation
The first phase of the evaluation consisted of the team compiling a matrix that lists important attributes of soldering irons. Each of the vendors evaluated were compiled into the matrix so comparisons could be made (Appendix 1.). The team then weighed each of the attributes from 0-1 (least to most importance). The weighted scores from each of the team members were then averaged and entered as the multiplier on the weighted matrix. From the information listed, a score from 1-5 (worst-best) was given to each of the attributes for each vendor. The total score is the sum of the weight multiplied by the attribute score (Appendix 2.). The total scores were as follows:
Hakko 45.975
Pace 45.75
JBC 53.175
Metcal 42.125
Phase 2: Demo Units
Part 1. Performance based evaluation.
Each of the units was used for approximately one month in three locations. All of the units were utilized at rework stations by certified experienced solderers. After each vendor rotation, the user was given a questionnaire to fill out (Appendix 3.). Five out of the 20 questions ranked the irons against the Metcal iron (3 = same as Metcal, 5 = superior to Metcal, 1 = inferior to Metcal, etc) and the results are as follows:
JBC B2 B4 B5 Average
Ergonomics 5 4 4.5
Tip Change 4 5 4.5
Durability 5 4 4.5
Temp Recovery 5 5 5
Capability 5 4 4.5
Hakko B2 B4 B5 Average
Ergonomics 4 4 4
Tip Change 3 3 3
Durability 3 3 3
Temp Recovery 5 4 4.5
Capability 5 3 4
Pace B2 B4 B5 Average
Ergonomics 3 4 3.5
Tip Change 1 3 2
Durability 2 3 2.5
Temp Recovery 2 2 2
Capability 2 2 2
Part 2. Thermal performance based tests.
To evaluate the thermal performance of each of the soldering irons, we acquired the three following test units:
Soldering Iron Evaluation Results:
Tables 1 and 2 represent data collected on the first day (9-12-02) of having the Pace thermal load equipment. Representatives from JBC and Pace were there to assist the testing process. The Pace tester is certified to Government SR4 test specifications. Considerations for these types of tests are the following:
1. Use the same tip size and configuration.
2. Use the same temperature setting.
3. Use the same amount of solder wire for the tinning of the iron.
4. Tin both sides of the soldering iron prior to test.
5. Each tip is new.
Table 1: Thermal Load Test - Small Coupon (3/4" square) Pace 2100 (9-12-02)
Vendor Tip # Ave.
ERSA (PT) 832VD 22.1
Pace (HW) 0010 177 22.3
Pace (TW) 0010 177 25.7
Hakko 18.9
JBC 2245-008 10.3
Metcal STTC-117 18.6
Table 2: Thermal Load Test - Large Coupon (1 ½" square) Pace 2100 (9-12-02)
Vendor Tip # Ave.
ERSA (PT) 832VD 120
Pace (HW) 0010 177 116
Pace (TW) 0010 177 120
Hakko 82
JBC 2245-008 30
Metcal STTC-117 43
Table 3: Thermal Loading Tests - Small Coupon Pace 2100 (9-16-02)
Vendor Tip # Temp. (Set Point) Temp. (Actual) Run #1(John) Run #2(Shawn) Run #3(Brian) Ave.
ERSA (TT) 612ED 700 707 20.8 25.5 23.7 23.3
ERSA (PT) 832VD 700 698 24.5 17.1 16.6 19.4
Pace (HW) 0010 177 700 690 29.7 24.9 29.7 28.1
Pace (TW) 0010 177 700 645 31.4 33.5 29.5 31.5
Hakko 700 675 22.1 19.2 26.0 22.4
JBC 2245-008 700 715 12.2 13.2 15.7 13.7
Metcal STTC-117 700 726 17.9 14.9 12.7 15.2
Table 4: Thermal Loading Tests - ERSA Solder Pot (9-16-02)
Vendor Tip # Temp. (Set Point) Temp. (Actual) Ave.
ERSA (TT) 612ED 700 750 54
ERSA (PT) 832VD 700 702 52
JBC 2245-008 700 702 48
Metcal STTC-117 700 737 57
Table 5: Thermal Loading Tests - Small Coupon Pace 2100 (9-20-02)
Vendor Tip # Temp. (Set Point) Temp. (Actual) Run #1(John) Run #2(John) Ave.
ERSA (TT) 612ED 700 720-725 22.5 25.4 24.0
ERSA (PT) 832VD 700 720-725 17.7 23.7 20.7
JBC 2245-008 700 720-725 15.2 13.7 14.5
Metcal STTC-117 700 720-725 20.9 22.0 21.5
Table 6: Thermal Loading Tests - Large Coupon Pace 2100 (9-20-02)
Vendor Tip # Temp. (Set Point) Temp. (Actual) Run #1(John) Run #2(John) Ave.
ERSA (TT) 612ED 700 720-725 72.5 100 86.2
ERSA (PT) 832VD 700 720-725 66.3 93.5 79.9
JBC 2245-008 700 720-725 39.9 46.5 43.2
Metcal STTC-117 700 720-725 31.4 69.8 50.6
Table 7: Thermal Loading Tests - ERSA Solder Pots (9-20-02)
Vendor Tip # Temp. (Set Point) Temp. (Actual) Ave.
ERSA (TT) 612ED 700 701-707 63
ERSA (PT) 832VD 700 714-717 58
Pace (HW) 0010 177 700 703-708 93
Hakko 700 674-676 69
JBC 2245-008 700 700-705 48
Metcal STTC-117 700 716-720 61
Thermal Load Tests Overall Results: (JBC vs. Metcal)
Table 1: 44.6% faster
Table 2: 30.2% faster
Table 3: 9.8% faster
Table 4: 15.8% faster
Table 5: 14.6% faster
Table 6: 21.3% faster
Recommendation
After completion of the first two phases of this project, it is our recommendation that the JBC Advanced Series soldering iron is more capable than the current vendor Metcal. JBC has outperformed Metcal and other evaluated vendors in nearly every evaluation category. It is our recommendation to purchase two JBC Advanced Series units to complete an extended tip life study, as well as a complete cost justification analysis to prove a cost benefit. This would allow the last two phases of the project to be completed.
Appendix 1.
Appendix 2.
-----Original Message-----
From: TechNet [mailto:[log in to unmask]]On Behalf Of Dehoyos, Ramon
Sent: Friday, July 23, 2004 2:12 PM
To: [log in to unmask]
Subject: [TN] FW: JBC Soldering Comparison
What do you think about this report?
Regards,
Ramon
Attached please find the Plexus Comparison Study that you requested through Mr. Dave MacMaster, Janel, Inc.
If you have any questions regarding this document, you may call Dave at 610-517-2715.
Regards,
Susan
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