As industrial and consumer products continue to evolve rapidly, demand for high-mix, low-volume production has increased significantly. In PCB manufacturing, frequent first-article testing and process-parameter adjustments for product changeovers can affect production line utilization. Many small and medium-sized PCB manufacturers operate high-mix, low-volume product lines, and their output value accounts for approximately 53% of the global PCB market, representing a significant share and contribution.

SynPower stated that in the current PCB pilot-production process, each station relies on manual monitoring for process control. When process abnormalities lead to defective products, real-time monitoring is not available, resulting in wasted production time and costs while also limiting yield improvement.

The PCB industry faces high-precision, high-mix, low-volume product lines, and each line change requires considerable time for process-parameter tuning. Currently, the process optimization time for a single part number is more than 2.5 hours, limiting production efficiency. In addition, rapid prototyping of high-precision PCBs with line widths below 50μm often results in lower process yield.

To address these PCB process challenges，SynPower Develops a Rapid PCB Pilot-production Manufacturing System，including an intelligent predictive parameter optimization system and a real-time monitoring system for every process station，using intelligent parameter prediction and optimization technology，is expected to improve pilot-production process efficiency by 75% or more，combined with the real-time monitoring system，ensuring that all process stations operate normally。

The system integrates SynPower AVRIOT to digitally upgrade selected instrument panels on existing equipment. Through SynPower’s Edge PC / Server architecture, it enables communication, data collection, parameter feedback control, and abnormality alert functions.

To support customer product designs, SynPower also provides a customized QR-code traceability system for circuit-section processes. Product QR-code information is linked with corresponding process parameters from each station, turning the data into analyzable information. By using data AI tools for analysis and modeling, the system provides predictive optimized parameters. During first-article pilot production for an individual part number, it can quickly achieve accurate parameters and significantly reduce the time experienced engineers spend on parameter adjustment and optimization.