06.B – Panel Separation Tab-Routing or Hybrid (Starter Activity)

0️⃣ Data Fields Overview

ID	A-6-PSEP-300-V2S
Name	Panel Separation V-Cut
Process	Panel separation
Category	Execution
Level	Unit
Linked Resources	Panel Separation Tab Routing Hourly Rate V2S
Linked Drivers	V2S_PCB_Shape pcb_width pcb_height panel_width panel_height panel_factor
Linked Expenses	No linked Expense
Calculation Method	Formula
Revision	V2S-2.0.0
Revision Date	01-NOV-2025

1️⃣ What This Activity Is

Panel Separation: Tab-Routing / Hybrid (V2S) models the manual or tool-assisted depanelization time per PCB when using tab-routed or mixed (V-cut + tab) panels.

It automatically estimates the total number of routing tabs from panel geometry – including internal seams and external frame edges – and multiplies them by an average per-tab cut time.

A shape complexity multiplier adjusts for irregular outlines or notched panels, giving a compact yet realistic model for most mechanical depaneling setups.

2️⃣ Why It Matters

Tab-routing and hybrid depaneling are slower but gentler than pure V-cut, especially for boards with delicate components or non-rectangular shapes.

Accurate timing ensures the right balance between operator utilization, router machine scheduling, and product handling time.

This V2S version lets engineers fine-tune routing time and tab spacing using just a few constants. No manual entry from CAD data or external tab counts required.

3️⃣ Where It Fits in the PCBA Flow

Performed after PCB assembly, typically at a dedicated workstation.

The process precedes inspection or test and defines when individual boards become fully independent for packaging or handling.

4️⃣ Linked Resources

Panel Separation Tab Routing Hourly Rate (V2S) – represents the technician using a manual router, cab Hektor, or similar tool for tab-based separation.

5️⃣ Formula Overview

This formula models manual or tool-assisted depaneling time for tab-routed or hybrid panels, focusing on three key physical contributors:

The number of routed seams and perimeter edges (based on panel layout).
The number of tabs distributed along those edges (from geometry + tab spacing).
The per-tab cutting time, scaled by part shape complexity and any handling overhead.

Since the formula infers everything from the panel and PCB dimensions, it gives a credible first-order time model – without the need for CAD data – suitable for quoting, scheduling, and operator planning.

💡 Understanding the Logic (Step-by-Step)

Edge inference: The model divides the panel into a logical grid of ROWS × COLS based on PCB and panel dimensions. It then computes all internal and external seams, representing the physical cut paths.
For example, a 3×2 panel (6 PCBs total) produces 2 internal vertical seams and 1 horizontal seam, plus 4 outer edges.
Tab distribution: Tabs are assumed to be evenly spaced along these seams. By dividing the total seam length by a nominal tab spacing (40 mm default), we estimate the number of tabs. Hybrid panels (mixing V-cuts and tabs) likely show a higher tab density.
Time per tab: Each tab takes a few seconds for approach, routing, and retract. This includes the router’s tool-path transition and operator handling.
For example, a 6-up panel with 30 tabs × 4s = 120 s = ~20 sec per PCB.
Shape multiplier:
The multiplier amplifies time for complex outlines.
- 1.0 = clean rectangle
- 1.15 = some notches or internal contours
- 1.30 = multiple edges, cutouts, or odd geometry
  Complex boards often require slower movement or more repositioning.
Handling constant: Adds a fixed few seconds (if needed) for clamping, vacuum table setup, or flipping the panel.
6. Panel → PCB conversion: The total panel time is divided by panel_factor (PCBs per panel) to produce seconds per board.
Output rounding: Rounded to one decimal to keep reports clean and readable while maintaining ±3% precision.

Batch overhead represents once-per-run prep tasks such as bit change, dust cleanup, or fixture setup.

Unit-level formula

// Panel Separation Tab-Routing / Hybrid
// Manual/Tool-Assisted Panel Separation with Tab-Routing or Hybrid (V-Cut + TR) panelization method
// Model: per-panel auto tab estimate + per-tab routing time + panel handling

// ------- DRIVERS -------
PANEL_FACTOR := panel_factor;   // PCBs per panel
PANEL_W_MM   := panel_width;    // panel width  (mm)
PANEL_H_MM   := panel_height;   // panel height (mm)
PCB_W_MM     := pcb_width;      // PCB width    (mm)
PCB_H_MM     := pcb_height;     // PCB height   (mm)
SHAPE        := V2S_PCB_Shape;  // 0=normal, 1=irregular, 2=highly irregular

// ------- CONSTANTS (tune to site) -------
TAB_SPACING_MM     := 40.0;  // nominal spacing between routed tabs along edges
TAB_ROUTE_SEC      := 4.0;   // approach + cut + retract per tab
PANEL_HANDLING_SEC := 10.0;  // load/clamp/release overhead per panel

// Shape multiplier (optional but useful)
// ↑ Increase if outlines have notches/fillets that slow handling/cutting
SHAPE_MULT :=
if (SHAPE = 2) { 1.30 }
else_if (SHAPE = 1) { 1.15 }
else { 1.00 };

// ------- LAYOUT INFERENCE -------
COLS := max(1, floor(PANEL_W_MM / max(PCB_W_MM, 1)));   // PCBs across
ROWS := max(1, floor(PANEL_H_MM / max(PCB_H_MM, 1)));   // PCBs down

// ------- ROUTED EDGE LENGTH (mm) -------
// Internal seams + outer perimeter edges (tabs distributed along all seams)
VERTICAL_EDGE_MM :=
(max(0, COLS - 1) * ROWS * PCB_H_MM) +  // internal vertical seams
(2 * ROWS * PCB_H_MM);                  // outer vertical edges

HORIZONTAL_EDGE_MM :=
(max(0, ROWS - 1) * COLS * PCB_W_MM) +  // internal horizontal seams
(2 * COLS * PCB_W_MM);                  // outer horizontal edges

TOTAL_EDGE_MM := VERTICAL_EDGE_MM + HORIZONTAL_EDGE_MM;

// ------- AUTO TAB COUNT -------
// Use ceil() to ensure whole tabs; remove ceil() if you prefer fractional estimate
TOTAL_TABS := ceil(TOTAL_EDGE_MM / max(TAB_SPACING_MM, 1));

// ------- PANEL & PER-UNIT TIME -------
PANEL_TIME_SEC :=
(TOTAL_TABS * TAB_ROUTE_SEC * SHAPE_MULT) +  // active routing time
PANEL_HANDLING_SEC;                          // panel I/O overhead

UNIT_TIME_SEC := PANEL_TIME_SEC / max(PANEL_FACTOR, 1);

// ------- OUTPUT -------
round(UNIT_TIME_SEC * 10) / 10

Batch-level formula

// Panel Separation — Tab-Routing / Hybrid (batch)

// Fixed setup/teardown per batch (fixture check, vacuum, debris cleanup)
BATCH_SETUP_SEC    := 180;
BATCH_TEARDOWN_SEC := 120;

TOTAL_TAB_ROUTING_BATCH_SECONDS := BATCH_SETUP_SEC + BATCH_TEARDOWN_SEC;

TOTAL_TAB_ROUTING_BATCH_SECONDS

👉 Formula logic explained

👉 List of all Starter (V2S) Drivers

6️⃣ Customization & Tailoring

💡 Tune for your site:

Adjust TAB_ROUTE_SEC (default 4s)
Modify TAB_SPACING_MM (default 40 mm) – reduce to 30–35 mm if you want more strict spacing than generic IPC guidelines.
Tweak SHAPE_MULT (default 1.0–1.3)
Add PANEL_HANDLING_SEC (default 10s) – reduce if done faster at your site.
Adjust BATCH_SETUP_SEC and BATCH_TEARDOWN_SEC to your site realities.

💡 Simplify for quick rollout:

If all panels are rectangular, you could fix SHAPE = 0.
Leave only TAB_ROUTE_SEC and TAB_SPACING_MM as your main tuning levers.

💡 Increase accuracy:

If you prefer exact tab counts, replace the geometric line
TOTAL_TABS := ceil(TOTAL_EDGE_MM / max(TAB_SPACING_MM, 1));
with TOTAL_TABS := V2S_Tab_Count;.

💡 Hybrid tuning quick tips:

Lower spacing (e.g., 30 mm) → more tabs and slower process.
Raise SHAPE_MULT one level → captures careful operator handling on mixed V-cut/tab panels.

💡 For more detailed customization, visit the Professional Formula page.

👉 << COMING SOON >>

7️⃣ Linked Expenses or Activities

No direct linked expenses are defined.

Commonly comes after PCB assembly, soldering, inspection and coating, and precedes post-depanelization activities such as testing, assembly and packaging.

8️⃣ Summary

Panel Separation: Tab-Routing / Hybrid (V2S) offers a clean, geometry-based model for manual or semi-automatic depaneling.

It balances realism and simplicity, auto-estimating tab counts and adapting to shape complexity without requiring CAD inputs. Tune a few constants for your tool and product mix, and you’ll have accurate cycle times for nearly all routed or mixed panels.

06.A – Panel Separation V-Cut (Starter Activity)