2 months from dead start to 1000 boards completed? OK, now I know you are nuts! Maybe an experienced guy could pull this off, setting up a new shop and cranking out boards. Let's list the issues:
1. getting machines in, powered, air supply, air conditioning MUCH greater than needed for office space, vent duct, etc.
2. getting software to talk to P&P machine, format required files from CAD/CAM data, etc.
3. Programming vision system for actual components you will use. Some will come straight out of library, some may
need special attention.
4. Setting up stencil printer to get proper registration and print with the pastes and stencils you will be using.
5. Dealing with errors on the P&P, fiddling with the feeders to get good pick-up, getting the vision system to be able to
detect the leads on all the parts without rejects.
6. Getting the oven set up to reflow everything without tombstones, bridges or head in pillow defects. With good,
clean boards and high quality solder paste, this ought to be a non-problem. But, if it IS a problem, it will drive you
to distraction. I've been down this road, and it is littered with carcasses. I even spent $170 to import some SAC305
from England on a recommendation. it was GOOD paste, but just too much hassle and expense. I'm still looking
for the "best" paste, but the stuff I'm using now is just OK.
OK, so, assume that everything you need is in place the first day (Ha ha ha!) and that it all fires up and works properly.
You will still be fiddling with learning the machines, the software, setting up the paste printer, and the oven profile for quite some days. I can't BELIEVE you can get there in less than 2 weeks. So, that leaves 6 weeks for production.
Assuming 5-day weeks, that is 30 days. Now, assuming your 9-up panels actually will fit in the P&P and the oven, 1000 boards is 111 panels. Assuming each panel takes 20 minutes to place (I think you mentioned, but I can't find the estimated time) that gives you 24 panels per 8-hour day. Well, it would only take about a week to run these.
Of course, after that week, you will need a 3 month vacation before even wanting to look at your machines again!
I can't IMAGINE the horror of running a batch like that! Now, with all those automated SMEMA conveyors totally automating the process, it should seem like just sitting back and watching the robots do all your work, but PLEASE, talk to somebody who actually RUNS a line. I'm sure my setup is total crap, but if you have even 1/10th of the feeder issues I have, with a multi-nozzle high-speed machine, I think you will be pretty busy fiddling with things. (Remember, every time you open the guards to fiddle with a feeder, the machine stops.)
The 0805 resistors just go wit the rarest attention, but some parts just slowly drive me nuts. Oh, also note that many machines have big problems with round-top parts like MELF diodes and domed LEDs. So, I have had to find what works and what doesn't on my machine. 0603 flat-top LEDs are just too small on top, so I had to go up to 0805 LEDs. Way too many mispicks on the 0603 LEDs, even after careful alignment of the feeders.
As for stencils, I have kept notes of what worked and what didn't. For 0805 and up, nothing matters, but excess paste makes little beads around the pads after reflow. As the IC lead pitch gets smaller, the aperture size needs to be reduced more an more to avoid bridges. If you are going to do leadless, CSP and such, then the solder amount is insanely critical, or bridges will be all over the place. The chip sucks down and spreads the paste. I did that once, and it was AWFUL. I ended up redesigning the board to not use that CSP part.
Jon