Call for a Quote (510) 580-8500

Or Email Us at Sales@Sonicmfg.com

The largest EMS in the Silicon Valley

Call for a Quote (510) 580-8500

Or Email Us at Sales@Sonicmfg.com

The largest EMS in
the Silicon Valley

pcba

PCBA – Design for Manufacturability

Whenever you bring a new product to market, there are many considerations and iterations required to find the optimal design. A key element that designers often don’t consider early enough is the ease of manufacturing the final product. When you’re focusing on adding functionality and improving the product’s durability, the PCB’s assembly requirements may seem inconsequential. However, design for manufacturability (DFM) is crucial to ensure the successful launch of your product.

What Is Design for Manufacturability?

Two distinct processes ensure your product’s manufacturability. Applying design for assembly (DFA) and design for fabrication (DFF) principles early in the product development process will save a lot of iterations and rework when finalizing the design.

Design for Fabrication

DFF focuses on issues relating to the fabrication of the boards. With DFF, the board’s layout considers not just the lines and bond dimensions but includes solving issues such as heat dissipation, connector location and any possible future updates to the product. By applying DFF design considerations early, you optimize both the PCB’s layout and cost before moving to the manufacturing stages.

Design for Assembly

Once you’ve optimized the DFF of the board, you’ll need to find the best assembly process for the final product. DFA ensures you develop the manufacturing process instructions (MPIs) that will make your product’s assembly run efficiently. Here at Sonic Manufacturing Technologies, we assist you by developing the required MPIs directly on an active production line.

Whether it’s a demo or development board, using active production lines during the prototype stages will ensure you find the optimal assembly processes early. It will also highlight any design deficiencies before they become showstoppers in the product’s manufacturing lifecycle.

Why You Need DFM for Your Printed Circuit Board

Design teams often leave the manufacturing considerations to the vendor. Once the vendor receives the design, they’ll conduct a manufacturability analysis and make the necessary changes to optimize the assembly process. If any disconnection exists between the designers and the manufacturing company, they may neglect communicating all the changes to the design team.

The impact of these changes could have drastic effects on the final product’s functionality. To eliminate the risks associated with this, getting the manufacturer involved early and collaborating with them during every iteration of the design is essential.

Sonic Manufacturing’s PCBA Design for Manufacturability Services

Sonic Manufacturing Technologies uses state of the art production lines to develop the MPIs and optimize the layout of the design. Our engineers can highlight any issues with the initial design and suggest changes that’ll improve your product’s feasibility.

Our services include:

At Sonic Manufacturing, we use an agile manufacturing process to ensure changes and updates do not disrupt any production runs. Additionally, our in-house engineering team will ensure you find an optimized assembly process for the product by developing an efficient MPI for any prototype or demo board.

Take Advantage of Sonic’s Manufacturing Optimization Processes

To guarantee your next product’s successful launch, partner with Sonic Manufacturing to ensure a smooth and efficient development process. Our state-of-the-art facility enables design teams to test designs and find optimized solutions for your product during the early stages of development.

When you need to optimize the design of a solid PCB, a flex board, or a combination of the two, you should get in touch with Sonic Manufacturing Technology’s talented team today.

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New Product Manufacturing Checklist

Creating a New Product Manufacturing Checklist

When it’s time for your new product to enter the manufacturing process, the team at Sonic Manufacturing Technologies prepares a new product manufacturing checklist for that product. This manufacturing plan provides key information to help you prepare for the upcoming manufacturing process. This plan is crucial to plan for equipment, personnel, and capital requirements, and needs developing early enough in the process to allow for appropriate lead times on any new equipment you may require as well as development time for new testing approaches.

Contents of a Successful Manufacturing Plan

What should be included in your manufacturing plan? Our checklist includes eight key sections.

1. Objective

We start by stating the objective of the new manufacturing plan: to document the process flow and high-level test requirements for the new product being developed and to identify the necessary people, facilities, and equipment required.

2. Manufacturing Process: Assembly Strategy

In this section, we define the manufacturing process flowchart for your new product. We also identify alternatives and risks and suggest how to develop the capacity of the line.

3. Manufacturing Test Approach

The third section of the plan consists of an overview of the testing process, followed by detailed manufacturing test information. The overview summarizes testing at all stages of the process and specifies product design requirements. The detailed information documents the steps manufacturing personnel will perform to test your product. (Click here to learn more about our quality assurance and testing processes.)

4. Equipment and Facility Requirements

This part of the plan details the capital/tooling requirements, identifies all necessary equipment and estimates the approximate lead time and costs for this equipment. This section should also establish equipment selection criteria and create a facility layout that shows the floor space required.

5. Logistics/Materials Plans

In this section, we identify long lead items and vendor quality requirements, as well as create an ordering plan for the internal prototype forecast and later production units. We also identify product packaging and shipping plans.

6. Personnel and Related Costs

This part of the plan projects direct labor and direct labor overhead goals and estimates. It also estimates the number of people needed, the training required, the special talent required, and estimated manufacturing cycle time.

7. Training Requirements

If new processes are developed or new equipment put in place, we specify the training requirements for various operations personnel. We also indicate who will develop and deliver this training, as well as the type of training required and the projected class sizes.

8. Other Specifications

Finally, we detail other key specifications, including equipment failure mode effects analysis, equipment preventive maintenance plans, equipment calibration plans, and ESD controls.

Developing the Manufacturing Plan

How do we develop this new product manufacturing checklist? We start by creating the first draft during the development phase of your project, working directly with your team. Then we discuss the plan and bring any questions or issues to team meetings and pertinent design reviews. We use this feedback, as well as any new information, to revise the manufacturing plan before the beta build or as it enters into next phases of production. The final version of the plan is then distributed and approved by all parties.

Planning Matters

At Sonic Manufacturing Technologies, we recognize the importance of planning before initiating the manufacturing process for your new products. You can depend on our manufacturing and materials knowledge and experience to develop comprehensive plans for your new product introductions.

For expert advice, thorough new product manufacturing checklists and guidance throughout the new product introduction process, be sure to contact Sonic Manufacturing Technologies at (510) 580-8500 or online at sales@sonicmfg.com.

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Electronic Prototyping for New Product Development

Concept Prototyping for New Product Development

Getting a new product off the ground is a tough enough job without needing to worry about the capabilities of manufacturers too. Once the engineers have put in all the work, the build quality of your prototype should ideally match the final, shippable product.

That’s why joining forces early with a company that offers complete electronic manufacturing services is important. Sonic Manufacturing Technologies enables a quicker time to market from design to shipment by using an agile process – a process that suits new product introduction (NPI) perfectly.

For a complete product development analysis, building the prototype alone won’t suffice. The implications of the manufacturing process requirements will determine the final feasibility of the device. Sonic will assist you with finding and understanding these issues, providing advice and guidance every step of the way.

New Product Introduction Process

Developing Dependable BOMs & MPIs

After you’ve completed the design, the next step to building a quality, reproducible product requires a comprehensive bill of materials (BOM) and accurate manufacturing process instructions (MPI). At Sonic, using an actual production line for product development means early identification of build issues, leading to clearer assembly instructions.

Sourcing Material and Components

Once the BOM and MPI inform the build processes, Sonic will help you source the materials that determine lead times and total unit costs. No matter the PCB or FCP complexity, we use an automated sourcing tool (called HAL) to source the BOM.

With an international procurement office, we can source any component and ensure its quality. Authorized franchise channels, reduced transport delays, and expert clearance services ensure the materials arrive in time for the production run.

Testing, Quality Assurance, and Change Management

No product is perfect from the start. Testing results provide opportunities to enhance both the final product and the processes used to manufacture them. The quality assurance checks and tests we carry out will provide a stable build benchmark for future product runs.

Sonic Manufacturing Technologies runs an agile production process. We adapt to changes in BOMs and MPIs quickly and effectively, working with you to ensure your product’s success.

Scheduling and Demand Management

Sonic will ensure your company can meet demand once the schematics, manufacturing instructions, and BOMs are final (using sophisticated outbound logistics management practices). With eight surface-mounted assembly lines and comprehensive order fulfillment processes, your company will benefit from shorter replenishment cycles and reduced lead times.

Regionalized Manufacturing Using Agile Technology and Processes

Sonic leads the way when it comes to embracing innovative changes to manufacturing and supply chain management processes. Using technology to integrate the entire process, from forecasting to order placement and delivery, means we can help reduce your total cost per unit.

Our focus on the tiniest manufacturing details and ability to do daily material requirements planning (MRP) allows us to produce what you need, when you need it. From our headquarters in California, Sonic serves the Bay Area, San Jose and Silicon Valley as well as Salt Lake City and Sacramento. Contact us today for any electronic manufacturing service advice you need.

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