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
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.
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.
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.
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 email@example.com.
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)
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.