Call for a Quote (510) 580-8500

Or Email Us at

The largest EMS in the Silicon Valley

Call for a Quote (510) 580-8500

Or Email Us at

The largest EMS in
the Silicon Valley

Considerations in Electronic Box Build Services

Inordinate amounts of considerations go into finding the perfect industrial design for your latest product. Is it functional? Does it serve an innovative need? Can it be cheaper? How long will it take to source from the manufacturer and assembler? All of these questions influence the final specification and layout of the product and are vital considerations in electronic box build services. Antoine de Saint-Exupéry famously said that you achieve perfection not when you have nothing more to add, but instead when there’s nothing left for you to take away from your creation.

The perfect design doesn’t just emphasize the functionality and usability of a product, it includes the aesthetics and user experience as core principles involved during the entire design lifecycle. The founder of Braun, Dieter Rams, established ten design considerations for engineers to subject each new product specification against before moving to the production phase.

Innovative Approaches to Electronic Box Build Services

A balance exists between creating something that is utilizable without compromising on its appearance. It should preferably also leave a lasting impression on end-users, fostering brand recognition in the longer term, and be designed for manufacturing with reduced errors and high efficiency. This may sound like a fantasy in traditional design and manufacturing cycles, as the next launch is always too soon, and the market’s expectations are too great to achieve a viable turn-around within these constraints.

This is exactly why agile design and manufacturing provides a new and innovative approach that helps product designers succeed in achieving such lofty goals. With agility as a cornerstone of the design and build lifecycle, entrepreneurs, startups, and established product designers can create continuous cycles of innovation and product improvement.

Sonic Manufacturing’s Agile Supply Chain and Electronic Manufacturing Services

At Sonic Manufacturing, we don’t necessarily consider change as a bad thing when collaborating with customers for electronic box build services. In fact, we may recommend a different backplane assembly or improve on your box frame and connector selections during the prototype or manufacturing stages. The primary goal is to improve your final product’s manufacturability and reliability, as well as accommodating for innovations discovered after your initial release to market.

Working with our customers, we assist with the initial wiring diagram creation and provide product layout services to find the perfect balance between function and aesthetic. As we prototype directly on the production line, the final specification includes all DFMA (Design for Manufacturability and Assembly) considerations at the outset of the project. Sonic Manufacturing understands that good ideas often come after the fact, and we designed our processes specifically to accommodate these situations.

Sonic Manufacturing’s electronic box build services include:

  • Product layout and assembly prototyping.
  • Housing design and weather tight finishing.
  • Supply chain logistics optimization with automated ecommerce solutions.
  • Adaptable forecasting and daily special runs.
  • Outbound and reverse logistics for improved order fulfillment.

Although our facility is in the US, we can ship products anywhere around the globe. We can also source components from the major OEM manufacturing zones using our International Procurement Office situated in Singapore.

Sonic Manufacturing as Your Agile Electronic Manufacturing Company

Sonic Manufacturing uses flexible, high-speed lines that assist with New Product Introduction as well as JIT or Kanban manufacturing processes for any level of volume. With our ecommerce component sourcing solution that handles the bulk of our procurement tasks, our team is free to focus on the primary goal of bringing your idea to fruition and find the perfect design for a sustainable product.

For more information regarding the primary considerations in electronic box build services, as well as product layout and manufacturing optimization, speak to one of Sonic Manufacturing’s expert production engineers 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

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High Tech Electronic Manufacturing in the Bay Area

High Tech Electronic Manufacturing in the Bay Area

“Imitation is the purest form of flattery”, said the English cleric Charles Caleb Cotton in the early 19th century. If that really is the case, we should be flattered! What started as a novel approach to beat the trends of sourcing electronic assembly from abroad has turned into a business model now copied by other startups in the Bay Area.

What Sonic Manufacturing has done that is different from everybody else is embrace change in an industry that considers it a dirty word. For companies who are always striving to push down the bottom-line, re-forecasting and order adjustments simply don’t work in traditional, waterfall methodologies. The difference Sonic brings to the table is an agile and lean production process.

Reforecasting at Your Leisure

Change is inevitable, but for supply chain and manufacturing operations, they can be business killers. It’s the nature of the business. Lines require retooling in order to adapt to changes, shutting down production for a period before new runs come online. At Sonic, this isn’t a big deal. In fact, it’s something we thrive on.

Technology Drives the Agile Facility and Manufacturing Processes

We are the leading electronic manufacturing services (EMS) provider in the Bay Area and our ingenuity has prompted other companies to copy our model.

According to a report published by the Bay Area Council’s Economic Institute, production and manufacturing is coming home. The report came 20 years after we had already successfully weathered the offshore storms and delivered a solution to companies that specialize in global innovation.

Innovating Manufacturing Cycles Before the Start of the Millennium

Three men started Sonic in 1996 with a vision that technology could actually deliver on the change-management capabilities it promised. This led to a supply chain solution that is intelligent enough to place 70% of all orders and constantly monitors the data to self-correct according to change.

It also resulted in a factory of 85,000 square feet that houses eight surface mount production lines. While production continues unabated, introducing new prototypes or manufacturing test runs happens with little or no fanfare. Outbound logistics hum along clearing the bays and delivering products in as little as one day lead times.

The Game Changer at Sonic Manufacturing

We provide all the services you may require as a peak production and manufacturing facility, but we don’t scoff at incubators and startups. Using the same assembly lines for both prototypes and the actual manufacturing, we don’t just test your product’s design feasibility—we determine how to build them quickly and cost-effectively, implementing changes rapidly.

New product introductions go through the analysis cycle quickly, speeding up your release to market. Manufacturing products using the benefits of close-proximity sourcing and an international buying office enables us to deliver on time, on budget and at the exact quantities you require.

Sonic Manufacturing Technologies is Essential in the Changing Economy

We serve the Bay Area including San Jose and Silicon Valley as well as Sacramento and Salt Lake City from our headquarters in Fremont, CA. With a seasoned team of experts and a willing attitude to do what’s required, we have provided the industry with a model worthy of copying.

Our services include every facet of the product design and manufacturing lifecycle, including component sourcing and finalization such as packaging and labeling. For electronic manufacturing that delivers quality products quickly, we set the trends that currently drive Silicon Valley’s electronic manufacturing industry.

For expert advice and guidance throughout the new product introduction process, contact Sonic Manufacturing Technologies on (510) 580-8500 or today.

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