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

Tag: design for manufacturability

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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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 sales@sonicmfg.com.

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