Month: October 2018

Five Key Benefits to Rapid Prototyping

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In electronic manufacturing, rapid prototyping is the quickest and most seamless way to reduce the speed to ramp. Electronic products need to be thoroughly tried and tested before they can be launched to market. We provide customers with a working version of their Printed Circuit Board Assembly (PCBA) so that they can check functionality and meet the design specification. Our prototyping, however, goes beyond PCBs; we produce entire complex multi-level system products for our customers, including racks and cabinets.

Key benefits to rapid prototyping include:

 1. Maximise efficiency

When we produce rapid prototypes, we support our customers by engaging early on in their design process with our New Product Introduction (NPI) team. We take time to determine their exact product requirements and we never cut corners in terms of quality, measurement or process. This approach means our customers’ products are made with long-term efficiency, life and cost-reduction in mind, at the point where the design is still fluid and changes can easily be made.

2. Built-in contingency

Wherever possible, we build-in attrition and contingency plans. This means that if anything goes wrong, we can monitor progress and still deliver the full amount of product requested. However, our strict governance protocols and processes are designed to eliminate the risk of problems or failings at every stage, using automation to eliminate human error and increase efficiency.

3. Smooth transition to large scale production

The equipment we use for prototyping is the same we use for volume production. Prototypes are initially created in optimal batch sizes according to each customer’s requirements, which avoid any wastage. When the product is ready, we ensure a smooth transition to large scale manufacturing.

4. Generate accurate labour costing

We have developed sophisticated labour estimate algorithms which allow us to generate accurate and rapid labour costing based on the construction of specific items. Actual process times are measured with set KPIs against these estimates, meaning we can stay on top of progress and ensure everything is realistic and sustainable. 

5. Establish baseline costs with smart software

 We have a custom-developed programme which compares a customer’s bill of materials against our in-house stock base, before filtering this out via APIs to various distributor networks. This is a rapid and effective way to establish baseline costs and sets us apart from many of our competitors, who approach this process manually.

benefits to rapid prototyping

When a technology start-up from the US came to us for help in manufacturing its cutting-edge AR helmet, we relished the challenge. The product design was still at an early stage so we were able to quickly implement robust processes and deliver the product from concept to ramp in the shortest of timeframes.

Simply irresistible: Brexit and the UK electronic manufacturing sector

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Making it easy for others to do business with you is vital, especially in the current political climate

There is no escaping the current headlines around Brexit, from scaremongering over the repercussions of a hard deal or the unknown consequences of no deal at all. For UK manufacturers, indeed for all UK businesses, the most frustrating aspect of this situation is exactly that: the unknown. Knowing the likely outcome and what will happen, won’t happen, or needs to happen is vital: without this knowledge, it’s like walking into a meeting with no agenda or starting a project with no strategy. Business works well within parameters and when it’s driven by facts, plans and targets; this current situation leaves no room to make any such plans, let alone embark upon them.

However, Brexit is not the first defining moment in British business and certainly won’t be the last. The priority now is for ‘UK PLC’, from the political stage down to each and every boardroom, to collectively work to make themselves an attractive business proposition. Whether Brexit is hard, soft or deal-less, the fact remains that we are a nation with goods to give and services to offer. The same goes for businesses: no matter what the specific circumstances or market conditions are, if we shout loudly about what we do, how we do it better and the results we can deliver, the rest is largely inconsequential.

In business, opportunity is everything. Turning every challenge into a door to be opened and a new prospect to be explored is the best way forward. In terms of Brexit, despite inevitable challenges, leaving the EU will present new opportunities and the chance to try new avenues and strategies. This can be translated into business: every challenge encountered is and should be an opportunity to try a different method, whether it’s trying a new supplier, switching to automated processes or opening a new location.

With any business negotiation, it’s crucial to establish what factors you can emphasise or accentuate in order to sell your best strengths and make it difficult for the other side to disagree to your terms. Now is the not the time to be modest: shout about your achievements and showcase your results. That said, it’s also vital to convey a positive attitude and sense of collaboration. No one is going to want to do business with any individual or organisation that seems as if it will be a tricky customer.

Whatever happens with the Brexit negotiations, it’s essential that the UK is perceived as an attractive prospect and an exciting partner: a lesson that can be taken and repeated in every business. Together, if we play our cards right, we could be a force to be reckoned with.

Electronic product testing: Delivering integrity and confidence

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Electronic product testing strategies

The increasing complexity of electronic technology that OEMs seek to produce demands an ever more efficient, agile and precise manufacturing process.

At the same time, OEMs also are looking for EMS partners who can not only deliver this but also offer highly effective test strategies at every stage of production.

And the key words here are strategies at every stage of production.

When it comes to testing electronics there is no universally right or wrong method that can be plucked magically from the hat or pulled ready-made from the shelf.

Instead there are a variety of methods that can be determined only by an analysis of factors such as the profile of risks arising from the specific production processes, the intended use and the throughput requirements. It’s also vital to consider the material characteristics of each component used and of course data arising from current failure mode capture and defect history.

By gaining insight and understanding of each of these elements, it’s possible to determine the most cost-effective testing processes needed to achieve the required levels of integrity.

This is why the increasingly complex OEM demands call for an EMS partner with a variety of testing capabilities and a track record of ensuring integrity in products far beyond the ramp and into the product’s full life-cycle in market.

At Chemigraphic, we do not hold to the oft-cited view that the importance of testing lies solely in ensuring products hit the critical timing required for an orchestrated market entry to maximise market share.

It is true that in electronics manufacturing, product launches can be delayed by faults that should have been identified and resolved much earlier in the production process.

However, testing policy should extend beyond just the physical test process…

OEM product design engineers often define their own test processes and since their primary concern is usually design validation, a version of this can then migrate to serve as the manufacturing test solution.

However, design validation is about methodically configuring, exercising and stressing every area of circuitry, giving confidence that each of the design elements meet the functional requirements. Since the validation tests are often undertaken by the design engineers themselves, they can be complex, requiring deep analysis of signals and timing. They are also often undocumented, use expensive analysis equipment and are manual in nature. Design validation is often a singular non-repeating event, so the length of time taken to perform these tests is largely irrelevant, and a single setup is usually sufficient.

All of this is not operationally efficient and may not even be appropriate, within a manufacturing environment where the key objectives for testing are:

  • To ensure the test captures the actual profile of risks likely at a given stage. In a manufacturing environment, these will relate to construction and assembly, components and workmanship, rather than design.
  • Eradicating redundancy. Testing is an overhead cost and performing tests which do not ultimately capture defects results in the unnecessary waste of time and resource. For instance, if there is some form of signal processing chain, then a designer will want to know how each segment performs and will undertake interim measurements. From a manufacturing perspective, it is more effective to check the output and, if correct, then all the interim stages must be correct by default. The facility to undertake interim measurements as part of a debug cycle to isolate defects is useful, but there is otherwise no need.
  • Simplification. The ideal manufacturing test is a quick go/no-go, pass/fail test that any operator can perform. Hence we try to eradicate any complex software setup/configuration, or interpretation of results.
  • Scalability/ parallel testing. Reliance on a single test setup causes a dependency and potential bottleneck. Investing in an expensive fully automated, high-speed test solution may seem prudent, but if a number of more modest setups can be run concurrently, then the overall throughput and cost-per-test can be better.

A testing strategy with true integrity must future-proof electronic devices not just for launch but for life.

Defects not detected at an early stage of production carry increasing cost implications the later they are detected in the manufacturing process.

Likewise, defective products reaching end customers risk high return costs and incalculable reputation damage.

Both can destroy the bottom line – and both should be avoidable.

The best EMS partners can deliver confidence to OEMs and integrity to their products through a rigorous, flexible and comprehensive test solution.  The earlier a trusted EMS partner gets involved in product development, the better an effective (and cost-effective) test and inspection strategy can be comprehensively defined.

Early engagement lies at the heart of testing integrity and may involve a critical analysis of the product complexity and make up of PCBs, including component density and type. Commercial consideration will also be given to the volume profile, maturity and current stage in the lifecycle of the product.

All of this will ensure that the deployment of a suitable test and inspection solution neatly matches the required new product introduction process.

 

Electronic product testing at Chemigraphic

At Chemigraphic, we offer comprehensive quality control programmes and test services that ensure our customers have 100% confidence in the integrity and functionality of their products before they go to ramp.

Our testing capabilities support the full lifecycle of your product, from design to obsolescence, and include:

  • Inline automatic optical inspection on all SMD lines
  • Endoscope for defect analysis
  • ‘Bed of Nails’ ATE for MDA, or where appropriate, combinatorial testing
  • JTAG – boundary scan
  • Device programming
  • Numerous bespoke functional test rigs
  • On-board programming of electronically programmable devices (EPDs)
  • Safety testing
  • X-ray technology on site

Our services don’t end when your product goes to ramp – we test for its full lifecycle.

Here’s an overview of the range of testing we offer.

AOI

Automated optical inspection (AOI) has been proven to be 65% more effective in identifying faults than manual inspection. With the ongoing progression in HD camera imagery and improved software processing, AOI is getting ever more reliable.

It is also increasingly affordable, making it no longer solely suited to the fully automated in-line production systems of high-volume product profiles. There are now some incredibly reliable and cost-effective bench-top systems for smaller product profiles available.

The latest systems have the capabilities to inspect the decreasing size of components and handle the ongoing reduction in size of PCB technologies on target boards.

Electrical testing

However, inspection alone can leave potential faults undiscovered. It is here that electrical testing is most efficient.

Electrical tests can be divided into two types: process tests and functional tests. Which type you use, or whether you use a combination, depends on the types of faults you are hoping to detect.

For a long time, the In-Circuit Test (ICT) has been the most effective method of electrical testing for high-volume manufacturing processes.

Tests for shorts, opens, missing, polarity, incorrect or defective parts have been laid bare using this bed-of-nails technique. The automated ICT now also allows you to power up the board under test and even perform a level of functional testing, or Boundary Scan, through the integration of testing instruments.

However, there are some drawbacks to ICT, particularly where the manufacturing volumes are not high. The cost of fixturing and programming can be high, and the need for test point access which requires ground up design for test (DFT), adds further to the testing investment.

Another option that offers an alternative to the one-off set-up costs of ICT is the Flying Probe (FP) system. This is ideally suited to product profiles that are lower.

Such systems vary in capabilities greatly, ranging from basic MDA (Manufacturing Defect Analysis) to the inclusion of Boundary Scans. The major advantage of FP is the relatively low cost to the OEM: as no fixturing is required and only a test program needs to be written. The best FP systems offer many of the same capabilities as ICT.

X-rays

Many products, however, will require an extra level of testing beyond those already discussed. For devices with hidden joints, such as BGAs and POP, AOI will not reveal voiding which can lead to product failure when being used.

X-Rays offer the best ability to detect such structural defects in solder joints. They can also be used to enhance fault detection in components themselves and in high density connectors.

Maximum test coverage – minimum opportunity for error

Chemigraphic offers a variety of tests that can be used in combination according to each product’s requirements. We maximise our test coverage to minimise the opportunity for error.

This offers you 100% confidence when products go to ramp and build in the integrity products need for their full life cycle.

From hackers to Brexit: the challenges facing defence manufacturers today

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The UK may have the world’s second largest aerospace and defence industry but it is facing some of the toughest challenges in its history at the present time. Cyber-security threats, Brexit and manufacturing challenges related to the hazardous environments its products are used in are three major obstacles to growth.

Yet help in overcoming these may be much closer to hand than defence OEMs (Original Equipment Manufacturers) imagine.

Here’s how partnering with the right manufacturing partner can help OEMs rise above the biggest challenges they face.

Data and cyber-security challenges

All UK manufacturers are under threat from professional cybercrime gangs looking to access intellectual property, but it is defence manufacturers that are the main target for hostile nation state actors.

Such hackers typically work on behalf of a government to disrupt or compromise defence OEMs. Their ultimate goal is to try and access classified information about military technology.

Nation state threats are thought to only make up about 10 percent of all cyber-attacks worldwide. Their impact, however, is disproportionately large: they are the hardest attacks to resolve and the trickiest to detect, and they are increasingly causing more and more disruption. SecureWorks research suggests it is taking five times longer to fully evict a nation state attacker from a network every year.

The Bronze Union is the nickname given to one such group of hackers. They are believed to operate for the Chinese government and, in recent years, they have made several high-profile attacks on defence manufacturers. One infiltration technique they use is a Strategic Web Compromise (SWC) – a targeted attack which infects websites that employers visit and lures them to access a malicious site.

Yet, attacks are not always as direct as this. Such groups are adept at locating and exploiting vulnerabilities and weaknesses in the OEM’s supply chain as well as its employee’s browsing habits. The notoriously aggressive NotPetya attack used trojanised updates via widely-used software to infect the PCs of organisations across the world, but particularly in Ukraine. The perpetrators are believed to have been working on behalf of the Russian government.

Never has it been more important for defence OEMs to partner with EMS providers who take the inherent risks of security threats with the same rigour as themselves. As we move into the full-scale implementation of Industry 4.0 new entry points can be exploited in IoT devices themselves as well as through the sheer volume of data that is being stored in the cloud. With so many sensors and data collection points now being installed within military devices and products there is now another layer of risk potentially embedded in each device that is shipped into service.

Challenges facing defence OEMs - Surveillance

Brexit and funding challenges

Not every threat facing the defence OEMs is a veiled one issued from the other side of the world. Perhaps the biggest challenge today is emerging from sources closer to home. The disruption to established trade relationships that Brexit may bring about has the potential to cause more severe losses than even a major malware incident. With more than half of its turnover realised through export, any losses from the UK defence sector’s overseas market will have resounding repercussions.

The UK’s standing and relationship with European Aviation Safety Agency (EASA) and the European Open Skies regime (ECAA) are still under question. If not quickly resolved, these could deliver a serious blow to the industry.

A further risk is the loss of EU grants and funding sources that the UK defence sector has enjoyed. These include $500 million each year that is potentially available from EU Defence Research and Development grants and EU space research funding, which is valued at around $15 billion over the next few years.

The possible disruption to the UK’s role as a part in the EU supply chain could wreak as much havoc as the loss of funding – and, given the UK’s persistent shortage of engineers, any barriers to the movement of people would have a similar negative effect to the movement of goods.

The way that Brexit will pan out is notoriously hard to predict – but it is clear that now is the time for OEMs to look to consolidate their supply chains to ensure they are operating at maximum efficiency.

And being highly selective in choosing EMS suppliers to partner with will play a significant part in achieving this.

Hazardous environments and manufacturing challenges

The most immediate way that contract manufacturers can support defence OEMs through the challenges that face them has nothing to do with politics or crime. Increasingly there are complex manufacturing requirements that must be met by electrical components used in defence products. An ongoing challenge facing OEMs relates to the environment their products will be used in.

Electrical components used in situations involving explosive atmospheres or flight require a number of extra measures to ensure they are robust enough to survive. In such conditions, adhering to Intrinsically Safe standards is vital, and something that the EMS partners chosen must be highly skilled and experienced in.

With any manufacturing process, it’s essential to keep comprehensive records, and this is particularly critical when it comes to developing products for the defence industry. As so many complex conditions and procedures are involved, every step in the manufacturing process must be accounted for, with the correct documentation and certification where required.

Only an EMS partner with a sophisticated data network can monitor and track this – and tracking this is just as critical to a successful product launch as the manufacturing process itself.

Overcoming challenges

Working with a trusted and experienced EMS partner can reduce many of the security, efficiency and manufacturing risks that defence OEMs face.

Yet, the industry will also require more than a robust and well-managed supply chain and highly-qualified manufacturing partners.

Defence is far from an open market and the success of the UK’s defence industry is closely associated with the level of government support it receives. Whatever the effects of Brexit may be, economic diplomacy that embraces military sales, must be seen by the UK government as a strategic policy tool to win the hearts and minds of friendly foreign states.

What does the IoT mean for Electronic Product Manufacturing?

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Manufacturers are leading the way as early adopters of the Internet of Things (IOT). Connectivity, constant communication and data sharing are being used to achieve a greater automation of tasks, a more responsive process and greater efficiency throughout.

The consumer market for IoT may hit the news more regularly but behind the scenes the real developments are taking place in manufacturing.

Within Electronic Manufacturing Services (EMS) all types of machinery are already embedded with sensors, switches and intelligent controls to generate data that is collected in real-time, analysed in the cloud and acted on immediately – and often automatically.

But the benefits of IoT do not just stop at the factory floor. Data on the performance of products, the supply of materials and despatch logistics are creating a smart supply chain that stretches from vendor to consumer.

The IoT is here

The IoT is already transforming manufacturing.

  • According to the latest IDC data manufacturing is spending $178 billion a year on IoT – and that’s more than twice as much as transportation, the vertical with the second largest spend.
  • It is predicted that manufacturing will lead the way in IoT innovation and implementation all the way into 2020 and beyond.
  • Research firm BI Intelligence expects the number of connected machines in manufacturing environments to increase four-fold – from the 237 million there were in in 2015 to 923 million in 2020.

Let’s take a look at what the IoT is being used for in the EMS sector.

What does the IoT mean for EMS - smart device

What the IoT means for EMS

Here are the smart ways that the IoT will transform EMS providers.

Smart ordering

Data can be streamed from sales to production, creating an autonomous assembly line that automatically reconfigures itself to produce products in small batches as demand arises.

Smart production

Productivity can be optimised by communicating data about system health – and machine learning can automatically act on this for plant-wide process control and maintenance.

Systems can be automated to adjust manufacturing sequences and speeds to help balance lines and match production more closely to customer demand.

Smart supply chain

The IoT can facilitate a transparent supply chain. The production-system portal can be accessible beyond the organisation’s boundaries, to allow suppliers to track consumption and quality issues in materials, for example.

Smart QC

IoT sensors and advanced analytics can make it possible to detect even the smallest error or defect during production, giving EMS providers more control over their output.

Smart fixes

Currently, most manufacturers address production issues or equipment failures as they arise, but with IoT and machine learning, systems can be automated to intelligently identify and address issues on their own without the need for human intervention.

Smart H&S

Early detection of malfunctioning systems – thanks to sensors and connected devices – can help prevent injury to employees who would have otherwise been unaware of the situation.

PCBs, ICs and the IoT

Before we get too transported into a Brave New World, it’s worth considering some of the challenges that the introduction of the IoT may bring.

Not least of these is the need to identify new protocols and standards across the supply chain.

To illustrate this, here’s some news from the frontline of IoT implementation that may serve as a cautionary tale.

The IoT is poised to enable the linking of wafer fab to the printed-circuit board factory.

EMS companies are increasingly manufacturing products with components such as bare die, MEMS, and optical devices, requiring more IC-like assembly equipment, precision placement processes and two-way communication between tools and factory systems.

In many ways this is blurring the distinction among EMS companies, OSATs and foundries.

Paula Doe, of SEMI, recently called for EMS providers to consider adopting the sort of automation standards already used in wafer fabs if they are to succeed in realising the potential of smart manufacturing.

She argued that vendors must collaborate to ensure their production equipment interoperates and supports factory analytics and data management systems.

This is an interesting snapshot of our times, revealing both the gains and challenges that IoT offers.

  • Firstly, it reveals how electronics assembly production has advanced beyond ‘board stuffing’ and is now more akin to fabricating ICs.
  • Secondly, it shows how production tools’ ability to communicate with each other can really start to blur the traditional boundaries in manufacturing: what once were discrete operations are increasingly being merged and integrated, creating ever greater efficiencies.
  • Finally, it shows some of the challenges that the IoT’s introduction can create. With more systems talking to each other throughout the supply chain there is an obvious need for a range of industries to come together and adopt common standards. Without these there is a very real danger that the full benefits of IoT won’t be realised.

For all the opportunities the IoT offers us, it’s just as important to remain aware of the challenges we face in the present as the potential it promises to deliver in the future.

Six Reasons to Outsource Electronic Manufacturing

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Manufacturing

The decision to outsource manufacturing can be daunting. Production needs can often be met in-house however, if there is an increase in demand, your organisation may need additional resources. Whether you’re a start-up or an established business, you may want to weigh up a number of factors before you take the leap. We’ve outlined the six main benefits to outsourcing manufacturing below:

1. Flexibility

If you experience a surge in orders for a particular product you may require additional resources to keep up with demand.

A contract manufacturer will often have more production capacity and be able respond quickly, supporting existing in-house manufacturing efforts and helping to fulfil orders without increasing direct labour costs.

It may be counter-intuitive, but larger manufacturing operations running high mix, often have more options for flex.

2. Expertise

Outsourcing manufacturing will allow you to take advantage of specialised contractors’ industry expertise and innovation. Typically they will take a strategic approach to your existing processes, recording your activity and suggesting ways in which to standardise production, improve accountability and increase efficiency.

A mid-size OEM might introduce 10 or 20 prototype designs in a year, whereas an EMS could deliver up to 500. This creates exposure to a vast range of technology, which demands a significant upscale of capability, systems and processes.

3. Scale

Mid-size OEM in-house manufacturing operations might support 20 different products totalling £2-3m in manufacturing costs. However, an EMS of scale can support 1000-2000 different assemblies totalling £20-50m in value.

This means an EMS organisation has ample justification to invest in the very latest of high-speed, automated equipment, which is often beyond the reach or justification of an individual customer.

Of course, the equipment is just half the story, as scalability also brings opportunities for sophisticated high-operational efficiency processes across the delivery of high volumes.

4. Cost

Outsourcing can provide significant savings on associated manufacturing costs including quality control, utilities, shipping, material handlers and equipment technicians.

Material spend is another significant factor. Consolidating several OEM material spends at an EMS creates a x10- x100-fold increase in spending power, providing direct access to global manufacturing channels and cutting out the proverbial ‘middle man’. This means EMS partners can overcome minimum order quantity (MOQ) restrictions, and access the very best price breaks.

Also, larger EMS material spending power means that components can be sourced in machine-friendly formats which increase automation and traceability, further enhancing product integrity and overall performance.

5. Efficiency

Your core competency as a business may not necessarily be manufacturing, in which case, outsourcing this non-core activity will help you to focus on what you do best so that you can increase revenue and profit.

6. Quality

International standards usually ensure that every aspect of the contract manufacturer’s business is well-run and subject to high quality control. OEM in-house manufacturing staff, though competent in many areas, may lack knowledge of the latest systems and technology needed to deliver the standards you require on a larger scale. Outsourcing to a partner with the capability and most up-to-date equipment will improve the final output, increase efficiencies and reduce costs in the long-term.

The key is to find a contract partner with the skills and knowledge to streamline your existing processes; enabling greater efficiencies and providing scalable solutions. Chemigraphic is adept at working with businesses to formalise the manufacturing process, eliminate inconsistencies and introduce product standardisation.

Read on for a detailed example of how Chemigraphic enabled Hydro, a leading provider of hi-tech water management solutions, to transition from self-manufacture to a sophisticated process-led approach.

Q&A with Margaret, Inspector & Auditor

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QA

Q&A: Margaret, Inspector & Auditor

  1. How long have you worked in the industry?

Just over 22 years! I was working elsewhere in the Electronic Manufacturing Services (EMS) industry for five years before joining Chemigraphic, and have now been working here for over 17 years.

  1. Why did you choose to work in this field and in the manufacturing sector in particular?

I have been working in final assembly for several years and therefore becoming an Inspector and Auditor was the next step in my career path. The role requires a high amount of experience as it involves managing one of the key quality checks carried out throughout the manufacturing process. Due to my long history in the field, I was offered the position which I gladly accepted.

  1. What do you love about your job?

There are many things I like about working for Chemigraphic. My role as Inspector and Auditor allows me to work somewhat independently as I am able to manage my own workload and prioritise jobs that I really enjoy.

I also love working here as it has a wonderfully friendly environment, where everyone involved feels part of the same big project. It is important to me to enjoy where I work, which explains why I have been here for so long!

  1. Describe a ‘typical’ day for you.

I inspect and audit Printed Circuit Boards (PCBs), checking the quality of assembly and ensuring that all the components are correctly placed. We check to see if there is any damage or polarity on the boards and their components. At Chemigraphic, the quality of our products is vital to our customers and therefore the business; we have several systems and control processes in place to check for product quality and to confirm they will be fit for purpose. Many of the products we manufacture are used in hazardous environments, or in defence or healthcare industries, and therefore their long-term reliability and functionality is critical.

  1. What’s been your proudest achievement in your career so far?

One year ago, I became the team leader which was a great experience and allowed me to achieve an NVQ in team leadership.

  1. What’s the biggest change or development you’ve seen since working in the industry?

A technological development that has improved efficiency is the move towards a paperless package, which allows us to look through the assembly instructions and specifications far quicker.