electronic product manufacture

Systems Integration: More than just a box of tricks

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Box-building is typically used to paraphrase the challenging stage of bringing together the many components within a single, ready-to-go product. This idea of simply connecting up various elements to create a box of tricks remains one of the EMS industry’s most understated descriptions. It remains a highly complex manufacturing process where the expertise and facilities of your EMS partner makes a big difference to your final product. Most importantly, this expertise begins before the box is even designed…

 The term ‘systems integration’ provides a more meaningful description of how Chemigraphic brings together custom PCB assembly with sub-assemblies and modules, enclosure design, fabrication, cabling and wiring. We transform these elements into complex, multi-tier systems – often sophisticated machines – and make ready through testing, software, programming and calibration.

Below are some key considerations regarding the systems integrations process.

PCB assembly should be a core offering

By offering PCB assembly (PCBA) using both Surface Mount Technologies (SMT) alongside conventional Pin-Through-Hole (PTH), it’s possible to check and guarantee the quality of components within the system. We are the only UK EMS to use automated JUKI SMT kitting machines and the automation allows us to build to specification, removing the opportunities for human error and reducing labour costs. We have unrivalled component management systems which allow us to place components in the most detailed configurations, meaning we can assist customers with any project, no matter how complex.

Think about the box build early on

Enclosures and casings are essential components of System Integrations – plastic and metal, or combinations. There are many off-the-shelf choices available, often with the advantage of lower unit prices and small minimum orders, but rarely this is without sacrifice – it won’t be unique, the components may not fit correctly, and there’s always the possibility a supplier might modify or withdraw the product. The need to fit PCBs securely alongside other electronics, modules, wiring and fans often drives our customers towards bespoke enclosures.

Since plastics and polymers are most commonly used it’s critical that an EMS supplier understands the differences between materials and manufacturing techniques. For instance, ABS is only suited to indoor environments as it will be compromised by prolonged exposure to sunlight, whereas ASA+PC resists high temperatures and harsh environments. New techniques such as MS-MMM injection moulding can incorporate soft-touch textures and colour, which avoids the use of different suppliers. It’s the job of an EMS provider to pass on this knowledge as customer benefits in the form of shorter, more reliable supply chains and economies of scale.

Chemigraphic also incorporates any metalwork using only carefully vetted suppliers of precision-fabricated materials. Coatings may be necessary to protect both the casing and components against the weather, corrosion, conductive or toxic dust particles, water and general contamination. In these instances we use automated equipment to apply protective coatings to selected board locations, increasing efficiency and reducing both the opportunity for human error and labour costs.

Don’t get in a tangle with wiring

The complexity of cable and wiring can vary enormously between System Integration projects, from a few wires stripped, twisted and tinned to complex harnesses with more than a 1000 ends and a multitude of terminations. Most projects require customised wiring – lengths, colours, special pin-outs, identification, connectors, etc. Our automated cable ‘cut and strip’ machines can accommodate low-volume complex harnesses through to medium-volume cable assemblies. Via our Shenzhen office, we can source and co-ordinate the entire supply chain with certifiable traceability.

Off-the-shelf still requires customisation

Many customers choose to make use of widely available Commercial Off-The Shelf (COTS) modules – boards and mezzanines, controllers, HMIs and displays, power supplies, etc. Development costs and timelines can be reduced using pre-tested sub-assemblies, but should be balanced against higher unit costs and possible compromises on functionality. We’ve found the most successful system integration projects take a hybrid approach, using both COTS and custom-builds to best fit the customer’s immediate and future requirements. It is rarely true that by purchasing a COTS product, no bespoke work will need to be performed. Chemigraphic has a wealth of experience integrating and combining COTS modules into larger systems. We use our Asian sourcing office to gain attractively-priced components.

Take extra care with moving parts

Electro-mechanical assemblies containing switches, electronic controls, gears, rollers, etc, contain moving parts and are inherently more challenging. Conflict with other parts especially from different manufacturers are routinely discovered. Chemigraphic has knowledgeable, specialised purchasers who are in touch with the global components markets. We use CAD 3D modelling equipment to improve the design process and have a well-equipped inspection area containing microscopes and electrical testing devices.

Honey, we shrunk the circuits: The amazingly small electronic products

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Electronics are shrinking.

Don’t let the rate at which smartphones have grown since the early years of this millennium fool you.

(Source)

The future of electronic products is to get smaller and smaller.

And these smaller devices will offer ever greater capabilities while using less power.

Smartphones’ growth in size belies this trend, but it’s a reflection of the fact that they have taken on the role of so many other devices.

It’s the need for a bigger screen that has led to their burgeoning size.

But look how slim they have become as their screen size grows.

(Source)

Consumers want smaller gadgets that can do more – and do it quickly.

So, the smartphone has become a pager, powerful camera, video recording and editing device, media player, sat nav, eBook reader, personal organiser, word processing tool, games machine, credit card, scanner and a lot more besides.

Less is Moore’s Law

The journey towards miniaturisation is being aided by advances in screen and battery technologies, but sitting right there in the driver’s seat are developments in components and circuits.

And it’s not just consumer goods that are getting smaller and smaller – this trend extends to industrial technology too.

Wherever you look less is more, and this is known as Moore’s Law.

Moore’s Law has held true for nearly 40 years now.

In truth, it’s more an observation than a law. It suggests that electronic devices will double in speed and capability about every two years.

What Intel co-founder Gordon Moore actually predicted was that ‘the number of transistors incorporated in a chip will approximately double every 24 months.”

And transistors are the tiny electrical switches that lie at the heart of any electronic gadgets you can think of. As they shrink they also get faster and consume less electricity.

Moore’s Law in effect

(Source)

It’s not just transistors that are shrinking, however.

The humble capacitor was once, in the 1970s, made from bulky axial leaded parts. These were replaced by the slimline 1206 ‘surface mount chip package’ which, at the time, appeared to be an impossibly microscopic 3.2 x 1.6 mm. But now we have 01005 packages, offering a further volume reduction of 98.5% and measuring just 0.4 x 0.2 mm!

Similarly, it wasn’t all that long ago that the tiny 60 x 60 mm IC (silicon chip) device, with 160 connection pins around the outer perimeter, was considered cutting-edge. Yet, its equivalent is now the 30 x 30 mm ‘micro-ball grid array’. This sits on a matrix of 900 solder sphere connections – and requires the use of an X-ray to fully inspect.

In recent years many have wondered if Moore’s Law is coming to an end, as components meet the limits of possible shrinkage.

Companies like Intel can mass-produce transistors 14 nanometres across – that’s just 14 times wider than a DNA molecule. They’re made of silicon whose atomic size is about 0.2 nanometers.

With transistors hovering at about 70 silicon atoms wide, the possibility of making them even smaller is starting to shrink.

We’re getting very close to the limit of miniaturisation.

We’ll return to this in a moment – first, let’s take a look at why small is considered so beautiful.

The miniature revolution in electronics

The miniature revolution in electronics is being driven by:

  • Aesthetic demandsWe have come to expect our tech devices to be design-statements and things of exquisite beauty.
  • Portability

    Our wireless devices should be easy to take with us. Light weight devices are enabled by the miniaturisation of components and PCBs, reduction in battery sizes and developments in plastics and metalwork.

(Source)

  • Cost savingsWhile cutting-edge miniaturisation can come at a premium, the use of less materials usually provides a reduction in cost in the long-term. Especially when the electronics industry absorbs and adopts innovations and the production costs for increasingly smaller parts shrinks correspondingly.
  • Eco-friendly power consumption reductionsSmaller parts use less power. This reduces running costs, extends battery life and offers greener products.
  • Less heat dissipationAs smaller parts consume less power, they lead to electronic products which generates less heat. When heat dissipation requirements are sufficiently reduced this can avoid the need for bulky heatsinks and mechanical fans. This, in turn, further reduces weight, cost, power consumption and intrusive noise.
What impact have smaller components had on electronic manufacturing?

(Source)

From an EMS and product manufacturing perspective, perhaps the most significant impact of this reduction in scale is the increased need for automation and use of robots.

The sophisticated soldering technologies now required to fit components and parts is no longer possible by hand. The precision required can only be carried out using high-tech equipment operated by skilled engineers.

It’s not just production that has become increasingly automated.

With components getting smaller and smaller they become, to the naked eye, identical. Many components no longer have any space to carry distinguishing codes or other markings to aid identification.

It has never been more important that your EMS partner can offer you a fully traceable and trackable supply chain and uses barcodes and sophisticated machines to inspect, select and verify (as well as place) every component used. Robust materials control is essential at every step of the supply and manufacturing process.

Are our shrinking days no Moore?

Many industry commentators have suggested in recent years that the gains we have enjoyed under the rule of Moore’s Law may be coming to an end.

Of course, we all believed things couldn’t get any smaller many times in the past.

But they did.

What’s different today is that we really are reaching the point where physical components are constrained by the demands of matter.

So, what’s next?

Some interesting developments that suggest we haven’t exhausted the potential of further miniaturisation include:

A team led by Robert Wolkow had long-known how to reduce circuitry to an atomic scale, but they have only recently found a way to perfect a technique that allows these circuits to be mass produced.

They suggest that this breakthrough could help manufacture smartphones that operate for months between charges and computers that run a hundred times faster but use a thousand times less power.

It looks like it may still become a smaller world after all.

Robotics: why are some manufacturers still afraid of the Big Bad Bot?

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The idea of a human-looking robot has been a staple of science-fiction for decades, and of mythological imaginings since as far back as the Ancient Greeks.

It is only in the last few years, however, with the recent publicity for Boston Dynamics, that this dream appears to be finally coming close to fruition.

Videos of Atlas the robot jogging through parks and practicing parkour in industrial sheds, or their ferocious military dogs resisting human kicks, are enough to send shivers down anyone’s spine.

atlas the robot

Source

The word robot comes from the Czech for ‘forced labour’ (robota) and much of the fear that exists in the manufacturing sector relates to the relationship between robots and employment. As  a Forbes’ commentator recently put it, ‘Robots Will Take Our Jobs And We Need A Plan’.

But what do we really have to fear from robots – and what do we have to gain?

When does automation become robotics?

Sorry to disappoint, but robots are nothing new.

The reality is that robotics – or at least advanced automation – has been widely used in manufacturing since the 1970s.

The machines just didn’t look particularly humanoid.

Robotics is automation plus AI. It’s the recent advent of the Internet of Things and machine learning that is increasingly making today’s robots so useful and, for some, such a threat.

The difference between robotics and automation is one of degree: automated machines perform a single set of operations but robots can smartly change their behaviour – by learning from sensory feedback or data feeds – to achieve better efficiency.

A brief history of robots in manufacturing

George Devol applied for the first robotics patents in 1954: his company Unimation were using robots to move items since 1956.

Automotive production lines were early adopters using machines to carry out repetitive processes which require high amounts of consistency such as spot welding and spray coatings.

Sophisticated robotics in logistics hubs and warehouses have been directing goods for dispatch for many years.

Today, robots are widely used in manufacturing, assembly and packing, transport, earth and space exploration, surgery, weaponry, laboratory research and the mass production of consumer and industrial goods.

In our own EMS industry, printed circuit boards are almost exclusively manufactured by pick-and-place robots, typically with SCARA manipulators: and as electronic components get smaller the need for smarter, more precise robots will only increase.

According to figures from the International Federation of Robotics the trend suggests there will be a dramatic increase for all.

Estimated worldwide annual supply of industrial robots (in units) (Source)

Today there are more than 2 million industrial robots in use – and it is expected there will be 3.8 million by 2022.

The biggest users of these are:

  • The automotive industry (33%)
  • The electrical/electronics industry (32%)
  • The metal and machinery industry (12%)
  • The rubber and plastics industry with (5%)
  • And the food industry (3%)

(Source)

What do robots bring to the table for electronics?

With the disruptive force of robots bearing down very heavily on the electronic manufacturing industry – and with IOT, data and AI looking set to increase their presence – now is a good time to take stock and review exactly what robotics is bringing to the table.

In relation to PCB manufacturing, robots can place hundreds of thousands of components per hour, far out-performing a human in terms of speed, accuracy, and reliability. As electronics shrink in size, the precision of robotic production methods becomes essential.

Robots can do much more than just build, place and weld. They can also quickly and accurately check all the components to ensure they match the required spec and are placed accurately.

As IoT sensors become ever more prevalent, the benefits start to really add up.

Using data from connected, always-on devices robots can respond to situations in real time. Our machines become not only faster and more precise, but also smarter and more aware. A robot can speed up or slow down based on its surroundings or the timing of small-batch production cycles. And it can collaborate with others to work more intelligently.

Here are some of the benefits that robots are already delivering.

  • They can work in environments dangerous to humans (such as deep sea, space or in hazardous environments.)
  • They can work faster and with more precision than humans.
  • They can create efficiencies throughout the process, from raw material handling to finished product packing.
  • They can be programmed to operate 24/7 – in lights-out situations – for continuous production.
  • Robotic equipment can perform complex functions and is absolutely essential for the latest generation of smaller products.

Why are we still afraid of the Big Bad Bot?

The threat of the robot – the opening scene of Terminator (Source)

Despite these obvious advantages, there remain three big fears that continue to hold back electronic manufacturers from embracing robots.

We touched on the first of these before: namely, the fear that robots will steal our jobs.

The second is the initial cost of introducing them.

And the third is the cultural and procedural changes that robotics inevitably demand.

  1. Consider the following, in relation to the ‘forced labour’ of robots stealing our jobs.

The cost-efficiencies of robots can help companies become globally competitive once more. They can reverse the trend of offshore production and create jobs by reshoring manufacturing work.

They protect workers from repetitive, mundane and dangerous tasks, while also creating more desirable jobs, like engineering, programming, management and equipment maintenance. By freeing up manpower manufacturers can maximize workers’ skills in other areas of their businesses.

As a recent McKinsey report put it:

‘The production systems of the future will still require people in many of the roles they hold today, but the nature of those roles will change. Operators will need new capabilities as low-skill tasks are automated and increasingly sophisticated equipment requires skilled people to run it.’

Robots will not steal our jobs. They will enable us to gain skills and compete more effectively for work we had lost.

  1. Consider these factors in relation to concerns over costs.

 Robots used in manufacturing tend to achieve ROI quickly, often within two years, thanks to their throughput and output gains.

Their upfront cost is quickly recouped.

Manufacturing robots are much more affordable today than ever before. Standard robot models are now mass-produced, making them accessible to smaller scale businesses.

And robotics as a service (RaaS) lowers the barrier even further, offering the rental or temporary acquisition of hardware to keep costs more manageable.

  1. And, finally, in relation to the fear of change.

 The barrier for entry has been lowered not just for cost. It has also been increasingly lowered in terms of the technical understanding and skills required to introduce robots to the assembly line. Plug and play installation is now very much a reality.

Nevertheless, the investment in the robot itself still remains only part of the equation. Resources must be committed to training and consistent optimisation, possibly over many years.

Robots also usually require a cultural shift. Fully integrating robotic solutions may well require fundamentally changing the way a business operates. Their disruptive potential can introduce changes to software platforms, material consumption, supply chains, ERP, MRP and even the working culture of a business.

Yet, the real question is are these changes for the good?

Do they introduce enhanced capabilities, realise efficiencies, result in cost-savings and create better products?

And the answer, we believe, is a resounding yes.

How Chemigraphic is using robotics to deliver the services today’s OEMs require

These are exciting times.

Times when we know we can continually enhance and improve the services we offer.

Robotics and IoT capabilities are an important part of this, but it’s investment in skills, talent and staff that ensures new technologies are optimised and effective.

Additive manufacture is already commonplace for us in areas such as enclosure development. It is also being used for immediate applications in some very niche technologies, such as specialist antennas and waveguides.

We continually monitor progress and developments in this for use in other fields, and our Design Centre collaborates closely with our customer base to take advantage of new technologies.

Our inspection tools are becoming ever more sophisticated.

Many years ago, simple comparator inspection systems – which look for differences between a stored image and the item being inspected – were superseded by inline Automated Optical Inspection, with 3D scanning and X-Ray capabilities.

Wireless monitoring systems are extensively being used to remotely check a range of conditions, including stock on shelves, reels on feeders and temperature or humidity in production areas.

And, as more RF-ID and IoT sensors collect increased amounts of data, we expect to introduce new automated tracking and production systems.

We have already developed libraries of complex database analysis and metric capture tools. These are displayed on dashboards and allow performance indicators to be assessed and immediately responded to. Machine learning and automated responses will be increasingly involved in our monitoring and decision-making over the coming years.

We’re not afraid of robotics

At Chemigraphic, we welcome the efficiencies and productivity gains that the further integration of robots, artificial intelligence and data capture will bring.

We intend to continue to harness this to deliver better service and better products.

We are not afraid of the Big Bad Bot! Are you?

How OEMs can best manage the issue of component obsolescence

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What are the biggest challenges facing OEMs today?

The usual suspects staring at us from a long line-up include:

  • Brexit and risks of disruption arising, in many different guises
  • The rise of electronics industries in low cost geographies such as Asia
  • The rapid pace of tech change
  • The concurrent need for faster production lead times

Critical though these issues are, it can be easy to overlook seemingly ‘day to day’ challenges that in reality, can have a catastrophic impact on the supply chain and the manufacturing process.

Sudden limitation of supply is currently a very hot topic and worth of an article on its own, but  outright component obsolescence– and the need to manage the risks it poses – is a specific associated problem that many OEMs tend to overlook, or at least fail to sufficiently prepare for.

The accelerated risk of obsolescence

The diminishing lifetime of electronic components is undoubtedly an issue, especially for those supplying the high-reliability medical, aerospace and defence industries.

The embedded systems used in these products are designed for a long working life. Electrical components, however, increasingly aren’t.

For defence OEMs in the past, obsolescence could be circumvented thanks to the volume and buying power they enjoyed. This is no longer the case.

Time and time again we see chip manufacturers placing products as end of life (EOL) that are required by high-reliability market providers. The simple fact is that usage is now so small compared to other more profitable product lines.

 As the life cycles of components shrink, we see counterfeiting risks growing.

To meet the swelling demand for disappearing parts – and avoid redesign and recertification requirements – some OEMs are relying, wittingly or unwittingly, on grey markets and counterfeit components. This situation is fraught with its own considerable risks.

 Another factor that is leading to increased obsolescence is the rash of mergers and acquisitions throughout the supply chain.

This is occurring as component suppliers look to enhance their offerings to meet the demands of new emerging markets such as Electric Vehicles, Smart devices and the Internet of Things (IoT).

With every purchase or partnership, the risk of component obsolescence increases. More products are struck off the list as lines are reviewed, rationalised and trimmed.

 The after-effects of mergers and acquisitions has led to unwieldy and complex supply chains.

These create problematic, diffuse communication channels that can lead to missed notifications, poor communication and increased lead times.

Other causes for component obsolescence include:

  • Lack of demand, making it unwise for manufacturers to continue their support
  • Suppliers going out of business or a catastrophic accidental damage to stock
  • Diversion of raw materials into other more lucrative areas causing legacy support to become less attractive

Many components are retired simply because they have been superseded or no longer satisfy the increasingly stringent demands of legislation.

For instance, updates to the European Union’s regulation for the restriction, evaluation, and authorisation of chemicals (REACH) and the directive for the restriction of hazardous substances (RoHS) caused many EOL notifications.

What are your options when component obsolescence occurs?

 Notifications can be easily missed or offer a very limited time for decision making.

Component manufacturers issue stock obsolescence risk flags including:

  • Product change notices (PCN)
  • End of life (EOL)
  • Last-time buy (LTB)
  • Last -time ship (LTS)

However, if OEMs are not relying on a partner to monitor these for them, such flags are notoriously easy to miss.  And some estimates have placed the proportion of components going EOL without any notice at all as high as 40%.

Often parts may only be ‘technically’ obsolete but still available under a different part number.

It’s vital that all parties understand the market and technological dynamics that can lead to physical parts being renumbered following a change in supplier or manufacturer. Once again this requires in-depth knowledge and monitoring of the entire supply chain.

By working with a manufacturing partner which is dedicated to watching the market for signs of change and has the knowledge to react to this and find suitable alternative routes, this process can be managed effectively without compromising timescales or cost.

Thankfully there are data-driven software tools that can scrub your Bill of Materials (BoM) and highlight any at-risk components.

Such predictive tools will reveal both EOL components and identify components considered at high risk of becoming obsolete. From here, of course, you can make the decision to identify last-time buys or replace the component.

The importance of an expert EMS partner

OEMs tend to focus on designing function, validating their creations and developing peripheral items, such as a functional test regime.

Yet the ultimate commercial success of any electrical product hinges just as much on having a fully developed and sustainable supply chain supporting it.

Even the most radical designs often have their roots in existing circuit architecture.

Your contracted manufacturing partner can scrub the existing BoM to suggest changes required – it is often tried-and-tested components that slip under the radar.

The risk of obsolescence can be mitigated by engaging early with an EMS partner which has an expert overview of all the current developments in the material market.

Of course, this early engagement in design is critical for optimising performance as well as managing obsolescence. Your EMS partner can help guide you to optimised materials selection while the design is still fluid. Once the product has undergone extensive regulatory validation it rarely remains cost-effective to make changes to minimise component life cycle risk or to improve performance.

In addition, trusted EMS partners will not only flag obsolescence risk. They will also be able to mitigate this risk before it occurs with viable and appropriate alternative suggestions, ensuring 100% BoM compliance.

In today’s dynamic global marketplace, reliable sources can suddenly come to an end. Only EMS partners with an entirely robust customer authorisation process can ensure compliance in all circumstances.

Part obsolescence cannot be avoided – but it can be managed, minimised and mitigated

Today’s rapidly changing supply chain will continue to throw up obsolescence challenges for electronics manufacturing.

That much is inevitable. But, by partnering with someone who offers you access to a robust, trusted supply chain you can minimise risk and maximise viable, cost-effective solutions.

With sound planning, a pro-active approach and long-term vision – along with solid, best in class supply chain partners – the threat of component obsolescence certainly loses its bite.

To learn more, read about Chemigraphic’s approach to effective component sourcing and supply chain management.

The disruptive effect of electronic devices on the transport sector

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“We now find ourselves at the gateway of a revolution in transport technology, the likes of which has not been seen since the invention of the combustion engine. These technological advances will create a new way of planning and managing our transport.”
Steve Yianni, Transport Systems Catapult

A perfect storm is set to hit the transport sector – and it’s not yet exactly clear where or when dry land will be reached.

Among the forces that are set to shake things up by creating new opportunities are advancements in electronic manufacturing. It’s time to chart these innovations and review exactly what their disruptive effects may be.

Before we do this, however, it’s important to note that it takes more than one weather front to create a perfect storm. The other forces bearing down on the sector are all directly or indirectly with these innovations.

They include:

  • The pressures of continued urbanisation
  • The increasingly sophisticated capabilities of automation and machine learning
  • The urgency of environmental concerns
  • The rise of the Internet of Things (IoT) and the power of cloud-based analytical tools
  • The switch back to public or shared transport and away from the private car
  • The sky-high expectations of consumers (or users as they are now known)

With all that bubbling under here’s a look at the way that advancements in electronics are making waves amongst this maelstrom.

Electronic payment and ticketing

“My smartphone is my preferred mode of transportation.”
Rt. Hon. Patrick MacLoughlin, former Secretary of State for Transport

The influence of digital and the rise of the smartphone has already transformed many other sectors, but transport is only just starting to feel its effects. The changes we have already seen in the airline sector with paperless tickets will prove to be just the tip of the iceberg.

Electronic payment and electronic gate systems will not only make the passenger’s life easier: they will also open up a whole new world of data and understanding.

Our smartphone is already becoming our ticket in many innovative UK schemes – and the Oyster Card has greatly simplified tube travel for years. Before too long it’s likely to be a wearable that allows us to glide through the turnstiles. And, shortly after this, will be pay-as-you-go travel where sensors know exactly where and when we have journeyed without the need for pre-booking or payment.

With electronic payment the transport provider gains visibility about who uses its services, where they go and how often they travel. This new-found rich data opens up the possibility for personalised marketing in a way that public networks have sorely lacked in the past (and are struggling to discover through online booking alone).

But the data advantage is not necessarily just the providers. Alongside new ways to pay we are also going to see new ways to travel – with the user at the centre of a transport network that is increasingly interchangeable and whose real-time operations are always at their fingertips. The start of such a world of choice can be glimpsed in the disruption caused to traditional taxis by Uber.

It is hard to see road usage continuing to be paid for by a blanket road tax. The introduction of green incentives has already started to stream charges, and toll roads, such as the Dartford Tunnel, use sophisticated number plate recognition to ‘tag’ each car that uses the route. Going forward more electronic monitors will line our roads, and it’s likely the price we pay to use them will be based on data gathered about congestion at the time – with our road tax, perhaps, paid online on a top-up basis.

This dynamic charging may sound far-fetched – but it’s already happening with parking. In San Francisco smart parking meters broadcast that a space is available to drivers and adjust their price according to the number of other spaces available. Such an easy-Jet pricing policy is also used in Moscow, Santiago de Chile and Barcelona – and at its heart lies electronic sensors.

Telematics could introduce another dimension to such a personalised way to fund our roads – and it’s this we’ll review next.

Telematics and the IoT

“A modern transport system that doesn’t stream data is inconceivable. Modern infrastructure must envisage, plan and build roads, rail and digital capabilities all as one.”
Alexander Dobrindt, former German Minister for Transport and Digital Infrastructure

The electronic sensors and data sharing that facilitate telematics are already widely used by insurance companies to offer lower premiums to the ‘right’ kind of driver. They are also used to ensure that emergency services are instantly notified of accidents. It’s not a massive leap of imagination to predict that telematic data will be used to penalise or reward drivers – and not just based on the routes they use but on their driving itself.

In logistics and transportations telematics have been extended into the realm of the IoT to collect, analyse and share data across a wide network – and to use machine learning to determine suggested responses.

Telematic-enabled fleet management has moved beyond GPS location tracking to include the use of geofences to enable alerts when a truck is nearing its destination, the optimising of routes using real-time traffic data and to automatically track driver hours and fuel usage. It can also track vehicle maintenance needs and issue alerts should warning signs concerning the vehicle’s health be detected.

In many ways, the IoT is the logical extension of such telematic systems: it can be applied throughout the supply chain rather than just for each journey taken. The IoT could integrate the ordering, manufacturing and warehousing chain: the need for new parts or consumables will be automatically broadcast and, as a result, the supply chain will need to be able to respond much quicker. Its monitors could also stay with a shipment across different countries and transportation methods.

Automation

“I have never seen anything like the pace of change we are seeing today.”
Larry Keeley, Founder of Doblin

Amazon’s drone delivery force and Google’s driverless car are two of the more visible ways that automation and machine learning are gearing up to change the world of transport as we know it.

Driverless vehicles are highly likely to affect both the consumer and the logistics market in the very near future.  Several auto manufacturers have introduced semi-autonomous driving capabilities in their vehicles and Uber’s Otto division is pretty much ready with its driverless trucks for deliveries.

The only real thing that lags behind at present are the regulatory and insurance questions such technology rises.

Electronic manufacturing and transport innovation

Electronic manufacturing is set to play a major part in the perfect storm that will engulf the transport sector.

And it looks like it’s the innovators that will ride the waves created.

What does Surface Mount Technology offer OEMs?

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What-does-SMT-offer-OEMs-1080x675

Surface Mount Technology (SMT) has become a core construction technology in current industrial electronic product designs.

Although there is still a considerable amount of conventional or Pin-Through-Hole (PTH) parts, especially on more rugged designs, SMT has become a fundamental method of assembly within modern electronics manufacturing and has helped expand and improve  the capabilities of the industry.

What benefits does SMT have vs. other processes?

SMT has significant benefits compared to conventional PTH processes. So let’s have a look at the most obvious advantages of SMT:

  • Reduced footprint: taking up less valuable PCBA surface area
  • Smaller mass: leading to lower power consumption (hence less use of energy, materials and heat dissipation measures)
  • Lower component cost: SMT devices often come in at a tenth of the cost of a PTH variant.

Although PTH tends to have better mechanical rigidity, this is generally not a concern unless associated with bulky connectors and high-power devices, so SMT satisfies diverse requirements.

However, SMT can also lower costs through less apparent benefits such as innovative machine-storage and component kitting processes. These techniques reduce the labour costs involved in manually retrieving components from storage as part of the kitting operation.

Automating these processes also lessens the chance of human error, eradicating costs associated with reworking recovery of these mistakes.

In addition, SMT automates the placement of components onto boards, through using innovative kitting technology such as JUKI Intelligent Storage.

Ensuring component reliability

SMT machine placement can also provide superior product yield and reliability in leadless devices, such as Ball Grid Arrays (BGAs), and more currently micro-BGAs, and chip-scale devices which require precise control during assembly but have the benefit of being a very repeatable process.

SMT also offers improved shock and vibration resistance as a result of the lower mass of components, further driving up reliability and increasing the product’s lifecycle.

The importance of kitting speed

A popular misconception in the mid-tier global manufacturing environment is that component placement speed is the primary hindrance to cost.  This is not the case.

By far the biggest variables affecting manufacturing cost and product quality in high-mix environments are:

  • Kitting speeds: pulling stock from storage
  • Setting-up component feeders
  • De-kitting: returning the components back to storage.

Whilst almost every Electronics Manufacturing Services (EMS) company will have some form of SMT capability, our focus on automation and process governance helps to drive significant benefits in terms of quality and cost.

We boast an array of assets:

  • SMT conversion design services, converting existing PTH designs to SMT.
  • Automated kitting infrastructure, such as a JUKI system, to speed up the assembly process whilst maintaining material control.
  • RFID tracking that codes stock usage with superior accuracy.
  • Automated component storage, removing the need for specific component bins. The system manages everything automatically.
  • SMT job clustering that minimises or even eliminates changeover times between jobs.
  • Intrusive re-flow options, allowing for boards to be retrofitted.

For further information on our surface mount offering, visit our manufacturing page.

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.