Anpllopcb

The Best Low-Volume PCB Assembly Production Guide

Anpllopcb

Preface

As printed circuit boards become an integral part of more and more devices, PCB prototyping has been at an all-time high. As companies continue to innovate, the hourly demand is for low-volume PCB assembly, which can provide high turnaround times without manufacturers getting bogged down by high inventory that they cannot utilize. Low-volume assembly is designed to optimize the quality of the board and solve any problems that may arise. That’s why techniques such as DFM (Design for Manufacturing) and DFT (Design for Test) are used in the process. They make it easier to identify any problems and optimize them before moving on to volume production. This blog will discuss what you must know about low-volume PCB assembly.

Why is low-volume PCB production an important part of all board development?

The printed circuit board manufacturing process is made up of three parts. These are board manufacturing, component procurement, and PCB assembly. The optimization of these three manufacturing activities depends on the synchronization between the contract manufacturer (CM) and the equipment and processes used for the design. There is a directly proportional relationship between the quality of the PCB and the establishment of your PCB CM’s DFM rules and guidelines. For small or large quantities, strict adherence to DFM and DFA is essential to achieve the highest yields and lowest production costs.

Regardless of the level of development or production, board fabrication may remain the same unless design changes dictate otherwise. On the other hand, the assembly may vary depending on whether you are making a prototype (or refining a design) or producing the board to be delivered. In some cases, production quantities may be small. For example, when manufacturing critical or specialized PCBs for aerospace, medical device, industrial, automotive, or military PCBs, the use of low-volume PCB assembly production methods upfront can provide both cost and efficiency benefits, allowing for efficient verification and faster time-to-market.

low volume PCB assembly498150

Prototype options for low-volume PCB assembly

(1) sequential

The most common approach to design verification is a sequential prototyping strategy that combines or tests a small number of design changes in each cycle.

(2) Parallel

Parallel prototyping can reduce or minimize the number of production runs required. This is accomplished by making multiple design changes to a small number of boards and testing all variants before the next manufacturing run. These variants are for assembly only, and all bare boards are manufactured similarly.

For both strategies, the following assembly options can be implemented.

(3) Do Not Place (DNP)

To test specific components or subcircuits, it is best not to place other components that may make testing and troubleshooting more complex and difficult.

(4) Use different variants

DNP is extended by placing different components on different boards to simplify testing.

(5) Use leaded solder instead of lead-free solder

During the prototyping process, rework is often required, and it is much easier to use leaded solder than lead-free solder.

(6) Use of redoable surface treatment

Since rework may be required, it is best to use a surface finish that can be easily reworked or not prototyped.

Low-volume PCB assembly method

Printed circuit boards are a complex business, and properly assembling small or large batches of PCB requires the right tools, parts, technology, and production processes. Having a professional perform the assembly means ensuring that quality control measures will be followed and testing performed throughout the process so you can rest assured knowing when you receive your PCB. There are three common low-volume PCB assembly methods on the market today.

(1)Turnkey PCB Assembly

Choosing turnkey printed circuit board assembly is a great solution for any business. With this option, our professionals will collect all the necessary parts and components and assemble the PCB. This PCB assembly production solution is cost-effective and helps save time because we will ensure we have everything we need to build it correctly. 

(2)Kitting/Commissioned PCB Assembly

Kit PCB assembly is a perfect option for those who know exactly what PCB they want but may not have the time or equipment to assemble it. You can buy and use all the components and parts you want and need from PCB manufacturers. This can help you better control production costs and know what to expect from the finished printed circuit board. 

(3)Combination PCB assembly

Maybe you know you want to use some components in your PCB but still need some parts to complete your electromechanical assembly – that’s where combinatorial PCB assembly comes in. You provide us with the parts and assemblies you have, and we’ll provide whatever you still need and expertly assemble them. This option still allows you to have some control over production costs and your most important components, combined with the ease and time-saving ability of a PCB manufacturer to get the job done. 

Why should low-volume PCB assembly be the preferred method for all industrial projects?

Cost Advantages: While economies of scale traditionally result in high throughput, low-volume PCB production offers significant cost advantages in an ever-changing technology scenario. For one thing, you won’t be producing more boards than you need. And, as technology changes, these boards will not become redundant.

During the prototype phase, you will often improvise on the design and functionality of your product. Low-volume production means you won’t be stuck with a defective product. Likewise, because you are able to outsource low-volume PCB components, it means lower overhead costs for your own business. You also save valuable time that could be spent in other productive areas of your business. For lower batches, you also tend to save on potentially increased storage costs in case you are burdened with a heavy inventory load, which would also be useless if the prototype fails. Therefore, low-volume PCB assembly can provide a low-cost test method.

Turnaround time: Small lot sizes also bring fast turnaround times. As a result, you can quickly evaluate whether to make any design changes. This reduces time-to-market, which can be a significant competitive advantage today.

Agility: If there is one attribute that stands between business success and failure, it is the agility of a company to respond to change. Low-volume PCB assembly inherently provides this advantage for businesses that are not overwhelmed by high-volume production and have the advantage of short turnaround times. By improving the ability to see if there are defects in the product and if changes need to be made to the design, companies can be very flexible in matching the product to customer needs. The chances of success are increasing.

Quality end product: With the short turnaround time of a quality end product-PCB prototype and the ability to identify defects early, you can improve your product and therefore enter the market with a quality product. This greatly enhances credibility as the product becomes successful in the marketplace and brings a reputation to the manufacturer.

Viable for startups and hobbyists: business is no longer just the domain of large corporations. The business has become a level playing field with low-volume PCB assembly and the low costs associated with testing ideas. Small businesses and hobbyists can easily test their ideas without investing much money. Getting a proof of concept and a business plan on paper is easy for startups that want to market to the input.

In summary, low-volume PCB assembly offers several advantages, starting with savings in overhead by outsourcing the work. Small order quantities automatically reduce turnaround time. And it is an easy and cost-effective way to test product design ideas without incurring high costs.

The price components of low-volume PCB assembly

(1)printed circuit board production :

    PCBs require plate-making materials and board-making instructions documents to go through the quotation process. Usually, the manufacturer of a PCB board needs to organize the information sent to the salesman; the salesman will be based on the special process you need, other manual processes miscellaneous charges for a quotation.

(2)SMT chip processing:

    SMT patch processing cost is always more difficult to calculate the category. Generally speaking, the PCB processing factory will be based on the number of SMD points you need to calculate the money finishing, but different manufacturers will have different algorithms; a piece of a point will calculate some, and some are calculated by a foot a point.

(3)components:

    Components include conventional resistive capacitors and special devices. The market price of conventional components is relatively transparent; after all, each producer’s offer online can be searched, is relatively easy to estimate the price of a board.

How to calculate the cost of low-volume PCB assembly?

Electronic product developers have a low-volume PCB assembly production process before mass production. The low-volume PCB assembly production is generally between 50-2000 pieces. Still, the average unit price of PCB proofing is often found to be high, mainly because of the need to charge engineering fees.

Because the PCB proofing volume is relatively small, the PCB and SMT chip processing production can not reach the minimum consumption standards, so that the electronic processing plant will charge engineering fees per the minimum consumption standards.

The price calculation formula for the production fee of low-volume PCB assembly is as follows:

Component procurement costs + PCB procurement costs + PCB engineering costs + SMT / DIP engineering costs + testing costs (customer requirements)

Engineering cost-specific price is mainly related to the difficulty of the process; the price of lead-free process requirements will be higher. Test cost will be determined according to whether the partner has test requirements.　

Multi-species, low-volume PCB assembly production plan preparation methods

(1) comprehensive balance method

The comprehensive balance method is based on the requirements of objective laws to achieve the plan objectives, to achieve the appropriate ratio between the relevant aspects of the planning period or the relevant indicators, interconnected and coordinated with each other, using the form of balance sheets, after repeated balancing analysis and calculation to determine the plan indicators. From the perspective of system theory, that is, to maintain the system’s internal structure in an orderly and reasonable manner. The comprehensive balance method is characterized by a comprehensive and iterative comprehensive balance of indicators and production conditions, maintaining a balance between tasks, resources, and demand, local and overall, and goals and long-term. It is suitable for preparing long-term production plans. It is conducive to tapping the potential of the enterprise’s human, financial and material resources.

(2) Quota method

The quota method is based on the relevant technical and economic quotas to calculate the relevant indicators to determine the planning period. It is characterized by simple calculation and high accuracy. The disadvantage is that by the product process, scientific and technological progress the influence of the larger.

(3) rolling plan method

The rolling plan method is a dynamic method of preparation of the plan; it is based on a certain period for the implementation of the plan, taking into account the changes in environmental conditions inside and outside the organization to adjust the plan in due course. Accordingly, the plan will be delayed for some time, and the current and long-term plans will be combined with preparing a planning method.

The rolling plan method has the following characteristics: the plan is divided into several implementation periods, of which the current plan is to prepare a detailed and specific, while the long-term plan is relatively rough; plan to implement a certain period, according to the implementation and environmental changes in the content of the plan and the relevant indicators to modify, adjust and supplement; rolling plan method to avoid the solidity of the plan, to improve the adaptability of the plan and the guidance of the actual work. It is a flexible and elastic production planning method; the preparation principle of the rolling plan is “near fine and far coarse,” and the operation mode is “while implementing while adjusting while rolling.”

The above characteristics show that the rolling plan method is constantly adjusted and revised with the changes in market demand, which coincides with the multi-variety and low-volume production method to meet the changes in market demand. The rolling plan method can improve enterprises’ ability to adapt to changes in market demand and maintain the stability and balance of the enterprises’ production, which is an optimal method.

How to maximize the efficiency of the low-volume custom PCB production process

While it is true that there are specific steps common to all PCB development and production, each board design follows a custom path. Functional goals, type and number of components, board materials, stacking, prototype iterations, testing requirements, and production levels may vary from design to design. For industries, the differences are even greater. Examples include designs for medical devices, aerospace, or advanced industrial systems (often dedicated) for low-volume production. So how can you maximize the efficiency of low-volume custom PCB production?

Low-volume PCB assembly production

It is a common misconception that PCB manufacturing and PCB production are synonymous. Although they are often used interchangeably, they are more accurately defined as follows.

(1)PCB manufacturing process is divided into two steps, including manufacturing: conversion of raw materials (such as laminates, substrates, solder resist film, Etc.) into printed circuit boards and assembly: the electronic components are mounted or attached to the printed circuit board through the printed circuit board soldering process. The process includes well-defined steps to perform functional goals by converting the design defined by a design package containing board layouts and materials, component lists, and other instructions into physical functionality. PCB manufacturing can create proof-of-concept, prototype, or finished boards.

(2) PCB manufacturing is implementing a PCB manufacturing process to create finished printed circuit board assemblies. Finished boards are typically used in the production process for more complex systems. There are two types of PCB manufacturing: low-volume and high-volume.

High-volume PCB manufacturing and high-volume PCB production can be considered the same process, which can be a major source of confusion between manufacturing and production, as both processes result in finished products in quantities of thousands or more. This is not the case for low-volume products, as not all PCBs are intended for end users or sales. For example, multiple PCB manufacturing is a common prototype iteration necessary to achieve optimal design quality in the development process. The number of boards per spin may be in the tens or dozens. The number depends on the product used for low-volume production and may be in the hundreds or less. Some examples are given below.

The table above does not include all the products that may utilize custom boards for low-volume production. However, it does provide common examples of low-volume production processes that often include custom designs, which allows us to define ways to make the production process more efficient.

Efficient low-volume custom PCB production

Efficient low-volume PCB production can achieve the maximum yield, shortest turnaround time, and best cost for the building board. These goals can be achieved by performing the following operations.

(1) How to achieve the highest yield

The yield rate is the ratio of usable boards to production boards. The rate can be maximized by adopting good design guidelines, including following CM’s DFM rules and optimizing design quality during prototyping.

(2) How to get the shortest PCB turnaround time

The standard indicator of a good PCB production process is the speed of the board build. However, speed cannot be used as compensation for quality. Therefore, your choice of manufacturing and assembly services is critical to optimize these key metrics.

(3) How to get the best cost

For low-volume custom PCB production, achieving the lowest cost is not necessarily the best choice. However, it is important to get the best cost. This is done by achieving a trade-off between time and cost trade-offs, Ensuring that your CM produces the highest quality boards with the lowest yields.

Conclusion

The main purpose of low-volume is to produce more prototypes in the shortest amount of time. Some projects require bulk prototyping and some require small quantities, so the quantities vary from project to project. Now, if your circuit plan requires a small number of circuits in a short period of time, low-volume PCB assembly is a better option. The use of low-volume PCB assembly for prototyping and design is growing rapidly because of its many advantages. It is attracting more startups with its low-cost, high-value products.

For testing purposes, this process is also a good option to understand the circuit without investing a lot of money. So, if you are considering low-volume assembly in your prototyping and design, our advice is definitely to try it at least once.

At Anpllo, we offer you low-volume PCB assembly, low-volume PCB prototyping, low-cost PCB manufacturing, and low-volume PCB fabrication facilities that meet your custom requirements. We have a state-of-the-art PCB manufacturing facility; fully equipped to provide you with high quality and low cost printed circuit boards. In addition, we offer turnkey PCB assembly services with short turnaround time.

Exit mobile version