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GreensTone Electronics is electronic contract manufacturer (ECM) that specializes in volume, turnkey PCB assembly services. The turnkey service utilizes a Design-for-Manufacturing (DFM) and a Design-for-Testing (DFT) service, engineering, programming and testing.
Design-for-Manufacturing (DFM) Service
To circumvent any engineering problems that may impede the manufacturing process, as well as potential delivery delays, GreensTone uses a Design-for-Manufacturing (DFM) service that functions as a quality check by reviewing a client’s engineering documents such as Gerber files, BOMs, assembly drawings, and circuit diagrams. In addition, it will panelize the PCBs, inspect your parts list to verify its correctness before the parts are ordered, and suggest a solder mask to obtain high yield rates. The DFM service is one of the prime ways GreensTone Electronics can pass on cost reductions to its customers.
Design-for-Testing (DFT) Service
To support your PCB testing procedure while providing recommendation on how to place test points throughout your PCB, GreensTone uses a Design-for-Testing (DFT) service. This product support service provides references on probe types, fixtures, and testing limitations. The DFT service will verify that your testing requirements, problem identification procedures, diagnostic instructions, and other references are functional.
Design-for-procurement(DFP)Service
Each new design project submitted to DfP experts is the subject of a detailed report of all its components and their associated risks. This reduces risks associated with procurement issues by providing access to crucial information on the sourcing of each electronic component, including:
The component’s maturity
The risk of obsolescence on the market
The number of sources of procurement
The possibility of replacing components with alternatives
Integrating Design for Procurement experts right from the start of product development is the safest way to optimize its design and secure its industrialization. In the current context, it is increasingly difficult to meet 100% of component requirements. It is therefore essential to anticipate crises and difficult situations by carefully selecting each component and preparing for all possible scenarios upstream of production.
Pre-Production Test Boards,to avoid the risks and added expenses associated with manufacturing rework, GreensTone will build a small amount of PCBs and send them to you for inspection prior to manufacturing the entire order. Once the order has been certified for full production, GreensTone will test all manufactured PCBS, check the Ball Grid Array and the quality of the leadless part assembly via X-ray inspection equipment. No PCBs will be shipped until all problems are resolved.
GreensTone takes pride in maintaining long-term relationships with its clients. We provide additional cost savings to our long-term customers by not charging for NRE and stencil charges on additional orders. In addition, Cost per part discounts are passed onto the customer since we use parts vendors who give GreensTone quantity discounts. Our global supplier relationships allow us to purchase quality parts at competitive prices. GreensTone ensures that our customers obtain the highest quality that a PCB turnkey service provider can offer.
GreensTone engineers team can provide components equvelent suggestion on passive components to cut down the parts cost.
Low-volume PCB assembly, typically involving smaller quantities of circuit boards, demands specialized techniques to ensure cost-effectiveness, quality, and timely delivery. In this guide, we will explore these techniques and how they apply to the context of low-volume PCB assembly.
1. Surface Mount Technology (SMT)
Surface Mount Technology is a widely used technique in low-volume PCB assembly due to its versatility and efficiency. SMT components are smaller and lighter, making them suitable for compact and lightweight devices. It also enables the assembly of complex PCBs with high component density. Fast and accurate pick-and-place machines are employed to precisely mount SMT components on the PCB.
2. Through-Hole Assembly
While SMT is the preferred choice for smaller components, through-hole assembly is still essential for larger or specialized components. Through-hole technology provides better mechanical strength and reliability for components subjected to mechanical stress or environmental conditions. In low-volume assembly, manual through-hole insertion and soldering techniques are often employed.
3. Mixed Technology Assembly
In many low-volume assembly projects, a mix of SMT and through-hole components is required. Mixed technology assembly combines the advantages of both techniques, allowing for a broader range of components and functions on the PCB.
4. Prototype Assembly Techniques
Low-volume PCB assembly often begins with prototype runs. Quick turn PCB assembly techniques are employed to produce small quantities of prototypes for testing and validation. These techniques prioritize speed, flexibility, and cost-efficiency to accelerate the development cycle.
5. Design for Manufacturability (DFM)
Designing PCBs with manufacturability in mind is crucial for low-volume assembly. DFM principles help optimize the PCB layout, component placement, and soldering processes to minimize errors and rework during assembly. Collaborating with experienced PCB designers can streamline the DFM process.
6. Component Sourcing and Management
Efficient component sourcing and management are vital in low-volume assembly. This includes selecting components readily available in the market, managing component inventory, and having access to alternative components to avoid delays.
7. Flexible Equipment Setup
Low-volume assembly often requires flexibility in equipment setup. Assembly lines need to be quickly reconfigured to accommodate different PCB designs and component types. Fast changeover capabilities reduce downtime and increase efficiency.
8. Skilled Workforce
Skilled technicians and operators are essential for low-volume PCB assembly. Their expertise in manual assembly techniques, soldering, and quality control is crucial for producing reliable PCBs.
GreensTone, a prominent name in the PCB assembly industry, offers specialized low-volume PCB assembly services in China. Here are some unique features of GreensTone's services that cater to the demands of low-volume projects:
1. Quick Turnaround:
GreensTone is known for its rapid turnaround times, making it an ideal partner for low-volume prototype assembly and urgent projects.
2. Customization:
GreensTone collaborates closely with clients to tailor its services to individual project requirements. This customization ensures that the assembly process aligns with specific component preferences and design complexities.
3. Diverse Component Capabilities:
GreensTone has expertise in handling a wide range of components, including SMT, through-hole, and mixed technology components. This versatility allows for the assembly of diverse PCBs.
4. Quality Control:
GreensTone places a strong emphasis on quality control, implementing rigorous inspection and testing processes to ensure the reliability and functionality of PCBs.
5. Cost-Effective Solutions:
Despite its quick turnaround times and stringent quality control measures, GreensTone remains committed to offering cost-effective solutions for low-volume PCB assembly projects.
Low-volume PCB assembly presents its own set of challenges that must be carefully managed to ensure successful outcomes:
1. Cost Per Unit:
Low-volume assembly can have a higher cost per unit compared to high-volume production due to the initial setup costs and lower economies of scale.
2. Component Sourcing:
Procuring components for low-volume projects can be challenging, especially for specialized or obsolete components. Efficient component sourcing is essential to avoid delays.
3. Changeover Efficiency:
Efficient changeover between different PCB designs and components is critical to minimize downtime and maintain productivity in low-volume assembly.
4. Quality Control:
Maintaining consistent quality in low-volume assembly can be challenging. Rigorous quality control measures are necessary to identify and rectify any issues promptly.
5. Flexibility:
The ability to adapt to changing project requirements and component availability is crucial for successful low-volume assembly.
Low-volume PCB assembly services have a wide range of applications across industries. Some notable examples include:
1. Prototyping:
Low-volume assembly is commonly used for producing prototypes and proof-of-concept PCBs for new product development.
2. Specialized Electronics:
Industries that require specialized, low-quantity electronic components, such as aerospace, defense, and medical devices, benefit from low-volume assembly.
3. Custom Electronics:
Companies that offer custom or bespoke electronic solutions often require low-volume assembly to meet the unique needs of their clients.
4. Legacy Systems:
Maintaining and repairing legacy electronic systems and equipment often involves low-volume assembly to produce replacement parts.
5. Research and Development:
R&D projects often start with small quantities of PCBs for experimentation and testing before scaling up for production.
Ensuring quality and reliability in low-volume PCB assembly is paramount. Quality control and testing processes play a crucial role in achieving this goal:
1. Visual Inspection:
Visual inspection is the initial step, where trained technicians check for soldering defects, component placement accuracy, and physical damage.
2. Automated Optical Inspection (AOI):
AOI systems use cameras and software to identify defects such as misalignment, solder bridges, and missing components.
3. X-ray Inspection:
X-ray inspection is particularly useful for checking hidden solder joints, verifying BGA and QFN component connections, and identifying any voids in solder joints.
4. Functional Testing:
Functional testing involves powering up the PCB and verifying that it performs its intended functions. This step is critical for ensuring the PCB's functionality.
5. Environmental Testing:
Depending on the application, PCBs may undergo environmental testing, such as temperature cycling, humidity testing, and vibration testing, to assess their reliability under different conditions.
6. Reliability Testing:
Reliability testing assesses the PCB's long-term performance, including accelerated life testing and thermal cycling.
7. Compliance Testing:
If the product is subject to regulatory requirements or industry standards, compliance testing ensures that the PCB meets these criteria.
8. Traceability:
Maintaining traceability is essential, enabling the tracking of components and processes to identify any issues and ensure consistent quality.
In low-volume PCB assembly, the importance of quality control and testing cannot be overstated. These processes help detect and rectify defects early in the assembly process, ensuring that the final PCBs meet the highest standards of performance and reliability.
