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How prototypes help identify and formulate design and save time

Prototypes can help manufacturers save manpower, time and money. It simulates the actual product that you can present to your customer. Read this blog to find out how. Prototyping: A powder-coated aluminium box was the proposed enclosure. We 3D printed an enclosure to check how the board fit and the placement of the button and switch. We presented the fabricated powder-coated box to the client. At this point, we proposed a brushed stainless steel enclosure for sophistication. The client accepted the suggestion. Rapid prototyping: To execute several revisions in a short time, rapid prototyping is often used. Rapid prototyping can reduce material wastage, and expenses and quicken the processing time. This can confirm the functioning and aesthetics of a product. Reasons for prototyping: Prototypes help the designer and engineer to work out a solution for a final product. The designer finalises the material, structure, functions and appearance of the solution. A prototype allows the designer and engineer to make informed decisions. You can create prototypes with available materials or other techniques. This helps you create a solution keeping the cost minimal. Prototyping helps simulate the actual product. An operating version of prototypes can give the customer an idea of the product. Building the concept tests the possibility of whether the idea is operable. Prototyping determines unanticipated technical, financial and other hurdles that may occur during manufacturing. Provide you with an idea of how the end user will interact with the product. Illustrating our recent prototype for Clarico Air: We have been rolling out tailor-made box builds for an Indoor Air Quality Management system. Before manufacturing the products, prototypes helped us develop a functional and appealing product. PCB design lifecycle: First, we began with a conversation with the client to understand their requirements. Then, our designer created a PCB design and fit it into the enclosure. But, upon testing the usability, the designer included a few changes to the design. After testing the board it was fit into the box. This was the final design. A few design changes were made with inputs from the client and to fit the PCB perfectly into the enclosure Enclosure design changes: Then, a powder-coated aluminium box was the proposed enclosure. We 3D printed an enclosure to check how the board fit and the placement of the button and switch. We presented the fabricated powder-coated box to the client. At this point, we proposed a brushed stainless steel enclosure for sophistication. The client accepted the suggestion. Enclosure design changes (contd): Manufacturing the fully finished products: Finally, on approval, the electrical and mechanical designs are finalised. Using both SMT and through-hole technology we manufactured the PCBs. The mechanical team fabricated the enclosures to place the PCBs in them. All the necessary wires and harnesses are fit. Brushed Stainless Steel enclosure. The logo is lasercut with a black background. Our take on the benefits of prototyping: Ensure to communicate to your customer that prototypes are mockups only. The client and the manufacturer benefit by saving time, energy and financial burn. Moreover, prototypes can project costs, technical specifications and programming glitches. By testing the functionality, minimise design flaws and include modifications. Drop several edits and quicken the design development process through prototyping. Check out Clarico’s case studies to know more about the Indoor Air Quality systems deployed by them in Noida and Gurgaon. Check Out Clarico Air To Know More About Their Capabilities And Project. Get In Touch With Us To Know More About The Services We Can Provide. We Are An EMS Provider And Specialise In Providing Tailor-made End-To-End Services To Meet Your Requirements. We Have The Capabilities To Deliver Low Or High Volume Orders.   Let’s talk for more information.   Call us on: +91 91764 18660   Mails us at: arkcircuitry@gmail.com   Visit us at: https://arkcircuits.com/ Facebook Twitter Linkedin Instagram Recent Blogs How prototypes help identify and formulate design and save time Regan February 9, 2023 Prototypes can help manufacturers save manpower, time and money. It simulates the actual product … Read More Reverse Engineering-13 ways to constructively use it in R&D Regan February 2, 2023 What happens if a product or machinery used becomes outdated and you can’t find its components? Can … Read More

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Is robust Supply chain important to an EMS provider?

The manufacturing industry partners with several companies when working on producing a product. It becomes tedious, and expensive and requires the management of too many resources for a manufacturing company to have all the departments in-house. Therefore to avoid managing a massive inventory and manpower, certain aspects of manufacturing are outsourced or as we like to say involving “partners” for manufacturing. These partners can be OEMs, CEMs, ECMs, ODMs, CMs and EMS. Here’s  How do you choose your service provider? Before we move to understand the relevance of EMS in manufacturing let’s take a look at other commonly used acronyms. Some terms used related to manufacturing are OEM, CEM, ECM, ODM, CM and EMS, each of which provide different services which at times are used interchangeably. However, at times, a combination of their services may also be used by manufacturers. In manufacturing, knowing which manufacturer to turn to depending on their speciality and your product is important. These providers can produce, manufacture, contract or source and procure specific components providing service and solutions for you to deliver your product. (i) Original Equipment Manufacturers(OEM) Original Equipment Manufacturers(OEM) produce certain or all components required for other companies to build their product and sell their finished items/goods to their customers. In other words, an OEM sells its parts/components to manufacturers who assemble them with several other parts/components to roll out a finished product. OEMs may focus on investing their time and resources on R&D and regularly work on innovating their products/components. OEM majorly focusses on B2B sales, although there has been a recent increase in customers building their own products(DIY  projects) and purchasing OEMs from distributors. The manufacturers also find it beneficial as the OEM usually provides warranty for the product and service is provided for a limited period of time. An OEM refers to components/parts made specifically for the original product (designed and developed for). On the other hand, the ‘aftermarket’ refers to the equipment made by some other company that a consumer may use as a replacement. (ii) CEM or Contract Electronics Manufacturer CEMs or Contract Electronics Manufacturers are companies that are outsourced by companies to make electronic products for them. The CEMs usually serve sectors like communication, medicine, defence, computer industries and transportation. They specialise in PCBA (printed circuit board assembly) and electro-mechanical services. They also provide design services to create electrical parts (they design, test and develop these parts)  used by OEMs and usually rebranded with the buyer’s logo. A CEM provides customers with the expertise in industry-standard, certifications required and regulations to be followed and uses advanced technologies. Thus, they would have an excellent and reliable supply chain to ensure a smooth flow in manufacturing. They are also known by another acronym which is ECM (Electronics Contract Manufacturing). (Iii)Contract Manufacturing(CM)​ CEMs or Contract Electronics Manufacturers are companies that are outsourced by companies to make electronic products for them. The CEMs usually serve sectors like communication, medicine, defence, computer industries and transportation. They specialise in PCBA (printed circuit board assembly) and electro-mechanical services. They also provide design services to create electrical parts (they design, test and develop these parts)  used by OEMs and usually rebranded with the buyer’s logo. A CEM provides customers with the expertise in industry-standard, certifications required and regulations to be followed and uses advanced technologies. Thus, they would have an excellent and reliable supply chain to ensure a smooth flow in manufacturing. They are also known by another acronym which is ECM (Electronics Contract Manufacturing). (iii)Original Design manufacturer(ODM) The manufacturer designs and produces products which are a part of a product or are rebranded and sold under another company’s name. Original Design Manufacturer (ODM) as the name suggests in actuality design, develop and own the IP (intellectual property) for the product which they can put out in the market, sell to a buyer(s) or as a white label product (a product sold under names of several buyers). Thus, the buyer usually chooses an ODM when they are looking for a finished product which is generic and not usually completely customised. The buyer looks for ‘private labelling’ where he chooses an existing product, might make a few changes and sell it under their brand name. (iii)Electronics manufacturing Service(EMS) OEMs or manufacturers often outsource a section or the entire process of procuring and/or manufacturing components (electronic components) required for the end product. Instead, they utilise their time and resources to focus on their core competencies such as research and developing their product and plan strategies for selling the product.  An EMS (Electronics Manufacturing Service) provider has a network of suppliers and vendors (or as we at Ark Circuitry call them as ‘partners’) who they have a longstanding relationship and thus are capable to procuring a wide range of products and since the partners understand the business, they would be able to cope with the peaks and troughs in demands. When this is possible it means that the EMS provider has an efficient and excellent supply chain. Why do OEMs choose EMS providers to procure all the necessary material on their behalf? Simple because it makes financial sense, i.e. the OEM doesn’t have to manage a procurement team as the EMS provider can carry out the operation at a much lesser cost. The Chartered Institute of Logistics & Transport UK (2019) defines ‘supply chain’ as: “Getting the Right product, in the Right quantity, in the Right condition, at the Right place, at the Right time, to the Right customer, at the Right price.” This definition is quite fitting for EMS providers. A good EMS provider will have the capability to provide manufacturers with a wide range of customised services that will deliver end-user solutions. Their services may include and not limited to (i) Electronic design & engineering (ii) Electronic assembly (iii) Electric manufacturing (iv) Electro-mechanical services, etc.  In order to be able to do so, the EMS provider must have excellent supply chain management, a network of suppliers and a well-experienced procurement team/member to be able to deliver

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Choosing the right test/inspection for a printed circuit board.

Why do PCB manufacturers encourage customers to opt for inspection or to run tests on the PCB? Is it really necessary? How do you avoid the hassle of reworking your product? What are the different tests available? Read this post for information.  Why is an inspection/test required? Before the device or system leaves the manufacturing unit a thorough inspection of the PCB mitigates problems in a  manufactured product. This helps companies cut down expenses and valuable resources.  Sometimes even as simple as solder flux can interfere with the functionality of the PCB  and using a non-clean low-residue solder paste is suggested. What are the different tests available? There are 3 widely used tests to check the functionality, durability and accuracy of the system : automated optical inspection, X-ray Inspection and burn-in test.   Automated Optical Inspection (AOI) The AOI uses cameras to capture pictures of the PCB and then compares them with detailed schematics to check errors. when capturing pictures, light is focused from different angles on the board. The images are put together to create a full profile of the board. This system helps in the early detection of nodules, scratches on the board, incomplete or thinning solder, open circuits, missing components and short circuits.  Relying on cameras, the AOI is limited to what is visually detected and is unable to inspect hidden connections, especially in multi-layer boards. Moreover, as external light is used, there could be errors during inspection due to the emerging shadows. Hence, depending on the complexity of the board manufacturers use a combination of inspections to ascertain faults or errors in a board. X-ray Inspection (AXI) For boards that are tightly packed with several components (especially small ones) and for multi-layer boards, AOI inspection might not be a suitable test. AOI only detects errors visually from the surface in comparison to X-ray inspection which provides better clarity and inspects the PCB in detail.  Besides, X-ray passes directly through objects and does not need external light as required in AOI. Furthermore, it helps detect issues by examining the board thoroughly as it goes beyond just the surface.  However, this method also has its limitations. The process is extremely time-consuming and setting up an X-ray inspection system is expensive. AXI requires an experienced operator to use the machine which is also an added expense. This leads to exploring the third option, the burn-in test.  Burn-in Test A burn-in test can enable the early detection of potential problems and helps keep the cost of testing and replacing parts at the lowest. In electronic devices, a burn-in test can determine the maximum temperature it can sustain. A burn-in may also be a part of routine maintenance or repair. The malfunction might not be straightforward until the hardware is warmed/cooled to a certain temperature or checked for humidity as a factor. Tests under these various environmental parameters could aid in diagnosing the problem and fixing it. The burn-in test can be performed for an entire system or individual components. The system is operated for extended hours or extreme working conditions to check its functionality and reliability. Running a quick burn-in test to check the PCBs Identifying defects at an early stage of the manufacturing process is the most practical way of reducing costs and allows errors to be rectified.  At Ark Circuitry we use high-quality components to ensure the proper functioning of a PCB. We also encourage customers to opt for testing as it is not only important to check the functionality of the product but also to avoid danger when used in highly sensitive applications. Ark Circuitry Ventures Is An EMS Provider And Specialise In Providing End-To-End Services That Can Be Tailor-Made To Meet Your Requirements.  Let’s talk for more information.  Call us on: +91 91764 18660 Mails us at: arkcircuitry@gmail.com Visit us at: https://arkcircuits.com/ Facebook Twitter Linkedin Instagram Recent Blogs Choosing the right test/inspection for a printed circuit board. Suneyna S JoJo November 4, 2022 Why do PCB manufacturers encourage customers to opt for inspection or to run tests on the PCB? Is it … Read More The process of a small run SMT Production Suneyna S JoJo October 27, 2022 Ever wondered what makes it important for your electronics to work efficiently apart from its … Read More

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