A global concept-to-product development services company sought an end-to-end manufacturing solution for dense assembly of fine pitch components, including leadless packages and system-on module (SOM) for use in embedded camera modules, USB camera boards, and other specialized imaging uses, including advanced industrial machine vision and other automation applications.
We were tasked to manufacture the client’s products and sub-assemblies in compliance with the specifications of each component’s equipment data package (EDP). Many of the components required intricate assemblies within small footprints, including ultra-fine-pitch ball grid array (BGA), leadless lead-frame package (LLP) and multiple printed circuits linked by delicate wiring harnesses. For streamlined production and quality control, the client also required both a comprehensive design failure mode and effect analysis (DFMEA) and process failure mode effects analysis (PFMEA) for every component to evaluate and eliminate potential manufacturing defects.
Our team used their product manufacturing expertise and worked closely with the client to efficiently develop durable, high-quality product prototypes. After conducting comprehensive DFMEA/PFMEA reviews for each product, our engineers recommended multiple enhancements for improved design and reliability. They reorganized and streamlined production methods, including adding an innovative QR code-based process for accelerated assembly of small-footprint circuit boards. Reviewing the client’s BOM expenses, they achieved significant cost savings, leveraging their global ecosystem of high quality suppliers. Our flexible manufacturing capabilities offered an optimal mix of high-product mix at flexible volumes. We re-engineered the client’s packaging for lower freight costs, while coordinating effective drop-ship retail distribution and adequate stock levels for online sales channels.
Five years later, our engineering savvy, proactive collaboration, and manufacturing flexibility has enabled us to remain an integral EMS partner for this client’s expanding line of imaging products. We continue to introduce innovative new products to markets worldwide.
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