Printed Circuit Board Assembly (PCBA)
The Cornerstone of Our Integrated Electronic Manufacturing Solutions
Manufacturing Equipment and Processes Designed for Higher Mix, Lower Volume, Higher Complexity PCBA
If you are in need of a supplier partner with administrative, supply chain, manufacturing and quality processes designed to support the unique requirements of higher mix, lower volume, complex printed circuit board assemblies, then Federal Electronics is the right choice.
Federal Electronics printed circuit board assembly manufacturing service is the cornerstone of our integrated electronic manufacturing solutions for OEMs of high complexity, highly engineered, and highly regulated products. Our processes and equipment have been carefully selected based on the unique needs of our OEM customers, whose products include a wide range of PCBA technologies with frequent engineering change order activity for variable demand in smaller lot sizes.
Federal Electronics Partnership Benefits
Process Technology & Equipment
Higher Mix, Lower Volume PCBA Equipment Selected for Faster Changeover
All surface mount lines are enclosed in a temperature and humidity controlled, ESD compliant, dedicated room. Each conveyorized line consists of a screen printer, solder paste inspection system, component placement machine, reflow oven, and automated optical inspection, all of which are connected to our internal network where revision-controlled work instructions, machine operating parameters, and component characteristic files reside.
Ovens bake moisture sensitive components and fabs prior to use, and X-ray inspection is used where required, such as for BGAs. The equipment was selected specifically for our operating environment, where precision is critical, and flexibility is mandatory. Faster changeover and setup have been prioritized to support a higher mix product profile.
Advanced Quality Controls & Testing for Improved Product Yields
Process Technologies Incorporate Early Inspection & Verification Capabilities
To continually drive improved product yields, process controls that track critical characteristics provide significant benefits. Pick-and-place machines electrically test the first 10 pieces for passive components from every reel and compare the results to the specifications on the network to ensure that the parts are as the reel label indicates, direct from the distributor or manufacturer.
Each component must also pass an automated 100% visual inspection before it is placed onto a printed circuit board assembly, and those that fail are eliminated from the line. In addition, the solder paste inspection system and screen printer “communicate” to the AOI system at the end of the line, allowing process engineers easy and immediate access to the conditions of the solder paste application that resulted in a potential non-compliance incident. Smart feeder technology tracks each component to the unique serialized PCBA to ensure traceability for heavily regulated industries.
Real-Time Operational Visibility Through Aegis FactoryLogix®
MRP and Scheduling Modules Capture Customer Demand Signals Nightly
Our Aegis FactoryLogix® system provides real-time operational visibility and accelerates production by providing operators with configurable work instructions. Material and labor allocations for all PCBA processes are captured by our nightly Material Requirements Planning and Scheduling modules. Bottlenecks and constraints are identified immediately and result in exception reports issued to materials and production control departments for mitigation, ensuring consistent performance and quality at highly competitive pricing.
Finished Product Stocking Through Custom Kanban Programs
Optimizes Inventory & Maintains Reliable Product Flow
OEMs of complex systems and capital equipment often have project profiles consisting of multiple printed circuit board assembly part numbers of both SMT and through-hole technologies, produced in lower volumes and delivered in complete sets. These profiles are ideal for limited liability agreements, driven by forecasted demand and replenished through 2-bin Kanban programs.
To support this environment, ERP modules for Material Requirements Planning (MRP) and Scheduling run every night, ensuring that material allocations and production schedules are aligned with customer priorities as we flex capacity in response to fluctuations in demand. Where Kanban systems are deployed, bin sizes for each printed circuit board assembly part number are reviewed and adjusted on a quarterly basis (at a minimum).
Entry Point for Integrated Electronic Manufacturing Solutions
Vertical Integration Model Eliminates Margin Stack-up
Federal Electronics printed circuit board assembly service is one of the foundational elements of our integrated electronic manufacturing solution. Customers can select from a variety of administrative and product configuration options, where printed circuit board assemblies can be shipped as discrete products or can be configured within complex, fully tested higher-level assemblies.
Our vertical integration model eliminates margin stack-up associated with EMS providers with limited manufacturing services, increases our influence over the supply chain, and extends our control over a larger portion of the total manufacturing process.
Administratively, Federal Electronics can support your production requirements with customized 2-bin Kanban programs to support JIT delivery to your factory.
Partner with Federal Electronics
Contact us today to learn more about our solutions that are designed to drive your success.