There have always been inventive ideas that don’t enter production because mass production quantities wouldn’t return a profit. Cost-effective manufacturing also applies to electronics, where refining a product for production is essential to its success. Designing electronics for production-ready assembly is vital to ensuring their success in development. To help, here is a new product introduction or NPI checklist for manufacturing to keep in mind.
| Why NPI? How NPI Manufacturing Differs from Traditional Productions | ||
|---|---|---|
| Traditional | NPI | |
| Cost | Profitability is the most crucial factor. | Profitability drives the process, but factors like time-to-market may be more pressing. |
| Turnaround Time | Depending on the available supply, turnaround time may be less critical. It is unlikely to experience increases in turnaround time as production matures. | NPIs can be extremely time-sensitive, and turnaround times can be upward fluid in the early stages. |
| Procurement | With an established product line(s), procurement can still pose challenges but is overall more flexible. | Procurement can increase turnaround times, making them highly volatile. Designers will want to lock in procurement as early as possible. |
NPI Checklist: Refining a Prototype into a Production-Ready Product
Prototype circuit boards can take many forms in electronic design. In some cases, a simple breadboard is a prototype; in others, it is a completed board design that is nearly production-ready. Usually, the prototype falls somewhere between these extremes and requires revisions for production through the NPI. While a prototype PCB is necessary for debugging circuits and proof of concept, it is rarely ready for regular production. It may be using outdated parts or components that are difficult to source, the part placement may not be optimal for PCB assembly, or the board may lack the necessary test point access for automated test procedures. Some prototypes use removable sockets or additional do-not-install (DNI) components for specific test and debugging purposes that are unnecessary in the final build.
For all these reasons, a newly designed circuit board must undergo revisions to ensure a rapid, cost-efficient, and error-free manufacturing job. However, not all PCB contract manufacturers are as skilled, experienced, and prepared for NPI as other assemblers. You must know before you start which vendor will give you the best NPI results with your design. Here are some items to consider before you commit.
A New Product Introduction Checklist for Manufacturing PCBs
Local Facilities
Circuit board manufacturers are ubiquitous across the globe, and while some larger manufacturers overseas may offer lower prices, there may be tradeoffs. For example, time zone differences and language barriers can slow the rapid change cycle typical with NPI builds. Getting fast and inexpensive shipping to work with your boards quickly is also worth considering. On the other hand, a local manufacturer will be able to work with you in real time and get a finished product to you quickly to keep the NPI process moving along swiftly. You can also be more confident of a local manufacturer’s qualifications, certifications, and capabilities.
Manufacturing Flexibility
PCB contract manufacturers vary in size and capabilities, and you need to find one that excels in flexibility. PCB CMs focusing on high-volume production may encounter challenges altering their processes to handle the sudden design changes during the NPI cycle. However, a manufacturer specializing in mixed-volume builds instead of high-volume is familiar with a rapidly changing production environment; these CMs typically make for a better NPI manufacturing partner. They will have multiple checkpoints built into their manufacturing lines for manual oversight and quickly adapt to any prototype or NPI build changes.
Engineering Expertise
Since the PCB NPI process focuses on readying the design for production builds, the manufacturer you choose must have a high degree of engineering expertise. The PCB CM must review the board for design for manufacturability (DFM) problems and verify the bill of materials (BOM) for assembly. As design changes arise during NPI, the CM should also be able to implement these alterations to both the layout and the schematic. Additionally, the CM should have the circuit, mechanical, and system-level design capabilities and capture all NPI changes in fresh documentation.
Component Procurement
One of the keys to full-scale mass production of circuit boards is using quality components at a reasonable price. Often, prototype designs use older or unavailable parts that need to be updated, and the CM must substitute these hard-to-source components with replacements. This process requires a procurement staff with a vast network of component manufacturers, distributors, and brokers, plus experience working with the electronic components supply chain. They must plan long-term production quantities and look for form, fit, and functional replacements when necessary. The CM should also have a good supply of stock parts and experience avoiding counterfeit components.
Business Relationships
A good CM for NPI builds will also have a network of business relationships they can leverage. Examples include circuit board fabricators, parts and materials vendors, and outside engineering services for additional tests or qualifications.
Additional Services
Lastly, a good NPI manufacturer will offer other services to help you. These services include turnkey production, box builds, cable and wire harness assembly, and 3D printing. Once you’ve qualified your vendor, you will be ready to have your NPI circuit board built. But first, there are a few things to do on your end that will help your manufacturer complete your project efficiently.
Your Contract Manufacturer Locks-In NPI Designs
The first item on your NPI checklist is to choose your manufacturing partner carefully. At VSE, we are a high-mix, mid-volume PCB manufacturer known for our flexibility in building prototypes and NPI boards for our customers. We understand your challenges as you prepare a design for total production. Our staff of experienced engineers and procurement specialists will ensure that your NPI design’s configuration is optimal. Our goal is your success, and we are committed to helping you develop and build a high-quality circuit board.
