Form, Fit, Function: A CM’s Approach to BOM Management

Circuit Board Components Precisely Engineered for Form, Fit, and Function

Installing the correct components on your circuit board is the foundation of its ultimate performance and success. PCB contract manufacturers are cautious about sourcing and using the parts you have specified in your design. However, there are times when the components you’ve selected are not available for assembly, and the manufacturer must use alternative parts instead. In these cases, the replacement components must match the original parts in form, fit, and function.

At VSE, we understand the importance of delivering a wholly assembled circuit board that functions according to your original design intent. When a component replacement is required, we have numerous resources to utilize to match your original part’s form, fit, and function.

Choosing the Right Components for a PCB Prototype

The prototype build is the first step in manufacturing a new printed circuit board design. Often, these boards are designed and built according to a tight development schedule and will reuse familiar circuitry and components from previous designs to save time and money. If the parts are too expensive or unavailable, this can lead to problems when the board moves into long-term production. VSE is well acquainted with the component needs of prototype designs moving into production.

Pre-Prototype Production Evaluation

BOM Review:

Lowest price?
Quantity/sourcing issues?
Manufacturer’s production status?

Component Changes:

Reduced part cost (relaxation of tolerance, packaging, etc.)
Improve time-to-market with better lead times
Improve functionality

Circuitry Changes:

Changing circuit function/scope due to component availability
Streamline manufacturing and testing with more appropriate component integration

The development goal of a prototype PCB is to use parts that will easily transition to long-term production. At VSE, our engineers have years of experience helping customers find long-term production components that are a good form, fit, and function replacement for the original prototype parts. To do this, we will work with you to create an approved vendor list (AVL) that is procurable and uses component suppliers that meet your standards. This process will give us the best opportunity to procure the necessary parts and materials to keep your prototype build on track and lower costs.

Component Replacements on Production Circuit Boards

Another important use of our component engineers is finding replacement parts for circuit boards in long-term production. In some cases, legacy designs will be in production for many years, and the components they use can change for the following reasons:

A component that has been in use for several years is now unavailable because the manufacturer has declared it obsolete and is no longer in production.
Other electronics manufacturers have bought the part’s current stock, which will take too long for the manufacturer to re-supply.
Prices on a specific part have escalated, making the board too expensive to build.
Other circumstances, such as national emergencies, have affected the supply chain for specific parts.

Although redesigning the board with different circuitry is an option, it can be expensive and time-consuming. In many cases, a redesigned circuit board must be re-qualified and re-certified for use, adding additional time and expense to the project. Here is where the component engineers at VSE can help by finding the perfect form, fit, and function replacement part to keep the production of legacy designs moving forward.

Form, Fit, and Function in PCB Components

Finding a form, fit, and function replacement component is integral to developing prototype circuit boards and their eventual long-term production. The part must have the same package outline and fit in the same component holes or solder to the same surface mount land patterns as the original. It must also perform precisely the same as the original part to qualify as a form, fit, and functionally equivalent part.

In some cases, however, an exact match isn’t available. Here is where the VSE engineers will go to work on the design and come up with the best solution. It may be that the form and fit are slightly different, which will require a redesign of the circuit board. Sometimes, a “better than” part is used, such as replacing a 5% resistor with a 2% version of the same part. The part’s form, fit, and function will be the same, but the resistor will have more precision. Whichever solution is required, we assure you that we will have the best manufacturing engineering team working for you with VSE.

Experienced and Knowledgeable Component Engineering at VSE

At VSE, we have over 40 years of experience building circuit boards, and we are proud to provide the following services for our customers:

Component engineers with expertise in all types and variations of parts
Design engineers who understand the circuitry requirements of your projects
Procurement teams with experience working within the component supply chain
Highly skilled manufacturing technicians and engineers who build high-quality circuit boards

VSE has a long history of building circuit boards; our engineering and component teams are well-versed in improving manufacturing outcomes by addressing component form, fit, and function. Let us know about your next printed circuit board design, and we can apply our component expertise to help you complete your project on time, at the best price, and with the highest level of quality.

If you are looking for a CM that prides itself on its care and attention to detail to ensure that each PCB assembly is built to the highest standards, look no further than VSE. Contact us today to learn more about partnering with us for your next project.