Box Build Assembly refers to the assembling of the PCBA as well as the box and enclosure in which the product is encased and parcelled. After the PCB has been designed, tested, and finalized, the box-build assemblies are then used in mass production. In this article, we will discuss some common mistakes that need to be avoided in manufacturing box build assembly.
Components of Box Build Assembly
Some of its most common components include connectors, custom cable assemblies, batteries, an enclosure, some heat sink attachments, brackets, fans, etc. Other components such as PCBs, AC-DC converters, sensors, motors, relays, buttons, touchscreens, lights, speakers, nuts, bolts, stands, peripherals, antennas, metal shielding, etc. are also present in the box build.
Box Build Assembly Process
Even though the process varies according to the complexity of the product, the general outline of the assembly process remains the same.
- Design Stage
In the first stage of the process, the product’s specifications, requirements, features, and detailed assembly and manufacturing instructions are planned and designed.
- Procure Necessary Components
In the second stage, all essential components of the box build such as the PCBs, connectors, switches, cables, buttons, etc. are sourced.
- Enclosure Preparation
Prepare the enclosure that will be used to enclose the components as well as all the mechanical components such as fasteners and brackets etc.
- Installing Components
Place the PCB and all other electronic components into the enclosure at the appropriate positions while considering the assembly instructions. Do so by using screws, nuts, adhesives, etc.
- Route Cables
Connect all the cables and wires between components according to the planned design. Make sure that they are secured so that no interference occurs in the enclosure.
- Install Power Supplies
Integrate power supplies as per the requirement of the circuit and ensure proper and safe connections throughout the circuit.
- Assembling Mechanical Parts
Assemble and secure all the required mechanical parts such as covers and structural components etc. with the help of fasteners.
- Software Integration
Integrate software or firmware onto the components, ensuring the accuracy of programming.
- Assessing and Testing Sensors
Assess and test the sensors and components to ensure their functionality. Moreover, do electrical testing of the components as well to verify the proper connections between the components.
- Assessing Defects and Errors
Finally, the end product is inspected for any defects or errors, and it is ensured that it meets all the quality requirements and standards.
Box Build Assembly
Common Mistakes that Occur in the Box Build Assembly
The following are the most common mistakes that box build assembly manufacturers need to avoid at any cost to proceed with the assembling process effectively and efficiently.
- Select Wrong Source for the Parts
There are two options for selecting a source for the parts or components used in box build assembly: one being a custom and the other being a readily available one. It is important to source the parts or components with accurate parameters, durability, heat tolerance, waterproofing, texture, etc. The basic function of readily available parts or components is that it not only has lower unit prices but also limited order requirements and thus limited custom ability. Whereas custom parts or components satisfy unique needs. Therefore, they are more expensive and time-consuming.
- Incorrect Documentation
It is crucial to ensure that all the documentation is correct and in place irrespective of the type of enclosure that you selected. The documentation must include a detailed history of all CAD drawings, versions, tolerances, BOMs, box build’s components, and assembly techniques so that the information related to any of these things is backtracked easily when needed.
- Poor Testing Procedures
The box build is only good to go when it undergoes rigorous testing of both the enclosure as well as the PCB. This is usually done through soak testing and stress screening which, when done properly, ensure the fitness of the box build for the targeted environment. In addition, some PCB-specific tests such as boundary scans, ICTs, flying probes, etc. ensure the feasibility of the product.
Soak testing tests the performance of software under immense data load whereas stress screening tests the durability of the product by pushing it to the point where it may face any failure. Similarly, PCB interconnects can be tested with the help of boundary scans at the integrated circuit level. On the other hand, In-Circuit Testing (ICT) can be used to verify the proper functioning of electronic components on the board. It also helps in assessing the quality of the components. It is usually done before moving on to the next stage of production or shipping the final product to the customer. Additionally, flying probe testing involves testing the probes from one test point to another according to the instructions given by the specific software for the board under observation.
- Other Issues
Some other issues arise if a quality box-build company is not selected. Therefore, the box build assembly manufacturers must consider the production volume, experience with the company, technical capabilities, and other services before outsourcing the box build. Additionally, they must also take care of the bill of materials (BOM) for the particular project. The BOM is of significant importance as it has a complete description of the components and materials required to make their product. It not only helps in finding the appropriate products for manufacturing but also provides a clear idea of the cost, space, and overall source requirements for the build.
Choose a Reliable Box Build Assembler to Avoid Common Mistakes
To avoid the common mistakes mentioned above, we should find a reliable box build assembly service provider. Before choosing a box-build assembler for your product, consider the following qualities.
- Only choose the companies that are proven to have experience in assembling box builds similar to that of your product.
- Visit their production facility and assess their assembly lines, equipment, technology used, testing procedures, etc., and ensure that they can provide you with your desired products.
- Ensure that the company has ISO certifications and FDA registrations etc., that ensures that they follow strict quality standards and procedures.
- Take feedback from the past and current customers of that company to find out about their experience and assess the quality and responsiveness of the company.
- It would be a plus point if the company is known to follow some rigorous quality control procedures such as in-process inspections and optical testing etc.
- Make sure that their staff and systems follow all project management protocols and take special care of schedule coordination, change management, client communication, etc.
- Examine their ability to manage their supply chain management processes as well as procurement, inventory, logistics management, etc.
- Make sure to get detailed quotes and compare costs across different assemblers for assembly, tools, components, etc.
PCBA and Box Build Assembly
Benefits of Outsourcing the Box Build Assembly
There are many box build assembly services that companies can benefit from.
- Streamlined SCM
Using a box build simplifies and streamlines the supply chain management process as the company only needs to source the product from a single supplier instead of managing different components coming from different vendors.
- Cost and Time Optimization
When the product is outsourced, the production is optimized, which reduces the costs. Additionally, since the supply chain management process is streamlined, the company does not have to look out for the manufacturing, assembly, testing, and quality control processes separately. Instead, all these processes are managed by a single vendor. This saves the company a lot of headaches as well as time.
- Reaching out to Professionals
One of the many advantages of outsourcing a box build is that one does not have to go into the intricate details of the several processes themselves. Rather, they can take advantage of the expertise and knowledge of the service providers who ensure a high-quality end product.
- Quality Control
Since the box build manufacturers are professionals, they maintain strict quality standards and run several tests to ensure that the product is of ultimate quality as per the needs of the client.
- Flexible Production
The box-build assemblers specialize in scaling production up and down as per the requirements of their clients. Therefore, they can be flexible and produce in small batches or do mass production by using their resources, top-notch equipment, technology, and skilled staff, etc. with greater ease.
Conclusion
To conclude, the electronic components and elements are all housed in a box build. Since box build assembling is a crucial and often complex procedure, many errors are bound to occur. Hence, if box build assembly manufacturers are assembling the box-build themselves, they must take into account all the possible mistakes that may occur and try to mitigate them. Additionally, they must also choose the enclosure and all necessary components and materials necessary for assembling the box build. However, if they lack the knowledge and expertise to do so, they can outsource the product to any of their reliable vendors. It is also important that one must understand the complexity of the whole process and outsource the box build to an assembler that has all the qualifications of an experienced assembler so that the production, assembly, time, quality, cost, etc. can be optimized. Moreover, they must ensure that their selected vendor follows all the quality standards and delivers the end product efficiently and effectively.