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Simply irresistible: Brexit and the UK electronic manufacturing sector

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Making it easy for others to do business with you is vital, especially in the current political climate

There is no escaping the current headlines around Brexit, from scaremongering over the repercussions of a hard deal or the unknown consequences of no deal at all. For UK manufacturers, indeed for all UK businesses, the most frustrating aspect of this situation is exactly that: the unknown. Knowing the likely outcome and what will happen, won’t happen, or needs to happen is vital: without this knowledge, it’s like walking into a meeting with no agenda or starting a project with no strategy. Business works well within parameters and when it’s driven by facts, plans and targets; this current situation leaves no room to make any such plans, let alone embark upon them.

However, Brexit is not the first defining moment in British business and certainly won’t be the last. The priority now is for ‘UK PLC’, from the political stage down to each and every boardroom, to collectively work to make themselves an attractive business proposition. Whether Brexit is hard, soft or deal-less, the fact remains that we are a nation with goods to give and services to offer. The same goes for businesses: no matter what the specific circumstances or market conditions are, if we shout loudly about what we do, how we do it better and the results we can deliver, the rest is largely inconsequential.

In business, opportunity is everything. Turning every challenge into a door to be opened and a new prospect to be explored is the best way forward. In terms of Brexit, despite inevitable challenges, leaving the EU will present new opportunities and the chance to try new avenues and strategies. This can be translated into business: every challenge encountered is and should be an opportunity to try a different method, whether it’s trying a new supplier, switching to automated processes or opening a new location.

With any business negotiation, it’s crucial to establish what factors you can emphasise or accentuate in order to sell your best strengths and make it difficult for the other side to disagree to your terms. Now is the not the time to be modest: shout about your achievements and showcase your results. That said, it’s also vital to convey a positive attitude and sense of collaboration. No one is going to want to do business with any individual or organisation that seems as if it will be a tricky customer.

Whatever happens with the Brexit negotiations, it’s essential that the UK is perceived as an attractive prospect and an exciting partner: a lesson that can be taken and repeated in every business. Together, if we play our cards right, we could be a force to be reckoned with.

Electronic product testing: Delivering integrity and confidence

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Electronic product testing strategies

The increasing complexity of electronic technology that OEMs seek to produce demands an ever more efficient, agile and precise manufacturing process.

At the same time, OEMs also are looking for EMS partners who can not only deliver this but also offer highly effective test strategies at every stage of production.

And the key words here are strategies at every stage of production.

When it comes to testing electronics there is no universally right or wrong method that can be plucked magically from the hat or pulled ready-made from the shelf.

Instead there are a variety of methods that can be determined only by an analysis of factors such as the profile of risks arising from the specific production processes, the intended use and the throughput requirements. It’s also vital to consider the material characteristics of each component used and of course data arising from current failure mode capture and defect history.

By gaining insight and understanding of each of these elements, it’s possible to determine the most cost-effective testing processes needed to achieve the required levels of integrity.

This is why the increasingly complex OEM demands call for an EMS partner with a variety of testing capabilities and a track record of ensuring integrity in products far beyond the ramp and into the product’s full life-cycle in market.

At Chemigraphic, we do not hold to the oft-cited view that the importance of testing lies solely in ensuring products hit the critical timing required for an orchestrated market entry to maximise market share.

It is true that in electronics manufacturing, product launches can be delayed by faults that should have been identified and resolved much earlier in the production process.

However, testing policy should extend beyond just the physical test process…

OEM product design engineers often define their own test processes and since their primary concern is usually design validation, a version of this can then migrate to serve as the manufacturing test solution.

However, design validation is about methodically configuring, exercising and stressing every area of circuitry, giving confidence that each of the design elements meet the functional requirements. Since the validation tests are often undertaken by the design engineers themselves, they can be complex, requiring deep analysis of signals and timing. They are also often undocumented, use expensive analysis equipment and are manual in nature. Design validation is often a singular non-repeating event, so the length of time taken to perform these tests is largely irrelevant, and a single setup is usually sufficient.

All of this is not operationally efficient and may not even be appropriate, within a manufacturing environment where the key objectives for testing are:

  • To ensure the test captures the actual profile of risks likely at a given stage. In a manufacturing environment, these will relate to construction and assembly, components and workmanship, rather than design.
  • Eradicating redundancy. Testing is an overhead cost and performing tests which do not ultimately capture defects results in the unnecessary waste of time and resource. For instance, if there is some form of signal processing chain, then a designer will want to know how each segment performs and will undertake interim measurements. From a manufacturing perspective, it is more effective to check the output and, if correct, then all the interim stages must be correct by default. The facility to undertake interim measurements as part of a debug cycle to isolate defects is useful, but there is otherwise no need.
  • Simplification. The ideal manufacturing test is a quick go/no-go, pass/fail test that any operator can perform. Hence we try to eradicate any complex software setup/configuration, or interpretation of results.
  • Scalability/ parallel testing. Reliance on a single test setup causes a dependency and potential bottleneck. Investing in an expensive fully automated, high-speed test solution may seem prudent, but if a number of more modest setups can be run concurrently, then the overall throughput and cost-per-test can be better.

A testing strategy with true integrity must future-proof electronic devices not just for launch but for life.

Defects not detected at an early stage of production carry increasing cost implications the later they are detected in the manufacturing process.

Likewise, defective products reaching end customers risk high return costs and incalculable reputation damage.

Both can destroy the bottom line – and both should be avoidable.

The best EMS partners can deliver confidence to OEMs and integrity to their products through a rigorous, flexible and comprehensive test solution.  The earlier a trusted EMS partner gets involved in product development, the better an effective (and cost-effective) test and inspection strategy can be comprehensively defined.

Early engagement lies at the heart of testing integrity and may involve a critical analysis of the product complexity and make up of PCBs, including component density and type. Commercial consideration will also be given to the volume profile, maturity and current stage in the lifecycle of the product.

All of this will ensure that the deployment of a suitable test and inspection solution neatly matches the required new product introduction process.

 

Electronic product testing at Chemigraphic

At Chemigraphic, we offer comprehensive quality control programmes and test services that ensure our customers have 100% confidence in the integrity and functionality of their products before they go to ramp.

Our testing capabilities support the full lifecycle of your product, from design to obsolescence, and include:

  • Inline automatic optical inspection on all SMD lines
  • Endoscope for defect analysis
  • ‘Bed of Nails’ ATE for MDA, or where appropriate, combinatorial testing
  • JTAG – boundary scan
  • Device programming
  • Numerous bespoke functional test rigs
  • On-board programming of electronically programmable devices (EPDs)
  • Safety testing
  • X-ray technology on site

Our services don’t end when your product goes to ramp – we test for its full lifecycle.

Here’s an overview of the range of testing we offer.

AOI

Automated optical inspection (AOI) has been proven to be 65% more effective in identifying faults than manual inspection. With the ongoing progression in HD camera imagery and improved software processing, AOI is getting ever more reliable.

It is also increasingly affordable, making it no longer solely suited to the fully automated in-line production systems of high-volume product profiles. There are now some incredibly reliable and cost-effective bench-top systems for smaller product profiles available.

The latest systems have the capabilities to inspect the decreasing size of components and handle the ongoing reduction in size of PCB technologies on target boards.

Electrical testing

However, inspection alone can leave potential faults undiscovered. It is here that electrical testing is most efficient.

Electrical tests can be divided into two types: process tests and functional tests. Which type you use, or whether you use a combination, depends on the types of faults you are hoping to detect.

For a long time, the In-Circuit Test (ICT) has been the most effective method of electrical testing for high-volume manufacturing processes.

Tests for shorts, opens, missing, polarity, incorrect or defective parts have been laid bare using this bed-of-nails technique. The automated ICT now also allows you to power up the board under test and even perform a level of functional testing, or Boundary Scan, through the integration of testing instruments.

However, there are some drawbacks to ICT, particularly where the manufacturing volumes are not high. The cost of fixturing and programming can be high, and the need for test point access which requires ground up design for test (DFT), adds further to the testing investment.

Another option that offers an alternative to the one-off set-up costs of ICT is the Flying Probe (FP) system. This is ideally suited to product profiles that are lower.

Such systems vary in capabilities greatly, ranging from basic MDA (Manufacturing Defect Analysis) to the inclusion of Boundary Scans. The major advantage of FP is the relatively low cost to the OEM: as no fixturing is required and only a test program needs to be written. The best FP systems offer many of the same capabilities as ICT.

X-rays

Many products, however, will require an extra level of testing beyond those already discussed. For devices with hidden joints, such as BGAs and POP, AOI will not reveal voiding which can lead to product failure when being used.

X-Rays offer the best ability to detect such structural defects in solder joints. They can also be used to enhance fault detection in components themselves and in high density connectors.

Maximum test coverage – minimum opportunity for error

Chemigraphic offers a variety of tests that can be used in combination according to each product’s requirements. We maximise our test coverage to minimise the opportunity for error.

This offers you 100% confidence when products go to ramp and build in the integrity products need for their full life cycle.

From hackers to Brexit: the challenges facing defence manufacturers today

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The UK may have the world’s second largest aerospace and defence industry but it is facing some of the toughest challenges in its history at the present time. Cyber-security threats, Brexit and manufacturing challenges related to the hazardous environments its products are used in are three major obstacles to growth.

Yet help in overcoming these may be much closer to hand than defence OEMs (Original Equipment Manufacturers) imagine.

Here’s how partnering with the right manufacturing partner can help OEMs rise above the biggest challenges they face.

Data and cyber-security challenges

All UK manufacturers are under threat from professional cybercrime gangs looking to access intellectual property, but it is defence manufacturers that are the main target for hostile nation state actors.

Such hackers typically work on behalf of a government to disrupt or compromise defence OEMs. Their ultimate goal is to try and access classified information about military technology.

Nation state threats are thought to only make up about 10 percent of all cyber-attacks worldwide. Their impact, however, is disproportionately large: they are the hardest attacks to resolve and the trickiest to detect, and they are increasingly causing more and more disruption. SecureWorks research suggests it is taking five times longer to fully evict a nation state attacker from a network every year.

The Bronze Union is the nickname given to one such group of hackers. They are believed to operate for the Chinese government and, in recent years, they have made several high-profile attacks on defence manufacturers. One infiltration technique they use is a Strategic Web Compromise (SWC) – a targeted attack which infects websites that employers visit and lures them to access a malicious site.

Yet, attacks are not always as direct as this. Such groups are adept at locating and exploiting vulnerabilities and weaknesses in the OEM’s supply chain as well as its employee’s browsing habits. The notoriously aggressive NotPetya attack used trojanised updates via widely-used software to infect the PCs of organisations across the world, but particularly in Ukraine. The perpetrators are believed to have been working on behalf of the Russian government.

Never has it been more important for defence OEMs to partner with EMS providers who take the inherent risks of security threats with the same rigour as themselves. As we move into the full-scale implementation of Industry 4.0 new entry points can be exploited in IoT devices themselves as well as through the sheer volume of data that is being stored in the cloud. With so many sensors and data collection points now being installed within military devices and products there is now another layer of risk potentially embedded in each device that is shipped into service.

Challenges facing defence OEMs - Surveillance

Brexit and funding challenges

Not every threat facing the defence OEMs is a veiled one issued from the other side of the world. Perhaps the biggest challenge today is emerging from sources closer to home. The disruption to established trade relationships that Brexit may bring about has the potential to cause more severe losses than even a major malware incident. With more than half of its turnover realised through export, any losses from the UK defence sector’s overseas market will have resounding repercussions.

The UK’s standing and relationship with European Aviation Safety Agency (EASA) and the European Open Skies regime (ECAA) are still under question. If not quickly resolved, these could deliver a serious blow to the industry.

A further risk is the loss of EU grants and funding sources that the UK defence sector has enjoyed. These include $500 million each year that is potentially available from EU Defence Research and Development grants and EU space research funding, which is valued at around $15 billion over the next few years.

The possible disruption to the UK’s role as a part in the EU supply chain could wreak as much havoc as the loss of funding – and, given the UK’s persistent shortage of engineers, any barriers to the movement of people would have a similar negative effect to the movement of goods.

The way that Brexit will pan out is notoriously hard to predict – but it is clear that now is the time for OEMs to look to consolidate their supply chains to ensure they are operating at maximum efficiency.

And being highly selective in choosing EMS suppliers to partner with will play a significant part in achieving this.

Hazardous environments and manufacturing challenges

The most immediate way that contract manufacturers can support defence OEMs through the challenges that face them has nothing to do with politics or crime. Increasingly there are complex manufacturing requirements that must be met by electrical components used in defence products. An ongoing challenge facing OEMs relates to the environment their products will be used in.

Electrical components used in situations involving explosive atmospheres or flight require a number of extra measures to ensure they are robust enough to survive. In such conditions, adhering to Intrinsically Safe standards is vital, and something that the EMS partners chosen must be highly skilled and experienced in.

With any manufacturing process, it’s essential to keep comprehensive records, and this is particularly critical when it comes to developing products for the defence industry. As so many complex conditions and procedures are involved, every step in the manufacturing process must be accounted for, with the correct documentation and certification where required.

Only an EMS partner with a sophisticated data network can monitor and track this – and tracking this is just as critical to a successful product launch as the manufacturing process itself.

Overcoming challenges

Working with a trusted and experienced EMS partner can reduce many of the security, efficiency and manufacturing risks that defence OEMs face.

Yet, the industry will also require more than a robust and well-managed supply chain and highly-qualified manufacturing partners.

Defence is far from an open market and the success of the UK’s defence industry is closely associated with the level of government support it receives. Whatever the effects of Brexit may be, economic diplomacy that embraces military sales, must be seen by the UK government as a strategic policy tool to win the hearts and minds of friendly foreign states.

What does the IoT mean for Electronic Product Manufacturing?

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Manufacturers are leading the way as early adopters of the Internet of Things (IOT). Connectivity, constant communication and data sharing are being used to achieve a greater automation of tasks, a more responsive process and greater efficiency throughout.

The consumer market for IoT may hit the news more regularly but behind the scenes the real developments are taking place in manufacturing.

Within Electronic Manufacturing Services (EMS) all types of machinery are already embedded with sensors, switches and intelligent controls to generate data that is collected in real-time, analysed in the cloud and acted on immediately – and often automatically.

But the benefits of IoT do not just stop at the factory floor. Data on the performance of products, the supply of materials and despatch logistics are creating a smart supply chain that stretches from vendor to consumer.

The IoT is here

The IoT is already transforming manufacturing.

  • According to the latest IDC data manufacturing is spending $178 billion a year on IoT – and that’s more than twice as much as transportation, the vertical with the second largest spend.
  • It is predicted that manufacturing will lead the way in IoT innovation and implementation all the way into 2020 and beyond.
  • Research firm BI Intelligence expects the number of connected machines in manufacturing environments to increase four-fold – from the 237 million there were in in 2015 to 923 million in 2020.

Let’s take a look at what the IoT is being used for in the EMS sector.

What does the IoT mean for EMS - smart device

What the IoT means for EMS

Here are the smart ways that the IoT will transform EMS providers.

Smart ordering

Data can be streamed from sales to production, creating an autonomous assembly line that automatically reconfigures itself to produce products in small batches as demand arises.

Smart production

Productivity can be optimised by communicating data about system health – and machine learning can automatically act on this for plant-wide process control and maintenance.

Systems can be automated to adjust manufacturing sequences and speeds to help balance lines and match production more closely to customer demand.

Smart supply chain

The IoT can facilitate a transparent supply chain. The production-system portal can be accessible beyond the organisation’s boundaries, to allow suppliers to track consumption and quality issues in materials, for example.

Smart QC

IoT sensors and advanced analytics can make it possible to detect even the smallest error or defect during production, giving EMS providers more control over their output.

Smart fixes

Currently, most manufacturers address production issues or equipment failures as they arise, but with IoT and machine learning, systems can be automated to intelligently identify and address issues on their own without the need for human intervention.

Smart H&S

Early detection of malfunctioning systems – thanks to sensors and connected devices – can help prevent injury to employees who would have otherwise been unaware of the situation.

PCBs, ICs and the IoT

Before we get too transported into a Brave New World, it’s worth considering some of the challenges that the introduction of the IoT may bring.

Not least of these is the need to identify new protocols and standards across the supply chain.

To illustrate this, here’s some news from the frontline of IoT implementation that may serve as a cautionary tale.

The IoT is poised to enable the linking of wafer fab to the printed-circuit board factory.

EMS companies are increasingly manufacturing products with components such as bare die, MEMS, and optical devices, requiring more IC-like assembly equipment, precision placement processes and two-way communication between tools and factory systems.

In many ways this is blurring the distinction among EMS companies, OSATs and foundries.

Paula Doe, of SEMI, recently called for EMS providers to consider adopting the sort of automation standards already used in wafer fabs if they are to succeed in realising the potential of smart manufacturing.

She argued that vendors must collaborate to ensure their production equipment interoperates and supports factory analytics and data management systems.

This is an interesting snapshot of our times, revealing both the gains and challenges that IoT offers.

  • Firstly, it reveals how electronics assembly production has advanced beyond ‘board stuffing’ and is now more akin to fabricating ICs.
  • Secondly, it shows how production tools’ ability to communicate with each other can really start to blur the traditional boundaries in manufacturing: what once were discrete operations are increasingly being merged and integrated, creating ever greater efficiencies.
  • Finally, it shows some of the challenges that the IoT’s introduction can create. With more systems talking to each other throughout the supply chain there is an obvious need for a range of industries to come together and adopt common standards. Without these there is a very real danger that the full benefits of IoT won’t be realised.

For all the opportunities the IoT offers us, it’s just as important to remain aware of the challenges we face in the present as the potential it promises to deliver in the future.

Six Reasons to Outsource Electronic Manufacturing

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Manufacturing

The decision to outsource manufacturing can be daunting. Production needs can often be met in-house however, if there is an increase in demand, your organisation may need additional resources. Whether you’re a start-up or an established business, you may want to weigh up a number of factors before you take the leap. We’ve outlined the six main benefits to outsourcing manufacturing below:

1. Flexibility

If you experience a surge in orders for a particular product you may require additional resources to keep up with demand.

A contract manufacturer will often have more production capacity and be able respond quickly, supporting existing in-house manufacturing efforts and helping to fulfil orders without increasing direct labour costs.

It may be counter-intuitive, but larger manufacturing operations running high mix, often have more options for flex.

2. Expertise

Outsourcing manufacturing will allow you to take advantage of specialised contractors’ industry expertise and innovation. Typically they will take a strategic approach to your existing processes, recording your activity and suggesting ways in which to standardise production, improve accountability and increase efficiency.

A mid-size OEM might introduce 10 or 20 prototype designs in a year, whereas an EMS could deliver up to 500. This creates exposure to a vast range of technology, which demands a significant upscale of capability, systems and processes.

3. Scale

Mid-size OEM in-house manufacturing operations might support 20 different products totalling £2-3m in manufacturing costs. However, an EMS of scale can support 1000-2000 different assemblies totalling £20-50m in value.

This means an EMS organisation has ample justification to invest in the very latest of high-speed, automated equipment, which is often beyond the reach or justification of an individual customer.

Of course, the equipment is just half the story, as scalability also brings opportunities for sophisticated high-operational efficiency processes across the delivery of high volumes.

4. Cost

Outsourcing can provide significant savings on associated manufacturing costs including quality control, utilities, shipping, material handlers and equipment technicians.

Material spend is another significant factor. Consolidating several OEM material spends at an EMS creates a x10- x100-fold increase in spending power, providing direct access to global manufacturing channels and cutting out the proverbial ‘middle man’. This means EMS partners can overcome minimum order quantity (MOQ) restrictions, and access the very best price breaks.

Also, larger EMS material spending power means that components can be sourced in machine-friendly formats which increase automation and traceability, further enhancing product integrity and overall performance.

5. Efficiency

Your core competency as a business may not necessarily be manufacturing, in which case, outsourcing this non-core activity will help you to focus on what you do best so that you can increase revenue and profit.

6. Quality

International standards usually ensure that every aspect of the contract manufacturer’s business is well-run and subject to high quality control. OEM in-house manufacturing staff, though competent in many areas, may lack knowledge of the latest systems and technology needed to deliver the standards you require on a larger scale. Outsourcing to a partner with the capability and most up-to-date equipment will improve the final output, increase efficiencies and reduce costs in the long-term.

The key is to find a contract partner with the skills and knowledge to streamline your existing processes; enabling greater efficiencies and providing scalable solutions. Chemigraphic is adept at working with businesses to formalise the manufacturing process, eliminate inconsistencies and introduce product standardisation.

Read on for a detailed example of how Chemigraphic enabled Hydro, a leading provider of hi-tech water management solutions, to transition from self-manufacture to a sophisticated process-led approach.

Q&A with Margaret, Inspector & Auditor

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QA

Q&A: Margaret, Inspector & Auditor

  1. How long have you worked in the industry?

Just over 22 years! I was working elsewhere in the Electronic Manufacturing Services (EMS) industry for five years before joining Chemigraphic, and have now been working here for over 17 years.

  1. Why did you choose to work in this field and in the manufacturing sector in particular?

I have been working in final assembly for several years and therefore becoming an Inspector and Auditor was the next step in my career path. The role requires a high amount of experience as it involves managing one of the key quality checks carried out throughout the manufacturing process. Due to my long history in the field, I was offered the position which I gladly accepted.

  1. What do you love about your job?

There are many things I like about working for Chemigraphic. My role as Inspector and Auditor allows me to work somewhat independently as I am able to manage my own workload and prioritise jobs that I really enjoy.

I also love working here as it has a wonderfully friendly environment, where everyone involved feels part of the same big project. It is important to me to enjoy where I work, which explains why I have been here for so long!

  1. Describe a ‘typical’ day for you.

I inspect and audit Printed Circuit Boards (PCBs), checking the quality of assembly and ensuring that all the components are correctly placed. We check to see if there is any damage or polarity on the boards and their components. At Chemigraphic, the quality of our products is vital to our customers and therefore the business; we have several systems and control processes in place to check for product quality and to confirm they will be fit for purpose. Many of the products we manufacture are used in hazardous environments, or in defence or healthcare industries, and therefore their long-term reliability and functionality is critical.

  1. What’s been your proudest achievement in your career so far?

One year ago, I became the team leader which was a great experience and allowed me to achieve an NVQ in team leadership.

  1. What’s the biggest change or development you’ve seen since working in the industry?

A technological development that has improved efficiency is the move towards a paperless package, which allows us to look through the assembly instructions and specifications far quicker.

The realities of manufacturing augmented reality tech

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Augmented Reality (AR) is often touted – alongside the IoT – as the next big thing for manufacturing. It’s set to revolutionise industrial processes, improve efficiency, open new opportunities, cut costs and reduce errors.

However, there is a distinct difference between the application of AR techniques to aid the manufacturing process itself and the challenges involved in manufacturing AR-enabled products and devices.

For all the solutions and opportunities that AR may be set to gift manufacturing, it can also in many cases present OEMS with a logistical headache.

Here’s the thing:

AR devices present manufacturers with very complex process requirements and a series of challenges that start at the supply chain and continue through to the assembly line.

Here are just some of the ways that AR presents a challenge to manufacturers producing cuting edge electronic devices.

  • Expert supply chain management is needed to juggle the multiple components and processes involved.
  • The use of exotic or hard to find materials calls for assembly conditions that have been rigorously prepared.
  • The necessary form factor miniaturisation complicates the level of accuracy required in product construction.
  • Heat dissipation is a major concern and precision optics need calibrating with great attention to detail.
  • The latest cutting-edge technology needs to be applied yet every solution must lend itself to scalability in the event of increased product demand.
  • And, of course, the expense of all the parts and processes involved leaves absolutely no margin for error.

Let’s expand on just one of these challenges a little further:

Form factor miniaturisation is never simply a process of making everything smaller. Miniaturisation of one phase of a product usually reveals limitations and obstacles in other parts of the overall design and manufacturing process. Advances in a specific technology—semiconductor fab, pc board, power, manufacturing or packaging—tend to leapfrog other technologies. And the assembly line is not the place to be trying to play catch up.

Thermal management is also closely related to miniaturisation, especially as device speeds and packaging densities rise. Heat loads are really putting cooling techniques to the test, calling for innovative solutions for direct, spot refrigeration of high heat-flux regions on IC dies.

We love the AR challenge: it plays to all of our strengths.

But to counterbalance all the ‘AR is the saving grace of manufacturers’ hyperbole we’d like to add our own take on the relationship between AR and manufacturing.

From the shop floor, as it were.

Not the ivory tower.

The reality of AR manufacturing

Daqri is a US technology start-up. Having already wowed the market with its wearable tech the team were hyper-keen to launch their cutting-edge AR helmet.

Daqri helmet

The helmet has a futuristic pilot-style ‘heads up display’ that uses advanced short-range optical projector technology to overlay the user’s vision with advanced data feeds based on real-time information.

Whilst Daqri had exceptional design and development capabilities, it had little experience of the controlled manufacturing systems needed to deliver its finished product at scale.

When the team reached out to us their most pressing concern was co-ordinating a highly complex supply chain of suppliers – and that’s exactly what we excel at.

They asked us to manage the supply chain so that they could scale up their existing prototype to produce 400 developer systems.

It wasn’t easy: where AR is concerned it never is. But we micro-managed the global supply network and introduced a flawless production processes that allowed Daqri to meet its tight delivery targets.

In fact, they made the leap from concept to product in the fastest possible time.

Daqri construction

The future of AR manufacturing

According to CCS Insight many companies are going to be needing EMS partners with expertise in meeting the AR manufacturing challenge.

It predicts that augmented reality device sales are set to hit $11.9 billion in 2021. In volume terms this represents 99 million devices – each of which will carry the same manufacturing challenges that we outlined before.

2021 is not a date in the distant future: it’s barely more than two years away.

Looking to capture some of this market are the big names in tech: Microsoft, Google, Sony and Apple have all invested in some high-profile initiatives.

You can be certain, however, that there are also many labs out there with a killer prototype seeking funding to enter production.

And we’re happy to help turn an AR prototype into an AR product.

It won’t be easy, but with our attention to detail, focus on precision and dedication to strictly governed processes, anything is possible!

Forget wearable tech – electronic medical devices are going invisible

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Wearable tech was born at the point where wireless connected technology grew up and became, paradoxically, smaller.

Today, integrated tech that can be discretely worn by users is everywhere – from music to fashion to fitness. Whether it’s smartwatches, heartrate trackers or even clothing, there’s no shortage of integrated, miniaturised tech that allows us to keep tabs on ourselves as we go about our everyday life.

And yet, as disposable as the fashion for wearables may seem, it is actually all part and parcel of the way that the Internet of Things (IoT) is using connected devices and sensors to create medical products that can truly change lives.

But these devices go well beyond being wearable – they are now becoming invisible.

From wearable to invisible

This move from micro-tech to invisible tech can be seen in our wider culture beyond the arcane innovations emerging in medical devices.

Here’s what Forbes has to say about this wider trend:

“The main future change I see for wearables is the ‘disappearance’ of them: the integration of their smart features into everyday items.

The rise of invisibles will see wearable devices built into the things we use every day, such as clothes, accessories, shoes and jewellery. And it will feed us data that is probably more biometric in nature than it is now for deeper insights into our health.”

Examples of this aren’t too hard to find. There are already smart trainers on the market that can record your jogging data and smart shorts are available that collect combined muscle load with heart rate data.

That’s right, a pair of running shorts that can measure the electrical activity of your muscles and share this in real-time via Bluetooth to an app. They may be well beyond most joggers’ budgets but that’s another matter.

From invisible to indispensable

Medical electronics continue to drive innovation throughout the healthcare industry.

The global medical electronics market has seen tremendous growth in the past twenty years, in terms of money invested, technical advancements made, increased healthcare reach and the integration of our healthcare with both IT and the IoT.

Research and Markets suggests that the total value of the medical electronics market will exceed $56 billion by 2020, growing at an impressive Compound Annual Growth Rate (CAGR) of 5.5% in the next five years.

Healthcare wearables are increasingly evident with bracelets, pendants or smart watches, performing functions such as tracking, recording and reporting every step and heartbeat of those who wear them. The new Apple iWatch Series 4 launched just week (Sept 18) goes one step further and has the ability to take an electrocardiogram (ECG), which offers a much more detailed picture of your heart rate. You’ll be able to take a reading any time and get an alert if the Watch detects any abnormal rhythms – a possible sign of atrial fibrillation. Apple Watch Series 4_EGC Yet, this is just the tip of the iceberg: it’s what we can’t see that is truly revolutionary.

As a solution for many patients, wearables are actually fairly high-risk. What if they are removed or simply not worn? Or they are worn incorrectly so that the collected can’t be trusted?

The trend – as in the consumer market – is towards devices and sensors so small that you can’t see them. Or remove them.

“Invisibles will create a world in which we don’t see technology or sensors; they are seamlessly integrated into the human body.” Stuart Karten

Valeritas Holdings, Inc. manufactures the V-Go® Wearable Insulin Delivery device. This is a highly-affordable all-in-one insulin delivery option that is worn like a patch by patients with diabetes.

Epidermal electronic systems (EES) have taken this idea one step further. Its medical tattoos are patches that allow researchers and clinicians to track vital signs. Variations have been developed that can be voice-activated.

“Our goal was to develop an electronic technology that could integrate with the skin in a way that is mechanically and physiologically invisible to the user.” John Rogers

The pursuit of an invisible device is far from new for hearing aid manufacturers. For many years, hearing aids have shrunk dramatically in size as their functionality, comfort and capabilities have correspondingly increased. Instead of buttons, Starkey Hearing Technologies has developed hearing aids that are controlled by natural gestures. Other devices use GPS and cloud-based technology to personalise settings for geotagged locations.

And from audio to visual: Plastic electronics are now being used in smart contact lenses. Impregnated with OLEDS, these have been invested in by Google, Samsung, and Sony for applications that include blood glucose level monitoring as well as vision correction and enhancement.

Meanwhile, inside our bodies, Organic Thin-Film Transistors (OTFTs) are being used as bio-sensors which, when placed in a patient’s body, can be used to predict a stroke, an asthma attack or to prompt a diabetic patient to take their insulin.

Electronic medical devices of the future

We are still only just discovering the possible range of uses of invisible electronic medical devices – but we’ve certainly came a long way from wearable step counters. The technology will inevitably continue to develop as it does in any sector – to suite the rising demands of the consumer.

From complex to complete: On-time, on budget delivery of a cybersecurity device

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Advanced technology means lots of components, many of which are not easily available. Bare board requirements are complex and the assembly process can be lengthy with many barriers.

With a combination of expert engineering capability, hawkish attention to detail and tightly monitored processes; we enabled a Private Equity (PE) funded cybersecurity OEM facing these challenges to get its product to ramp on time and on budget.

The customer develops disruptive technology to guarantee entirely safe remote internet browsing. Its product is a high-density, high-speed multi-channel data processing device using Surface Mount Technology (SMT).

 The challenges

The device requires a high number of parts and complex board assembly, plus the need for strict security compliance to be adhered to. Like any intricate project, it presented a number of challenges.

Printed Circuit Board Assemblies (PCBAs) were needed and then applied to system rack configurations – which had to stand up to stringent testing and rigorous cosmetic criteria. The Bill of Materials (BoM) contained several high value parts which had long lead times or were only available in limited supply. And it had to be a rapid, highly effective solution which complied with government criteria.

Early engagement in the design process

We joined product development discussions with the customer team whilst the design was still fluid, so this early engagement in the design process meant we could add valuable input around component sourcing and manufacturing processes, leading to a cost-effective, scalable solution.

Firstly, we developed the customer’s main controlling PCBA using the latest SMT device packages. Once the initial assembly was complete, we then supported other functional subassemblies and peripheral system parts, helping to produce entire product systems.

We then facilitated the selection, review and validation of several global bare PCB vendors and managed the complex supply chain of components and specialist made-to-drawing parts, which were critical to the project’s success. We then established scalable sources across the entire BoM and created processes, with evidential support, to satisfy all security requirements from each stakeholder, including the Government.

The result: a happy customer

The result was a resounding success despite the product’s complexity. It now has an exceptional yield performance and importantly it reached the market on time and on budget.

We now provide full system assembly of all of the customer’s rack-mount variants for this product and our support will expand into global manufacturing fulfilment in the near future.

Automation transforms the manufacture of electronic medical devices

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How-automation-is-transforming-medical-manufacturing

OEMs servicing the healthcare and medical sector are feeling the squeeze as new technologies introduce as many new challenges as they provide opportunities and solutions.

Let’s take a look at the role of automation – and how it is answering old problems as it creates a fresh set of challenges – to those researching, developing and producing medical devices and products.

Automation, manufacturing and the medical sector

In a recent McKinsey Report manufacturing was found to be one of the sectors where automation can most easily be introduced.

478 billion of the 749 billion working hours (64%) spent on manufacturing-related activities globally are automatable with currently demonstrated technology.

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Specifically, in relation to medical device manufacture it was found that 60% of the hours spent on activities performed by production workers are automatable.

There are compelling reasons for OEMs to capitalise on the accuracy, efficiency, connected communication and agility that automation can bring.

OEMs of medical devices are experiencing increasing challenges in terms of price and margin pressure, speed to market expectations, increased product (and manufacturing) complexity and more stringent regulatory compliance.

  • There is intense pressure to produce and distribute medical products within ever-decreasing timeframes.
  • Simultaneously, the products are increasingly complex and regulatory requirements are more stringent and labyrinthine than in the past.
  • The trend toward personalisation and miniaturisation of medical products simply compounds these challenges further.

In many ways, it’s the case of a perfect storm hitting the sector – tighter regulation, more product variants, complex designs and sophisticated manufacturing processes are all coinciding with an expectation that development and distribution will be faster than ever before.

But, in other ways, it is a perfect opportunity for those who are positioned correctly to take advantage.

So, how has automation helped cause this situation? And how can medical OEMs position themselves to benefit from it?

The automated future of healthcare

It’s not just in the manufacturing process itself that automation is affecting healthcare. It’s also affecting the products developed and the services delivered.

Five years ago the medical device connectivity market was largely insignificant but it is now expected to grow 38% over the next five years.

Source

The biochip market is estimated to be worth around USD17 billion by 2020.

Source

  • A new area of bioelectronic medicine is emerging, thanks to the miniaturisation of electronics – tiny devices implanted in the body may help treat arthritis, diabetes and asthma by influencing electric signals in nerve pathways.

Other areas of innovation include robotic-assisted surgery, next generation smart inhalers that can track use and the ability to produce personalised products in small batches for specific patient requirements.

Juki

Automation and the healthcare supply chain

Automation and machine learning are set to radically improve the supply chain for the healthcare sector.

‘When we have visibility of product from manufacture to finished goods to the use on the patient, and we actually capture consumption activity rather than purchasing activity, we significantly reduce waste and variation in the supply chain.’

Steve Kiewiet, Vice President of Supply Chain Operations, BJC HealthCare

Automated tools can help organisations increase price transparency and streamline healthcare professional’s orders.  Meanwhile, Radio Frequency Identification (RFID) technology can capture volumes of data from a product’s barcode.

More effective healthcare supply chain management could help check the $5 billion that the American healthcare sector loses annually to pilferage and waste.

Source

And data from devices collected during use can be continuously looped back to the manufacturer – for automatic ordering, performance feedback and even AI-initiated product improvements.

Automation: OEMs, EMS and the medical manufacturing processes

For OEMs, this data-connected supply chain will inevitably cause a shift from using many EMS suppliers to partnering with a select few. Inevitably, it will be those who are already intelligently automating and using smart technology to track and control production that will benefit.

Let’s look at the benefits that automation in the EMS sector can bring to OEMs.

From applying conformal coatings to protect circuitry and components in hazardous environments, to exclusive JUKI-automated kitting processes in our surface mount lines, we use smart, data driven techniques to not only increase the speed of production but also to eliminate errors and inconsistencies.

Stewart Gadd, Technical Director, Chemigraphic

Eliminating error and delivering flawless performance

The Internet of Things (IoT) is located at the point where physical objects with embedded electronics, software, sensors and network connectivity can automatically collect and exchange data with each other. For electrical manufacturing, this means smart machines that can accurately capture real-time data as they communicate with each other and the products they process.

This not only increases productivity, but it also identifies any inefficiency, increases quality consistency and avoids errors.

Many electronic components used in surface mount technologies are – to the naked eye – identical. But fitting the wrong part in the wrong place could be catastrophic for the product, and for the OEM’s reputation.

Control processes can be automated to avoid this. In relation to PCB, for example, each printed circuit board is given an individual barcode that enables manufacturing machines to access its production data. Enterprise Resource Planning (ERP) systems will only allow the movement of components and materials between each stage of the manufacturing process once the necessary criteria are fulfilled.

The ERP allocates a unique serial number per product which is automatically placed on it to avoid any possibility of duplication, lack of serialisation or inconsistency. All surface mount stock is managed by a fully automated kitting and storage system that avoids the risk and cost of human error.

In addition, RFID-enabled processing equipment tracks the movement of materials through the factory. Every operator, and operation performed, is tracked and measured against estimated figures and then monitored on site-wide dashboards. This means that we have the fully archived traceability of process necessary for regulatory compliance, and also live management data which is critical to driving truly effective improvement.

‘Our business relies on the strength and insight provided by the data network that runs throughout it. Automation is key to us – but, for us automation is about more than highly technical machinery.  Automation is about using the tools and information we have around us to implement the best and most consistent methods of delivering the best results for us and our customers.’

Stewart Gadd, Technical Director, Chemigraphic

Reducing speed to market

Regulatory approval for new products

The rate at which OEMs can get a new product to market is determined often by the time taken to gain regulatory approval. Such approval requires the collection of vast amounts of data through every stage of the product lifecycle.

The IoT provides a pathway for the efficient production of increasingly complex products, while capturing and analysing data flows to assist with regulatory compliance and process improvement.

Miniaturisation and personalisation

Advanced sensor technologies are increasingly enabling robots to take on tasks, like cutting gemstones, that had previously been reserved for highly-skilled craftspeople. The same technologies may even permit activities such as ‘painting’ electronic circuits on the surface of structures.

The role of automation is switching from high-speed and high-volume production applications to agile systems that can adjust on the fly, switching seamlessly between product types without the need to stop the line. Many emerging production technologies, from computerized-numerical-control (CNC) cutting to 3-D printing, bypass the need for tool changes, making it possible to produce batches of one.

Medical device manufacturers must remain competitive by responding quickly to changes in patient treatments. Customisation – and increasingly personalisation – of patient-specific devices will require high quality, high mix production that is perfectly suited to machine learning and automation.

‘One of the main areas of benefit the decentralised, smart manufacturing model offers is the ability to efficiently individualise products with high quality results — something that will be critical to success in the patient-specific devices market.’

Francisco Almada Lobo,  CEO, Critical Manufacturing

Technology is only as effective as the way it is used

Of course, in the medical sector, it is critical that this automated production is vertically integrated so that corporate processes cannot be avoided: quality processes may demand that a device requires additional verification steps before the production process can continue.

The implementation of automation will, as a result, always be tempered throughout the medical device production process by compliance requirements and the need for quality control.

And, this is just one way that automation will only ever be as effective as the skill, knowledge and experience of those who use it. This is something that our team at Chemigraphic has always firmly believed.

 The most successful EMS operations are those which combine the mass delivery and rigidity of automation with the intelligence and flexibility of those programming the machines.  

Stewart Gadd, Technical Director, Chemigraphic

Read about how we recently supported the market introduction of Elekta Unity, a ground-breaking cancer treatment technology.