How a novel approach cut takt time from 2 minutes to 2 seconds.

Poka-yoke is a Japanese term meaning mistake proofing. It was introduced by Shigeo Shingo as part of the Toyota Production System (TPS) and refers to simple fixes that address small variances in the manufacturing process.

Even production operations that focus on best practices in new product introduction (NPI) require poka-yokes. For example, SigmaTron International’s Tijuana, Mexico facility applies Advanced Product Quality Planning (APQP) and conducts failure mode and effects analysis (FMEA) to establish the most efficient, defect-free process. The facility utilizes a product part approval process (PPAP) for automotive projects to validate the process, while customer-specific validation processes apply to projects in other industries. Once production begins, the team monitors processes and tracks defects using statistical process control (SPC) and other forms of quality data collection. When defects occur, the team schedules a kaizen event, employing tools such as 8D problem solving, Six Sigma’s define-measure-analyze-improve-control (DMAIC) and poka-yoke to analyze and correct the root cause.

Schedules are not the only thing to prioritize.

Being a manager isn’t for everyone. In addition to technical skills, a manager is responsible for resource allocation and risk management. In the field of electronic design, a manager must balance being a technical person and a people-person. Beyond that, a manager overseeing employees involved in creative endeavors must comprehend the uncertainties and challenges that arise with an electronics design project. Of course, the electrical engineer will normally say the schematic is complete on the day it is supposed to be. Same goes for the mechanical engineer. Ever the optimists, they believe everything is going according to plan – until the day it isn’t. Surprise! (Though, honestly, it’s not really surprising.)

“Without capacity, there is no growth.”

As I write this column, the duty rate for 2- and 4-layer rigid printed circuit boards manufactured in China stands at 145%, while 6-layer and above – along with all other technologies, whether rigid, flex or metal – remains at 170%.

AI chips could drive technical innovation in fields from PCB materials to district heating

The semiconductor business as we know it today represents a tremendous global success story, achieving consistent and strong growth year on year. Analysts expect it to exceed $1 trillion in sales by 2030, and some predict a further doubling over the following decade. The overall figures are extremely impressive, although some sectors are stronger than others. While automotive has enjoyed a strong run for many years as vehicles have electrified, recent performance fell below expectations.