What you think may not be what you see.

Over the past couple months I have been in several discussions where the demise of the North American fabrication industry has been at the core of the various debates. While everyone in these exchanges was coming from different perspectives, ranging from technologist to financier to global consultant to marketer, and ranging in age from “young bucks” to seasoned retirees, the common thread of their thought process was fabrication as an industry in North America is dead or dying.

Various data points cited – accurate or subjectively interpreted – paint a bleak picture. The number of facilities is down to just over 200, with over half of those facilities under $5 million in revenue. New materials and supplies being commercially introduced are more often than not developed in and/or by Asian companies, and the reinvestment in capital equipment in North America pales in comparison to amounts spent everywhere else in the world. Yes, on the surface the picture is depressing – or is it?

Solve capillary issues by increasing solids content.

It is very important to control conformal coating thickness on a printed board assembly. Problems with coating over different surfaces, particularly sharp corners that can lead to shorts from tin whiskers, have been demonstrated many times.

FIGURES 1 and 2 show capillary action on an SOIC and QFP, respectively, where the thickness of the coating is much higher around the leads and the body of the devices. With very high fluidity and spray coating, liquid capillaries under the package are starving the area of the board close to the edge of the pads.

Diligence can pay off. (Sometimes.)

The call punctuated one otherwise listless afternoon.

“Can you come over for a meeting?”

Sure.

She never wants to order anything from us. She claims her process is perfect, hence no need for testing. She calls only when she wants to vent her spleen or get some free advice. She thinks our on-demand, zero-notice consultation time is limitless. No statute of limitations. She also really likes the value-added component of free advice, which she can mark up and pass along. That advice also tends to make her process more perfect than it already is. Imagine that: perfecting perfection. Did I mention that enabling wisdom was free?

Eliminating waste in medical box-build production.

Contract manufacturers typically have to find middle ground in the use of Lean manufacturing principles. Unless a customer is completely committed to a holistic Lean environment, there will also be some level of waste (muda) in the process attributable to customer-related constraints. That said, use of Lean principles to minimize the seven wastes can help mitigate defects and lower costs that would otherwise occur as a result of inefficiency.

These seven wastes are defined as: