Electronics Manufacturing
Electronics Manufacturing: production orders and BOM, stock and warehouse, quality and reporting.
Challenges
- Component lead times keep shifting, so the production plan stalls on sudden shortages.
- SMT placement consumption and feeder scrap go unmeasured, so the real cost looks lower than it is.
- AOI and functional test results are never recorded, so the root cause of defects stays hidden.
- Board revisions are not tracked separately, so nobody knows which BOM went into a board in the field.
Workflows
From BOM to placement
- A revision-controlled bill of materials and approved component alternates are defined.
- Material requirements planning raises purchase orders for the missing components.
- SMT placement and soldering operations are tracked on the work order.
From test to shipment
- AOI and functional test results are recorded board by board.
- Boards needing repair drop into a separate work order with a coded defect reason.
- Boards that pass are received into stock with a serial number and shipped.
Documents
- Revision-controlled bill of materials (BOM)
- Approved component alternates list
- AOI and functional test record
- Serial-numbered delivery note
Reports
- Component shortage and waiting report
- Placement scrap and feeder loss
- Test defect code distribution
- Actual cost per board
Metrics
- First pass yield
- Rework rate
- Component supply delay
- Production cost per board
Compliance
- RoHS and REACH substance restrictions
- IPC-A-610 solder quality acceptance criteria
- ESD (electrostatic discharge) protection procedure
Glossary
- BOM revision
- Version-numbered record of the bill of materials
- Alternate component
- Approved substitute item held on the bill of materials
- AOI
- Quality-control step and the record of its result
- Rework
- A second work order opened for repair
FAQ
Can I see component shortages in advance?
Yes — material requirements planning factors in lead times and lists the gaps early.
Can I define alternate components?
Yes — approved substitutes are defined on the bill of materials, and the one actually used is recorded in production.
Can I keep test results per board?
Yes — test results and defect codes are stored against the serial number.
Can I see the cost of rework?
Yes — repair is a separate work order, and its labour and material flow into the board cost.
Can I find the revision of a board in the field?
Yes — the serial number is linked to the BOM revision used in production.
