Fragmented assembly occurs when the assembly of PCB’s occurs through multiple unconnected partners. While it can carry flexibility and cost advantages this carries hidden risks beyond those seen in delays to manufacturing. 

1. Supply Chain Complexity

Fragmenting assembly increases the number of suppliers which must be managed by an OEM. The additional complexity creates more purchase orders, logistic activities and leads to more potential disruption points.  

If a supplier experiences: 

  • Capacity shortages 
  • Material shortages 
  • Equipment failure  
  • Labour issues 

The whole production schedule can be affected. This creates a real risk of increased lead times and reduced on time delivery performance. 

2. Reduced Traceability 

When multiple organisations handle different parts of the process, especially procurement, maintaining complete traceability becomes a difficult and time-consuming task. With PCB fabrication, component procurement and PCB assembly at different non connected 0partners, traceability of parts becomes fragmented. 

This causes the following: 

  • Delays identifying the root cause of issues, due to the longer process to consolidate traceability of parts. 
  • Challenges complying with customer, automotive, aerospace and medical traceability due to the fragmented procurement process. 

The major risk is a complex problem-solving process, for a field failure, delayed by determining where the problem originated from. 

3. Responsibilities Become Unclear

Reduced traceability links to another risk, of unclear responsibilities. With fragmented assembly the determination of ownership of problems is complicated. For example, a solder joint which has failed could be attributed to multiple different reasons. 

When you have multiple suppliers, the responsibility can be disputed, slowing down the corrective actions and prolonging the issues experienced by the customer. This carries the risk of reducing customer satisfaction and damaged to OEM reputation. 

4. Increased Quality Variation 

When an OEM chooses to fragment their PCB assembly across multiple CEM’s each supplier may have different: 

  • Process Controls 
  • Inspection Standards 
  • Operator Skill Levels 
  • Interpretations of Specifications. 

Even with suppliers following agreed electronic assembly IPC standards, variation can accumulate throughout the process. This can increase the defect rates and inconsistent product performance. 

5. Communication Breakdown 

Successful PCB assembly relies on effective communication. With fragmented supply chains effective communication is even more important as without it issues related to communication can quickly cascade. 

For example, common issues include: 

  • Engineering changes not reaching all parties. 
  • Incorrect revision levels being used. 
  • Missing process requirements. 
  • Delayed feedback when problems are identified. 

When the assembly of a product is spread across multiple partners separated from the OEM it increases the risk of miscommunication of changes. While also increasing the risk of delays from issues, such as obsolete or difficult to buy components requiring replacements. 

Miscommunication and communication issues can lead to production delays, and at its worst non-conforming products requiring costly rework and customer dissatisfaction. 

6. Logistics Risks 

When materials and assemblies are moved between different locations, logistic costs are increased along with the need for more administration and the increase of damage for components or assemblies through transit. 

Logistic risks compound for every time the components making up a product moves, components can go missing creating delays to final production schedules and affecting customer satisfaction. 

Solution 

Fragmented PCB assembly carries hidden risks that OEM’s need to consider when leveraging such assembly set ups for cost advantages and flexibility. The solution to fragmented PCB assembly is to integrate assembly through connected partners. Diamond Electronics are specialised in providing both kitting services and managed PCB manufacturing. This allows an OEM to leverage the cost advantages of kitting, while having the integrated communication and traceability which is required to minimise the risks associated with fragmented PCB assembly. Due to the multiple CEM’s available OEMs can also take advantage of the flexibility which can come with a fragmented approach. 

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