Comprehensive quality control processes and procedures – a must to ensure business continuity

Quality electronics manufacturing demands a range of control processes and procedures. Quality control methods can be grouped under 3 categories – Component Management, Process Management, and Data Management.

Component Management: All electronic devices depend on printed circuit boards and tiny, sophisticated components. The engineer designing the PCB has to have a clear understanding of the layout and the components he plans to use. Then is the act of sourcing these components. These have to meet the quality standards defined and be available on time. Challenges in terms of procurement, late deliveries and counterfeit could severely impact the project and the end product. To avoid these costly mistakes, quality control has to be maintained.

Procurement and availability of components also plays an important role. Challenges such as shortage, late deliveries and counterfeits impacts quality and delivery schedules. To mitigate these risks, the following are critical:

1. Checking on the availability of components at the designing stage
2. Using reputed vendors to avoid counterfeits and last minute surprises
3. Working on the logistics and finances to prevent late delivery of components

Process Management: This involves a well-defined set of procedures to be followed to confirm that the products and services comply with the established standards. These guidelines define the process that should be followed in design, manufacture, and assembly such as:

IPC 60 – This is a set of guidelines that establishes the general requirements for Printed Circuit Boards
IPC 610-A – This is defacto inspection standard used for electronic products to standardize the process of assembly
J STD 001 – This provides guidelines on soldering connections for electrical and electronic assemblies

Data Management: Accurate data is important to delivering effective services/ products. This is also helpful in identifying errors and ensuring the production is effective and seamless.

Syrma SGS – Proven quality. Globally recognised certifications.

Syrma SGS offers proven Electronic Systems Design & Manufacturing Services backed by optimal electronics design, engineering, and production solutions. The company boasts of a 40-year legacy of innovative electronics and specializes in high-mix, flexible-volume precision manufacturing, and designs and manufactures custom RFID and magnetics solutions. Over the last decade, the company has shipped more than 500 Million product units across the globe and has 11 world-class manufacturing facilities.

Syrma SGS has in place proven quality assurance processes in line with Global standards. We maintain internationally recognized QA certifications. Our assembly technicians include certified J-STD-001 specialists; our production and quality control managers are IPC-A-610 certified. We support all requirements of IPC610 Class 3 (Class 2 standard) and ANSI/NCSL Z540.3. Our QA standards include sophisticated, automated optical inspection (AOI) equipment checks.

PCB assemblies are thoroughly inspected for various potential defects. X-ray inspection methods check the solder integrity of leadless components. Our highly trained and experienced test engineers provide automated functional testing equipment based on customer specifications.

Reliability and safety tests evaluate planning and execution for incoming and outgoing parts. We have in place an exhaustive supplier QA that includes components failure analysis, corrective actions, first article evaluation, new parts/source inspection, new qualification, performance feedback, and periodic process audits.

System QA includes conducting in-process yield monitoring with documentation control, periodic ECN/DN verifications, new QA system implementation, process audits, product failure analysis, qualification of new products, and QA system audits.

Outgoing QA includes monitoring the quality level of our products, receiving customer feedback & analysis, and sampling inspection.

Syrma also conducts a comprehensive failure analysis (FA) of multiple electronic assemblies and components: Printed Circuit Boards (PCBs) and Printed Wiring Boards (PWBs); Integrated Circuits; memory chips; transistors, diodes, capacitors, and resistors; LEDs, and power modules. We analyze devices, components, and assemblies for specific defects, such as ESD, EOS, shorts, opens, corrosion, solderability, vibration, thermal fatigue, and connector failures.

Our test equipment includes ATT Micro testers, Profile Projectors, X-Ray inspection systems and customised Customized automated test equipment. We deploy a range of stringent tests to ensure our products perform efficiently.

Whether you are a multinational corporation with a presence across geographies or a start-up with big ambitions, Syrma SGS is well poised to be your EMS partner and is committed to help you succeed.

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Common to all these products is the fact that they are marvels enabled by miniaturization and the amazing developments made possible in design and manufacture. This is beyond the size reductions possible by shrinking semiconductor devices and newer approaches are needed to get to where we wish to. Among the most successful of the approaches being ushered in is ‘SiP’, System in a Package technology.

Simply explained, SiP technology is a completely sealed package consisting of all active and passive components of an electronic subsystem along with the required interconnections.

SiP presents very important benefits. For one, since the interconnections are short, high operating speeds can be achieved. Also, within the package, components can be stacked for optimum space utilization. The other design advantage is the effective EMC shielding and since the package is completely sealed, it is protected from the external environment, very crucial for wearable technology.

An excellent example of the SiP approach being deployed successfully in wearable technology is True Wireless Stereo (TWS), incorporated in the present generation smart earbuds. These earbuds do not need physical connections and can connect via Bluetooth. Also, their internal batteries are charged inductively. True wireless technology earbuds also offer features such as volume control and track selection, but the real differentiator is the accommodation of batteries in this tiny device. This has been achieved by shrinking the electronic components used in the earbuds through SiP technology.

Miniaturization of electronic subassemblies frees up space enabling designers to accommodate larger and more effective batteries without enhancing the size of a device. This makes it possible to create devices with longer battery life, a key requirement of end users across segments.

Manufacturing of such miniaturized subsystems requires a huge level of expertise and cutting-edge technology, a capability that rests with a few companies. Syrma SGS Technology offers the best electronic manufacturing services in India and has world class expertise in developing optimal electronics design, engineering and production. The company is one of the best electronic systems design and manufacturers in India and offers a high mix, flexible volume precision manufacturing and designs custom magnetic, memory and RFID solutions.

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Today, Syrma aims to be a partner of choice for startups to large corporates. It works with Global Fortune 500 companies, and exports constitute over 85% of its sales. The company has also established four satellite plants in Tamil Nadu to promote the employment of rural women and empower them. Syrma is in the process of merging with SGS Tekniks, an equi-sized company, to become an over Rs 1.000 crore entity post-merger to enhance “our geography, capacity, and capability footprints.” CEO since 2015, Sreeram has over 36 years of professional experience and has held leadership positions in companies such as Shanthi Gears Limited, Saint Gobain Automotive Glass business, Rane Group, and Sundaram Fasteners. In the former two, he served on the board of the listed entities. In a conversation with YourStory, Sreeram talks about the impact of COVID-19 and how the EMS industry is changing.

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Pandemic Global Supply Chain Disruption

Though the global PC shipments saw a minuscule growth last year, the highest in the last 7 years, this revamp sets to increase the demands of products, specifically notebooks, work stations, conferences, networking, and allied devices, higher rate. By 2023, the global traditional ICT market is projected to have a sustained growth to reach $4.4T, while the ICT with newer technologies is witnessed to grow at 6 times faster to reach $1.3T at a rate of 15.8% CAGR. This spike in newer technologies for ICT devices is due to emerging technologies and increased adoption of IoT, AI, robotics, augmented, and virtual realities. However, the unsettling trade war between the world’s largest consumer of ICT products and the largest exporter has begun disrupting the manufacturing supply chain. [1]

India’s ICT Hardware Manufacturing

India, one of the fastest-growing ICT markets, is projected to reach $144B by 2023, growing at a rate of 7.2% CAGR. Some of the key initiatives, such as Digital India, are creating faster adoption of emerging technologies due to its young population are some key factors fostering this growth in this sector. The digital innovation hub of the world with the largest global outsourcing market share of over 55% and fast-growing exporter of computer hardware with the growth of 14.78% CAGR in the last couple of years, India is well-positioned to transform into the next ICT hardware manufacturing hub in the years to come.

The “Make in India” and “Vocal for Local” initiatives, along with the announcement of much-awaited Government of India’s incentive schemes such as Production Linked Incentives (PLI), Scheme for Promotion of Manufacturing of Electronics Components and Semiconductors (SPECS), and Electronics Manufacturing Cluster 2.0 are a great step. This, along with India’s distinct advantages such as skilled workforce, competitive labor costs, proven prowess in design, and development of complex software, will help boost India’s ICT hardware manufacturing industry, including the component ecosystem.

Backed by 40 Years of Expertise

We contribute our 40 years of design and manufacturing expertise spanning multiple diverse markets. We look forward to discussing how we can deliver world-class products for OEMs across the globe. We understand our home Indian market, familiar with its vast regulatory and selling environments. We foster growth opportunities within India through our strong technology incubation ecosystem. We also assist global OEMs in entering the Indian market by leveraging the local supply chain and favorable operating environments for cost reductions.

Our flagship Chennai location opened in 2006 and lies within a Special Economic Zone (SEZ) for electronics manufacturing, offering economic incentives for imports and exports. This primary facility is within 90 minutes of the Chennai seaport and 20 minutes to the international airport. Additional road and rail connectivity links to the rest of India and beyond and infrastructure advantages with faster import and export clearances. We also have labor force flexibility, both technical and manual, to scale to demand rapidly.

To learn more about this topic, please contact us.

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