When it comes to complexity in manufacturing, there is no greater factor than Printed Circuit Board (PCB) assembly, as manufacturers and electronics design and prototyping professionals have discovered. While every manufacturer has their own strategy for addressing the complexity issue, a key question is "what factors contribute to increased complexity?" There are five key considerations that impact manufacturing complexity. We discuss these below with the help of an expert Nissan custom CNC PCB maker. Nissan's goal is to improve the quality and efficiency of every part in every vehicle produced by the company.


* Tool and Filler complexity - The tools used during the manufacturing process have a significant impact on the complexity of the assembly process. This includes not only the tools used by the assembly line operators, but also the operator's hand tools, machines, and even the temperature and humidity of the environment where the parts are put together. Depending on the complexity of the end product, the tool and filler complexity can range from extremely simple, like a screwdriver or screw in a plastic die, to very complex like a plasma cutter and sanding machine.


* Assembly method complexity - There is a widespread variety in the methods that different assembly lines use in their production process. Some companies use cold-press methods to feed components into the machine, others use hot-press or heat-tolerance press methods. Other assembly line methods, like gas tumblers, utilize a variety of techniques that are designed to feed components quickly and evenly into each other. And still other companies employ both hot and cold-press methods during the assembly process. It's impossible to accurately predict which assembly method will be most effective at your operation, but it is safe to say that any method that does not address issues of material consistency, component compatibility, or a lack of consistency among different components will increase complexity.


* Material Consistency Drivers - When a company chooses a certain method of assembly, it is usually because they can guarantee the best possible consistency of materials within the end product. Consistency means that the components will look identical, feel the same, and behave the same. If components are not uniform, or if the component surface is asymmetrical, the overall quality of the product will suffer. If component surfaces are not symmetrical, the signal, which is typically a conductive current, will be affected, and the end result of the product may not be as expected. In addition, if materials are not consistent, it becomes difficult to properly check the welds for weak areas and to ensure that the connection between adjacent components is accurate. All of these issues lead to a reduction in production efficiency, and a loss of customer confidence.


* Poor Assembly Method Knowledge - The assembly process is usually carried out by highly trained personnel, who have experience in performing the task without errors. However, the assembly process is often conducted by individuals who do not possess the appropriate level of knowledge to ensure a high-quality finish. It is also difficult to judge the fit of individual components, and to make sure that all connections are perfectly secure. If these problems are not addressed during the production phase, the company may lose opportunities for revenue and reputation, due to delays in the completion of products.


* Poor Quality Control - Even though it is easy to perform the task of producing a final print product, companies need to dedicate enough time and money to properly control the quality of the finished print product. Poor quality assembly, poor print quality, and poor company marketing can lead to a decrease in profit and a decrease in customer satisfaction. For example, if the company advertises a final print product with little information, or creates poor images with the printing process, it will have a negative effect on the company image. Likewise, if images are created with poor quality and are distributed without any type of quality checking, it will have an adverse impact on the company's reputation among its customers.


* Poor Software Selection - The complexity of a project often requires the integration of several different components, each with its own specific part requirements. For example, a new assembly driver should be made for every chip that is created in the process. If a single driver is developed for each component, then the driver will likely fail when changes are made to the individual components, or when a chip is replaced. This is why it is important to utilize accurate driver software programs.


Driver software allows companies to perform a variety of tasks, from the assembly of individual chips to the collection of customer data. These programs are designed to match exact specifications that companies need to create a final print product that is error free and complete. In addition to producing quality print products, the correct driver software must be used to support other aspects of the manufacturing process. For example, it must enable companies to monitor each of the many different components that are involved in the production process.