What are potential issue during electronic manufacturing in China
Once the procurement of raw materials and sub-part is operated, they need to be processed to give birth to the final assembled product, firmware need to be uploaded, the product test and finally it will be packed. Therefore there is still a long way before the final product to be ready to shipped.
Supplier who transform raw materials into parts are called processor or simply transformer. They are mostly either plastic injection company, die casting company, or they may also be some CNC contractor.
From electronics component and blank manufactured PCB, there is also PCBA manufacturing to process most of time using SMT and DIP production line, after what firmware has to be loaded into the chipset and final product has to be assembled.
There are several key point which are addressed during this manufacturing steps:
Controling the quality during electronic manufacturing in China
When talking about mass production, quality is a crucial Key Performance Indicator because it indirectly lead to no quality cost. Everything is related about how to minimize defective rate over a production and to avoid recall (which is the nightmare of every distributor or retailer).
How to control efficiently the quality when manufacturer are not organized and structure to do so ? You probably thinking they would manage everything well by themselves... and then you would probably have some surprise about the result. You plan to teach them, but you would discover 6 month later that high turnover have wasted your time since the people are not the same anymore and the instructions and information were not passed to the new team..
You plan to operate a final quality control ? You are right since this is necessary, but is it enough ? You would be amazed the number of company who do some Pre-Shipment Inspection on their production and finally have to face a high defective rate and some claim from customer 6 month after their products to be on the market.
Many buyer don't have experience in manufacturing process and got some product with quality fluctuating simply because quality procedure are not respected during manufacturing and they are not able to identify those issue earlier enough.
If local supplier may claim a defective rate around 1-2% on the paper it is not rare to get a two figures defective rate in the end. If you want to control your supplier know really its defective rate, simply ask them to see their inspection record which allow them to estimate those figures (remind: if you can not measure, you can not control). Rarely, local manufacturers hold a defect recording to be able to estimate the defective rate of their own production.
Transformer are partly paid for the time they allocate to transform raw materials into parts. For plastic injection a high number of parameters are considered (injection speed is one of them) and those parameters influence the cost of the transformation process. Those parameters are fixed to fit the requirement of the parts and not respecting them may involved to get the parts to fail after few months of use.
When a transformer wants to optimize its cost, he will simply change the parameters of its machine without you may notify it. At the beginning the part looks the same but on a long time of use the living reaction may become improper. Of course if you inject low end product, this is not a big issue, but if you are servicing military or nuclear industry probably the lasting life of a part become critical.
For this reason controlling fully the manufacturing process at every steps is essential.
If you need you product to be certified for rohs, you want to make sure the manufacturing is taking place according to this critteria. A supplier who mix his Rohs and No Rohs production line can give as a result some lead dust affecting your product to pass the test...
Producing your electronic product on time
If you are involved in the distribution of your product, you certainly know how important is the delivery time criteria to serve your demanding customers at the moment when they require to buy.
There are mostly three parameters which can affect delivery time:
- production capacity is not enough big to produce on time and you are a too small customer face to other big one to avoid being neglected by your supplier, so you don't have priority on the line and you get delivered late
- procurement is not on time and the production can not start on time either
- quality issue is appearing during production and delay the delivery
Managing Copy and Intellectual Property Protection for Electronic Manufacturing in China
When you manufacture your product you will get someone in the manufacturing chain who in the end get access to the full product and full concept related to your new idea, this is usually the final assembler, in charge of assembly all the parts, and to pack the product. If you don't control the supply chain, some information may go to sub-contractors you will never know the existence and those sub-contractor never signed a NDA with you...
Local manufacturer make product which they sell on their own distribution channel, they potentially have other customers who are your competitors and would probably be interested in buying your products directly at the manufacturing place. How do you ensure your IP and good idea which will allow you to stay ahead the competition will not benefit other.
Organizing Electronic Manufacturing in China
Most of time, when there is an issue on a production, it comes from organization. We found out that quite a lot of local manufacturer get difficulties to organize themselves properly, to optimize productivity and to anticipate issue.
- control of supply chain => tracability / copy / information given to third parties
- strategic packaging => hide packaging
- protect firmware => injection at the last moment
- protect product => final product unseen
- injection faster and not respected => save money
- defective rate to keep low
- coordination of vendor and control of sub-parts
How we handle electronic manufacturing in China
During the mass production PAG Electronics play the role of production monitoring, production assistance and quality control. We have two possible way to do so:
1./ All the production is handle by local manufacturer
In this case we are in charge of controlling the quality at different step : for raw materials, parts, finished products, packaging. We are also in charge to make sure the production is running smoothly and on time. We operate a regular and organized follow up with each stake holder and handle all their issue without polluting your time.
2./ We handle the final assembly
We are not a factory, we don't own some big machine, SMT line, mould workshop, and 300 workers but we have an assembly area which allow 90% of project we manage to operate an efficient operational intellectual property protection by performing 100% inspection, firmware loading, final assembly and packaging out of local manufacturers eyes and under our own roof.
Not only it ensure 100% quality of your product since 100% of them pass in our hand one by one, but it also allows to protect the intellectual property of your product, packaging design, and potentially final customer identity. So your product is not served to someone else, and don't come to cannibalize your market, hence giving you more time to sell your products at decent price and keeping margin up.
In both case scenario, prior manufacturing, we will establish necessary technical and organizational document allowing to make sure the mass production is properly structured and that even some team member of the manufacturing are leaving, the same procedure is implemented for next order.
During the manufacturing phase our project team work directly with each stakeholder of the supply chain (components supplier, processor, transformer, packaging manufacturer, assembler, logistic company) to ensure mass production is occurring without any issue (actually there are always some but we are here to solve and fix them in a way that you will not even feel them).
Our project engineer will closely monitor the schedule in order to ensure the production is on time.
We will allocate our quality control staff to inspect components, materials, parts and finished product during the manufacturing phase, so that we can control the quality.
Our electronic hardware engineering team will play the role of FAE (Field Application Engineer) to support PCBA manufacturers directly at their location in order to help them to debug hardware issue before involving the next step of the manufacturing.
Our mechanical engineering team will support processors and transformers to make sure plastic parts are injected following the conditions requirement, and that metal parts are machined properly and according to the requirements.
Our merchandiser will be in charge of setting and holding an accurate accounting and inventory of the parts during and after the end of the production.
How you benefit our electronic manufacturing in China
You will benefit a full team dedicated to your project and handling all manufacturing phase, controlling the supply chain and the quality while making sure your delivery is on time.
About Electronic Product Development and Manufacturing
Written by Electronic Desgin Engineering Product DevelopmentWho is PAG ?
- PAG Electronics said P. A. G Electronics is a western owned and managed product development and manufacturing company based in Shenzhen specialized in accelerating product development and optimizing manufacturing in Asia in the electronic field.
Our company is legally registered both in Hong Kong and in China (110 KUSD of fully remitted capital) and is fully accredited by the Chinese government to perform import / export procedure, and assembly on its own.
Our team is made of western engineer, industrial product designer and Chinese technical sourcer and merchandiser who all got several years of experience in the asian manufacturing and product development environment.
What Services do we provide:
- Consulting
- Feasability sutdy
- Industrial Product Design
- Brainstorming
- Sketching
- 3D Rendering
- Packaging design
- System Engineering
- Electronic Design
HARDWARE
- Component Selection
- Schematics edition
- PCB Design
- PCB Layout
- PCB Routing
EMBEDDED SOFTWARE
- Firmware Programming
- Mechanical Design
- Plan edition
- CAD Drawing
- Assembly simulation
- Stress Simulation
- Injection Simulatio
- Software engineering
- Android
- iOs
- Linux
- Windows
- PHP Mysql
- Prototyping
- SLA
- SLS
- CNC Machining
- 3D printing
- Assembly
- Testing
- Certification
- CE
- ROHS
- FCC
- WEE
- Bluetooth
- SAR
- Documentation Management
- Product Quality Manual / SOP Edition
- Supplier Contract edition
- Mould and Die Manufacturing
PLASTIC
- Plastic Injection Mould
- Silicone and ruber Mould
METAL
- Die Stamping
- Die Casting
- Procurement
- Sourcing
- Supplier coordination
- Manufacturing
- Plastic processing
- Metal Processing
- PCB Manufacturing
- PCB Assembly
- Final Production Assembly
- Quality Control
- Conformity and Authenticity verification
- Incoming Quality Control
- During Production Quality Control and Monitoring
- Final Quality control
- Logistics
- Storage
- Inventory Management
- Dropshipping
WORK WITH PAG ELECTRONICS
How do i get started
- Send us specification and as much details as you can
Do I need full specification to start
- Better but if you don't have we can work with you to establish them via feasability study
INDUSTRY AND APPLICATION
What industry do you serve
-See application area
TECHNOLOGY
Which technology you work with
- Microcontroler
- RF
- FPGA
- ASIC
CONFIDENTIALITY
What about my IP
- NDA
- see how we protect ip
PROJECT MANAGEMENT
How do you handle project
- With pragmatic, technical and marketing way: we consider customer side, but also manufacturing side. We believe in system, process and organization. We consider every product like a system, every team like an organization.
What project do you prefer
- Complex project where high added value, expertise and knowledge is necessary.We also of course manage with small project with low added value, we prefer to face complex situation so we can value our expertise. this is one of the main difference between doing some procurement only and developing product: complexity is much high in product development.
Which Project Management methodology do you use ?
- for Project management we use agile methodology
- for software developpemnt with use V cycle
What software do you use for product development
- Rhino for product design
- Pro E / Unigraphics / Solidworks for Mechanical engineering
- MPLAB / IAR for electronics design
- PADS Layour / ORCAD and Altium for PCB Design
Are you capable to make any kind of product
- This is the strength of our company: When overseeing a project our approach is not to consider a product type as what most of manufacturers do, but as system consideration. Because of our approach to consider any product as a general system, we have capability to deal potetnially with any kind of item without knowing them in the beginning.
Are you capable to operate reverse engineering
- Yes we do
MANUFACTURING
Do you handle with manufacturing ?
- Yes we do
Can I use your service to perform procurement of finished goods?
- Yes you can, in this case another business unit of our company will handle this as it doesn't require the same skills
Do you have MOQ
- We talk in terms of PO value and not in terms of MOQ
Do you manufacture yourself ?
- We manufacture in our own assembly area product which get IP sensible.
QUALITY AND CERTIFICATION
What about quality
- As our core team comes from manufacturing, quality control and engineering, we took the good habits from the beginning : we perform quality control at different stage of the development, procurement and manufacturing following some strict quality assurance procedure. On this base, by multiplying control check point (whereas most of other companies don't) at different steps of the supply chain we diminish drastically risk to get defectives, no conform product.
What about certification of my product
- We are not a laboratory capable to certify your product however we work closely with both famous and unfamous laboratory (still capable to deliver certification)
What about warranty
- We guarantee 12 month our work and product that get manufactured via us.
MOULD AND TOOLING
What about tooling
- tooling is belonging to you
CLIENT
What kind of client do you serve
- We mostly serve Small and Medium Enterprise having the wish to outsource their development directly to a competent firm based in Asia, capable to handle product development from A to Z while coordinating several stakeholder: part and material supplier, manufacturer, engineer, logistic third party,
BUDGET
What king of budget can I expect to develop a product ?
- The development cost depend on so much parameters that it is impossible to find a one fit for all answer to this question. We recommend you to contact us with as much information as possible about your project after what we can estimate the necessary amount. In the past we have quoted from 5K USD an extremely simple product to develop until 150K+ USD project for highly complex product.
Can you reach my target price ?
- See our feasability study service
TIMING
How long the Product development phase is lasting ?
- Again, here it is extremely variable depending on the product complexity. From our experience a full project starting from scratch requiring to make some tooling and certification take minimum 2 month and until 10 months (because of some certification process being long)
Earphone Electronic Design and Product Development. Product Design, Electronic Engineering, Manufacturing, Prototyping, Production
Written by Electronic Desgin Engineering Product DevelopmentElectronic Product Development of earphone in China
The market of the earphone is on his come back since apple brought back music via iPod. In 2005 Apple launch the IPOD which revolutionize the music industry. In 2007 this is Monster and Beats who launched the trend with the Headset distribution. Headset is so far one of the most common element used to get private music or hearing from Media Player, Mobile Phone, Tablet etc...
Earphone can be used with computer but more particuliary recently with handheld product: tablet mid, mobilephone, external and portable media player.
Electronic Development of Earphone
Trend of Headset becoming also a promotional item kept going to spread around the word. With bluetooth 4 new standard, this is also bluetooth headset who recently get developped and went on the market.
There are several possible applications with Headset. Among the most common application:
- Headset for promotionnal
- High end Headset
- Bluetooth Headset
- Headset for airline industry
Electronic Product Development of Headset with our Electronic Product Development Firm
- electronic design of Headset
- electronic development of Headset
- mechanical engineering of Headset
- firmware customization and user interface ergonomic optimization
What special when developping earphone
Electronic Development and Design of earphone require some important skills in electronic, audio, physics, and fluidic. As audio is generated by wave in a fluid environment, fluidic and electronics play an essential part of the design as the electronics in charge of signal processing while audio and fluidic directly influence the result of the wave. Those elements hence need to be chosen carefully and calibrated properly to fit market requirement. Such elements like bass and treble frequency signal to noise ratio, power output are essential part which are considered during product development for earphone.
Headset are small device and have high requirement on spacing constraint, on this base mechanical design and engineering optimization is an important point to consider.
Headset electronic engineering also require audio and acoustic skills to be able to supply your customer with an excellent customer experience.
When considering product development of Headset, choice of components (especially driver) is absolutely critical. Positioning, spacing and design related acoustic engineering is also a critical point in product performance.
Some other mechanical elements such as cable, pin connector, quality of wire, and ergonomic are also to consider to make sure the robustness of your product. Finally the ergonomic and comfort are the first priority: design properly shape of part is more important than anything else and this to avoid compromising comfort of the user.
Finally, when considering engineering of Headset several industry area apply: acoustic, fluid physic, electronic, and mechanic.
Assisting you in developping earphone
Our Electronic Product Development company based in China already faced experience about earphone manufacturing and development. We have the confidence in our capability to accompany you in developing earphone in order for you to enter on the market with a product which could compete with current major.
Our electronic engineering service can define the system architecture adapted to your need, perform testing and simulation to optimize the output of your earphone.
Our western design team via our industrial design service can study with you different possibility to create your external casing and other part in order to optimize ergonomic, functionality and any other material, color to fit with the targeted market and public you want to reach
Performing procurement for electronic product development in China
If you choose to develop your product using a Chinese manufacturer instead of developing it with a product development company like us, the supplier will provide you a one finished product which they have operate the procurement and the assembly of the part. In this case you don't have to manage with procurement of parts and raw materials since the manufacturer is doing it by himself.
It may look simplifying your process because you finally deal with a single company, however it make you loose control of the supply chain on the material and the parts used to manufacture your product because in 99% of the case very few manufacturer accept to give access to their own supplier to their client.
It doesn't sounds a big problem at the beginning and you will probably not care about having access the part source because you will feel comfortable that your product is perfect since it had passed a Final Quality Control. Yet, electronics products have several opportunity to become defective a few months after manufacturing is over even with a passed Final Quality Control: components with shortened lifecycle which become unstable, plastic material not adapted to environment change starting getting cracking, metal parts getting oxidized, etc...
This is as much elements which are directly related to material and component selection during the procurement phase and which indicate why control over the supply chain is essential.
Why most of principal prefer to delegate this task to their Chinese manufacturer instead of handling it? Because logistic and sourcing doesn't look easy to them.
Why we handle procurement for parts in China
We know how important it is to keep hand on the supply chain and the source because in China playing cost down to optimize profit by substituting materials by others is a national sport. In the same time we understand that it can be complex for an overseas company to manage (contracting, payment, transportation and transit of the goods, quality control) and coordinate several suppliers of materials based in China who don't speak English and who require to be paid in local currency.
For this reason our local established structure can handle the procurement function that a manufacturer would usually do. We have the capability to pay in local currency via our Chinese structure, we are working on the same time zone than Chinese suppliers so we can coordinate easily transits and logistics, and our staff is bilingual Chinese English so we can contract in both language.
Having control on the procurement allow us to have a complete view of the product, being able to analyze and masterize necessary parameters of your product production and to make sure that decided raw materials are used and not substituted one.
What do we do during procurement of parts for electronics product development.
Our technical sourcer and procurement manager will handle the procurement function for you in order to supervise and coordinate the purchasing or raw materials, components and parts.
They will particularly be in charge of :
- sourcing reliable supplier of raw materials and components
- perform negotiation and contract with those suppliers
- anticipate potential issue and misunderstanding
- verify authenticity of the materials and components used
- hold accounting and booking keeping
- perform payment in local currency one by one
- coordinate and manage with transit and logistic between supplier and processor
Why you will enjoy our procurement service for electronics in China
Your main benefit is we work like an asian manufacturer would do : they perform procurement and we do so too. The main difference is you keep control fully on the source and raw material used to manufacture your product whereas a chinese manufacturer will probably not show you who are the supplier of raw materials, so you know exactly what your product is made and in case of issue analyzing the cause is much faster because the transparence is here.
Feasability Study for Electronic Product Development in China
Written by Electronic Desgin Engineering Product DevelopmentWhy performing a feasability study when doing product development for electonic in China
Electronics industry being a wide environment, product type can vary very highly depending on a high number of parameters: application, end user requirement, functionality, external constraint, environment, market trend etc...
In a result, it may be difficult in only a few minutes or hours to verify the capability to develop and manufacture a product within strict technical requirement and agreed pricing without having done a minimum of investigation.
How we perform the electronic feasability study for product development in China
When customer or principal come to us with limited knowledge of product development, material cost and manufacturing process, while being very directive about price sensibility or functionality to achieve; before involving them with development fees, we usually propose them to perform a short feasibility study which intend to estimate roughly the technologies current available on the market capable to realize what function they need to achieve, and to estimate their related to cost.
The feasability study can also be a good way to evaluate the capacity to use the base of an already existing item that get adapted instead of starting from scratch a whole new project.
What do we do during a feasability study
Our team will study deeply your technical specifications and target price, and will define bottle neck and key element which affect the pricing and the realization capability of your product.
We will scan the market to perform a verification of rough price of estimated key components to some local suppliers which may affect functionnality, specification and price.
Benefits of performing a feasability study
Realizing a such feasibility study allow to mitigate the risk to start involving fund while ending up with a result different that what is expected. It gives a diligently advice about the go/nogo to start the development of your product based on your requirement.
We have seen in the past, some of our competitors starting project without performing feasibility study by promising a target price to their customer that in the end they could not achieve discovering during the engineering phase they overpromised their customer by undervaluing the cost of the bill of material. In result the customer was taken in hostage in the middle of the project with as choice loosing development fee or going with an unsellable product on his market
Why perform Mechanical Enginering in China for Electronic Product Development
An electronic product is generally made of a PCBA being wrapped and positioned into a physical mechanical enclosure which play the role or carter. Interaction with other machine, accessories or human can be done with mechanical elements such as plug, button, switch, indicator or any other element of communication (connector, antenna, etc...).
If body and skeleton of your product are made of mechanical parts, especially if those parts are in motion and subject to an important aging by an intense use, or even if static parts such as enclosure are subjects to tough environment constraints, then those mechanical pieces may play an important role in the fact that product is functioning or not.
If your product doesn't work anymore after having pushed 100 time a press button because the structure of the part was badly designed, if the connector of a SD card doesn't fit the hole of the enclosure because assembly simulation where not performed properly, if your enclosure is cracking itself at -10°C because material selection was improper, or if your parts wastage are 50% instead of 0.5% when performing plastic injection because the shape of the parts was not corrected to handle high temperature and pressure, then you may understand why mechanical engineering have to be taken seriously before engaging in the next step of the product development and manufacturing.
Industrial Product Designer may have good idea and concept, however although they may have some material background, they are mostly not educated to validate mechanically a structure, calculate a material robustness, consider manufacturing process optimization, consider electronic specificity, and handle other practical point which are related to the mechanical engineering field. For this reason, the involvement of a mechanical engineer is required.
Why we handle Mechanical Design for Electronic Product in China
We are well aware about mechanical issues that manufacturing can meet and our experience indicates that a high number of principals neglect quite often mechanical engineering phase thinking this activity is only subject to generate a CAD file. Yet, it is doing much more...
Our Mechanical Engineering Service supply valuable analyze and feedback to avoid our customer to face with issue related to mechanical point.
We verify and validate that product concept is physically and technically achievable (both in terms of physical structure and in terms of manufacturing process) before going on the next step of the product development by performing modeling and simulation. If it is not, then we will correct and adjust the product by taking in consideration the whole set of parameters of the project.
In terms of manufacturing, because most of time plastic and metal parts needs to be manufactured in high quantity, then tooling become a necessary process and often they are expensive. So, you have one shot to make them proper from the beginning if you don't want to waste time and money by constantly correcting them. For this reason, simulation is good choice to make sure all the parts fit properly
What do we perform during Mechanical Engineering phase of Electronic Product Development
The Mechanical Engineer will particularly handle the following:
- Validate or correct the industrial designer assignment (material selection, shape, assembly)
- Test strength and robustness of the parts and enclosure
- Verify the manufacturing process can be achieved and is optimized
- Simulate part assembly
- Make sure plastic injection, die casting or metal stamping can be achieved
- Verify heat dissipation can be performed properly
- Simulate aging test of part face to stress test
- The assembly process is optimized for asian manufacturing
- Dust and IP resistance is achieved if necessary
- Access to part being maintain
- Electromagnetic emission threshold is respected
- Generate 2D plan and CAD file so the prototyping and mould manufacturing can be executed
- Calculate the cost of the mechanical part
Benefit you enjoy while delegating your mechanical engineering to us
By using our Mechanical Engineering Services you benefit from our expertise and experience in terms of asian manufacturing, material, and structure knowledge. We will optimize mechanically your product so the assembly can be smooth, fast and optimized for asian manufacturing.
Parts having the need to take in consideration electronics components constraints, the mechanical engineering will work closely with electronic hardware engineering to make sure PCBA and parts can be assembled together properly and that heat dissipation due to electronics components can be performed properly trough the parts.
The same mechanical engineer will follow up with the tool manufacturer to ensure the tooling are realized accordingly and parts can be molded without any problem.
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