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Standard of Excellence: The Perfect PCB Fab—A Vision for Five Years Ahead

To sustain a standard of excellence, it’s equally important to look at both what we’re doing today as well as what we’ll do in the future. In other words, plan ahead. In that spirit, I thought it would be prudent to peek into the future and talk about what a printed circuit board fabrication facility with a “standard of excellence” will look like five years from now.

It is obvious that the perfect PCB company of the future will undergo a significant transformation to meet the demands of innovation, sustainability, and efficiency. Here are some of the characteristics you can expect to see.

1. Advanced automation: The company will heavily rely on automation, utilizing AI-driven robotic systems for precision fabrication, assembly, and quality control.
2. Sustainable materials: Environmentally friendly materials will be at the core, with a commitment to reducing waste and the use of hazardous substances. The important thing here is that the entire world will (hopefully) sign up and standardize the effort to reduce the waste of hazardous materials and substances.
3. Clean energy: The company will transition to renewable energy sources, reducing its carbon footprint and operating costs.
4. Digital twin technology: Utilizing digital twin technology, this future company will create virtual representations of physical processes, allowing for real-time monitoring and optimization.
5. Supply chain integration: Expect to have seamless integration with suppliers, ensuring just-in-time deliveries of materials and components.
6. Customization: The company will have a strong focus on customization, allowing customers to design circuits tailored to their specific needs and requirements. Some companies have been offering this for several years already.
7. IoT integration: They’ll be incorporating Internet of Things (IoT) devices for real-time tracking of production and equipment health. Many of the new pieces of equipment we are buying today have incorporated IoT and AI as well.
8. Blockchain for transparency: The company will employ blockchain technology to maintain a transparent and tamper-proof record of the supply chain and production processes.
9. Collaborative robotics: Collaborative robots (cobots) will work alongside human employees, enhancing efficiency and safety.
10. Additive manufacturing: There will be integration of 3D printing for rapid prototyping and producing complex circuitry.
11. Data-driven decision-making: By utilizing big data analytics and machine learning algorithms, the company will be able to make informed decisions in real-time.
12. Smart factories: The entire manufacturing facility will be interconnected and self-optimized, resulting in reduced downtime and increased efficiency. We already see this and we can expect to see many more in the future. In fact, I believe they will become more common five years from now.
13. Zero-defect manufacturing: Employing advanced quality control systems, the company will ensure every circuit board meets the highest standards without defects.
14. Global accessibility: Offer online design tools and remote collaboration for customers and partners worldwide. Hopefully the world will become a calmer and more peace-loving place to make this more possible.
15. Distributed manufacturing: Establish smaller, distributed fabrication centers to reduce transportation costs and time-to-market.
16. AI-Enhanced design assistance: Plan to provide AI-powered design assistance tools that help customers optimize their circuit designs for efficiency and reliability.
17. Continuous training: You will see a company implementing ongoing training and upskilling programs for employees to adapt to new technologies and processes. We have never had enough training in our industry. This must change, especially as we invite varied demographics to join our industry.
18. Regulatory compliance: There will be strict adherence to international regulations and standards, ensuring the safety and reliability of products. We all know these will get sterner and more rigid as we become more influenced by global sustainability.
19. Circular economy practices: Companies will embrace a circular economy approach, where old circuit boards are recycled and reused to minimize waste.
20. Customer-centric approach: The company will focus on providing exceptional customer service, with 24/7 support, easy communication channels, and rapid response to inquiries. I put this one last for emphasis because it matters most. We continually bring the customer to the table, and we must do it more going forward. I see a complete collaborative and cooperative effort between the supplier and the customer becoming the backbone of the “standard of excellence” fabricator five years from now.

In summary, the perfect printed circuit board fabrication company of the future will be characterized by advanced technology, sustainability, connectivity, and a strong commitment to meeting the evolving needs of its customers. By embracing automation, digitalization, and eco-friendly practices, this company will not only remain competitive but also contribute to a more sustainable and innovative electronics industry.

What I find interesting is that we have already started using so many of these things, and I can testify from personal experience that they work. We have already incorporated many of these tools our company has been growing because of it. I can only imagine what we’ll dream up in the meantime.

Anaya Vardya is president and CEO of American Standard Circuits; co-author of The Printed Circuit Designer’s Guide to… Fundamentals of RF/Microwave PCBs and Flex and Rigid-Flex Fundamentals. He is the author of Thermal Management: A Fabricator's Perspective and The Companion Guide to Flex and Rigid-Flex Fundamentals .Visit I-007eBooks.com to download these and other free, educational titles.