Dan’s Biz Bookshelf: ‘In Defense of a Liberal Education’
American Made Advocacy: A Growing Presence in Washington in Turbulent Times
The Economics of Reducing Cycle Time in PCB Fabrication
October 29, 2015 | Jason Marsh, InsulectroEstimated reading time: 2 minutes
The area of cycle time most visible to the market is the total product cycle time through the fabrication process. This is an area of great importance to both OEMs and bareboard customers. As circuit board fabricators are constantly pressured for cost reductions, speed is definitely one thing worth paying for in 2015. For North American fabricators, there is a great deal of emphasis on quick-turn and development work, resulting in a high-mix, low-volume market whereby job setup is a key factor in the cycle time. In fact, it is not uncommon for 10–20% of the total product cycle time to be eaten up during layout, CAM and planning, which must be completed prior to releasing a job.
Leaders in the quick-turn and prototyping market reserve a significant percentage of their capacity for supporting this demand. Even so, they realize it is important to reduce cycle time for steps like sequential lamination, drilling, imaging, and final test.
Following are actual examples of industry practices that successful fabricators in the quick-turn market embrace that can help those companies who want to reduce cycle times in their operations.
Less is More
Some fabricators, such as Streamline Circuits, differentiate themselves by running a largely toolless process, which means that everything is digitized from laser drilling to LDI imaging and from LDI solder-mask to digital legend printing, and finally to flying probe testing at the end of the line.
With a 100% filmless process, Streamline can tool more than 20 jobs per day, which, once released, can move rapidly through the shop from start to finish without waiting on test fixtures, phototools, or legend screens. Investing in the latest equipment, such as a digital legend printer, 25-micron AOI, and 18-micron LDI capability and increasing press capacity also contributes to improved cycle time.
The Importance of Culture
Another critical aspect for cycle time that can’t be conveyed in a brochure, is culture. An example of this is at APCT Inc., in Santa Clara, California, where a healthy culture is embodied throughout every level of the company. Everyone, from top management to shop floor operators, is committed to quick-turn, including the theory of constraints mindset and a sense of urgency, which will contribute to the customers’ needs being met day in and day out. This approach has allowed APCT to establish a core competency as a high-speed HDI operation, one that can consistently produce a 10-layer board, with vias on every layer and five sets of copper- filled laser micro-vias, and four lamination cycles, within a week.
APCT is unique in that they confirm the raw material delivery date from their supplier before they will quote turn time to their customer for the job. Other quick-turn specialists employ consignment inventories and close communication and partnership with their material suppliers as a means of delivering on the speed requirements in today’s market.
Editor's Note: This article originally appeared in the October 2015 issue of The PCB Magazine.
Share on:
Testimonial
"Our marketing partnership with I-Connect007 is already delivering. Just a day after our press release went live, we received a direct inquiry about our updated products!"
Rachael Temple - AlltematedSuggested Items
Connect the Dots: Sequential Lamination in HDI PCB Manufacturing
07/31/2025 | Matt Stevenson -- Column: Connect the DotsAs HDI technology becomes mainstream in high-speed and miniaturized electronics, understanding the PCB manufacturing process can help PCB design engineers create successful, cost-effective designs using advanced technologies. Designs that incorporate blind and buried vias, boards with space constraints, sensitive signal integrity requirements, or internal heat dissipation concerns are often candidates for HDI technology and usually require sequential lamination to satisfy the requirements.
All Flex Solutions Upgrades Lamination Layup
06/22/2025 | All Flex SolutionsAll Flex Solutions has invested in Ulrich Rotte lamination layup stations in their rigid flex layup area. The Ulrich Rotte stations automate the layup process by handling the lamination plates, which are heavy, and sequencing the layup process for the operators.
Real Time with... IPC APEX EXPO 2025: Exploring Burkle's Innovations at IPC APEX EXPO 2025
03/27/2025 | Real Time with...IPC APEX EXPOBurkle North America's Andy Turner shares insights from the show, highlighting the excitement surrounding the event and Burkle North America's growth potential. He invited attendees to their booth to interact with the InfoCube, a cutting-edge touchscreen showcasing Burkle's diverse product offerings.
All Flex Solutions Upgrades Lamination Layup
01/17/2025 | All Flex SolutionsAll Flex Solutions has invested in Ulrich Rotte lamination layup stations in their rigid flex layup area. The Ulrich Rotte stations automate the layup process by handling the lamination plates, which are heavy, and sequencing the layup process for the operators.
Effects of Advanced Packaging and Stackup Design
12/26/2024 | I-Connect007 Editorial TeamKris Moyer teaches several PCB design classes for IPC and Sacramento State, including advanced PCB design. His advanced design classes take on some really interesting topics, including the impact of a designer’s choice of advanced packaging upon the design of the layer stackup. Kris shares his thoughts on the relationship between packaging and stackup, what PCB designers need to know, and why he believes, “The rules we used to live by are no longer valid.”