Do you work for an original equipment manufacturer or OEM? Chances are you’ve crossed paths with a project requiring an electronic manufacturing services company.
Electronics manufacturing services (EMS) are those offered by companies that design, test, build, deliver, or give aftermarket help for electronic parts and assemblies. A steady, expert hand guiding you through the manufacturing process can give your product a leg up on your competitors.
Electronics contract manufacturing services vary by supplier. Any given partner may offer anywhere from one to all of these services:
Some of what you see here is industry-standard, while other offerings are more niche or specialty. Either way, here are a few thoughts on EMS companies:
Here’s what to expect with EMS:
Electronic design services should turn your product concept into a reality, no matter the complexity. And the experience and skill of your PCB design company should be on display from initial discussions through final product validation.
All products need to be well-engineered, built, often attractive, and sometimes all three. State-of-the-art electronics contract manufacturers routinely develop custom housings in conjunction with PCB form factors and should advise you on the ideal material, whether it’s stainless steel, aluminum, or injection-molded plastic.
OEMs should expect support with product development that meets ISO 9001, ISO 13485, and AS 9100 standards.
Printed circuit board assembly, or PCB assembly, is the process of using surface mount technology or through-hole to solder components like transistors, resistors, and integrated circuits onto a bare board. A completed PCB lets you route power and signals between physical devices.
Through-hole takes a little longer because it involves more human interaction with the board. Surface-mount technology is more advanced but is the standard for most modern products.
Advanced electronics manufacturers can also turn aged through-hole products into more modern SMT-designed products to maximize the lifespan and useability of their life. This is thanks to state-of-the-art machinery that’s improved both speed and accuracy.
Circuit board parts are so small, that you don’t necessarily know you’re building it wrong until you test them. Luckily, the complete electronics manufacturer will offer fully functional in-house testing services. We'll get into more on that below.
Custom cable and mechanical assembly can also be a one-stop experience when working with state-of-the-art electronics manufacturers. Specializing in harsh environment cables, an experienced ECM should be capable of producing reliable cables for mining, medical, instrumentation, and other fields.
With a certified quality management system, your contract electronics manufacturer should be able to engineer, test, and produce quality cable assemblies ranging from micro push-pull connectors to harnesses and complex mechanical subassemblies.
There’s more than just cable assembly to these services. Other products associated with these services include:
The well-rounded provider will engineer, test, and manufacture the products.
For cable assemblies, manufacturing is done with hand soldering — your vendor should be certified in this. Many can also have injection over-molding capabilities. This refers to a process in which a single part is created using multiple materials. Typically the first material (sometimes called the substrate) is at least partially covered by subsequent materials (over-molds) during manufacturing.
Does your vendor offer custom over-molding capabilities? It’s something worth checking out before you buy.
Time to test? Cables can receive a functional test and a pull test. The testing process doesn’t need to be as rigorous as with PCB assemblies.
Forms of these tests include automated cable testing, and continuity and “hipot” testing. “Hipot” is short for high potential, which in turn means high voltage. A hipot test is the opposite of a continuity test in that it makes sure no current will flow from one point to another.
These services refer to products such as box builds. Depending on the manufacturer, these enclosures come:
A robust electronics manufacturer may have a dedicated final assembly team for these services.
A vendor can also offer:
Configuration management is a means of establishing consistency in your product’s performance and look. Potting is the process of filling a finished assembly with goo-like stuff to improve moisture, vibration, shock, and corrosion resistance. Heat shrink is a shrinkable plastic tubing that goes over the cable. So you’re getting another layer — ranging from paper-thin to industrial-sized — of abrasion protection for your product, whether it goes in a mine or another dangerous place.
All electromechanical assembly work should be done with intrinsic safety in mind -- both in the design stage and the manufacturing process.
Sometimes you need an expert, and that expert does not exist inside your building. That’s OK.
Contracting out design lets you take advantage of industry-specific, expert engineers and production teams. They will generate:
The vendor should be doing this while providing documentation to you every step of the way and meeting regulatory approval.
But EMS can really shine when a vendor jumps all in on the product development process. That means getting involved before the product design takes place.
Electronics manufacturing services should include the engineers, material manager, and others helping refine a contracted design through:
Did “costing exercises” catch your eye? You can come to a vendor with your price problems — it may be able to find substitute components that are less expensive, all without lowering final product quality!
Before that shipment of circuit boards arrives on your doorstep, you want to be sure you’re getting what you paid for -- a properly assembled, fully functional board. Anything less can compromise your supply chain.
Failing to commit to PCB testing can
The ways your electronics contract manufacturer can test a PCB assembly are staggering. Manufacturers’ offerings range from a visual inspection (basic) to a functional test (allows for a turnkey operation).
Types of PCB testing include, but are not limited to:
If you opt for extensive testing before you receive your product, you’ll know it was built to your specifications. Most importantly, you’ll know whether your product needs additional testing or it’s ready to send off to your own customers.
Messing up an electronic device rollout can be painfully expensive. PCB prototyping can help you avoid an embarrassing situation when you head to launch.
Many of the justifications for prototyping are obvious, but not all of them:
PCB prototyping services often take one of these four forms. As you go down the list, the build gets more "complete":
You can learn more about the types of PCB prototyping here.
Your ECM’s commitment to customer satisfaction must continue long after product delivery.
Check for three qualities in an electronics aftermarket services provider: experience, expertise, and technology. For example, Matric Group keeps the customer’s supply chain going with product upgrades, calibration, and repair services handled by state-of-the-art equipment run by skilled technicians.
Regardless of where your industrial or consumer was made or what it was made for, your electronics manufacturing services provider should have the know-how to service it properly.
This can include work on products manufactured by another company and on legacy products that require sustaining engineering.
Some service providers can even help you get ahead of the issues with failure analysis. If the same repair is being done repeatedly, a provider may jump in and quote a redesign that will save you money in the long run.
Obsolescence is a similar issue in electronics manufacturing. When a part is nearing the end of its life, your supplier can quote you for new supplies so you’re not caught unprepared.
There are three possible recommendations the provider will offer:
To help manage component obsolescence, a vendor should offer life-cycle analysis. This assessment looks at the total environmental impacts of a component through its entire life. Before you even finish production, your vendor can proactively look for parts that will need replaced and help you them obtain alternatives.
So, despite the term “aftermarket,” some of these services can benefit you before customers see your end result. You should always be aware of the risks before you send a product to market!
This is just a beginning overview of electronic contract manufacturing services. As you can see, what you get varies greatly by vendor. Some are simply looking to print bare boards in huge volumes. Others offer complex, creative solutions in smaller volumes and assist with several steps of the supply chain.
Surprised how much the right electronics contract manufacturer can do? Don’t be — there are reasons the best electronics manufacturers offer all-in-one services:
Click here if you have further questions about what an electronics manufacturer could or should provide.
(Editor's note: This article was originally published in May 2018 and was updated in August 2022 to reflect updated and current information)
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