New production introduction (NPI)

Contract manufacturing service

Scale up to push-button delivery

Service the entire NPI process


Since 2012, we are dedicated into NPI (New Products Introduction)  and manufacturing of IoT products (Internet of Things).

We utilize our knowledge and expertise to help customers bring prototypes into production, lead it through certifications, solve the most critical manufacturing issues, aim for low-cost high-quality manufacturing.

We inspire, motivate, guide customers, thereby making it possible to optimize production at lower costs, higher reliability and larger quantities. We ensure that production meets the requirements for performance, certifications and "push button" deliveries.


Our customers and partners include industry leaders in China, Thailand and Europe, where products are distributed worldwide.

Let's make your products affordable, reliable and prolong their lifetime. 

Contact us and get a free call without obligation, find out how we can help you bring your fantastic product into production and out into the world.

What is NPI?


The NPI phase brings a product from proof of concept to a working prototype for mass production.

Each new product will go through three phases below:

1. Prototype maturation

Prototype build, P1
Prototype build, P2

2. Certification
3. Mass production

Pilot production, PP + MP

NPI model

NPI model

HIGHLIGHTS OF OUR SERVICE


BOM (Bill of Material) review
 

  • √ Reduce cost and lead time with a BOM review
  • √ Consider component alternatives more readily available in China without compromising on quality

DFM (Design for manufacturing) review of product design
 

  • Provide manufacturing
  • Plan test and assembly procedures in product design considerations
  • Anticipate and prevent problems before production
QR code tracebility

TRACEABILITY

Delivering a global market is challenging as regulations vary from country to country and new rules are updated from time to time.

To keep each delivery's specifications under control, we help define and implement a traceability system so you can easily identify each delivery and track the manufacturer's root.

Documentation

DOCUMENTATION

- Production flow diagram
- P1, P2, PP evaluation reports
- IQC specs
- QA plan
- Definition of '' golden '' and '' rotten '' samples
- Assembly instructions
- Fixtures, stencils maintenance, etc.
- Testing and programming instructions -
- Testing and programming of equipment specifications

Testing

TEST


Schedule product design testing

Design test fixtures, implement and verify reliability
Programming and calibration
Documentation as well as quantized testing provide reliable products.

Reliable
 

Safe test reliability
Achieve automatic testing instead of operator control

 
Affordable  

Testing without the need for embedded test SW in the product
Cost
-effective test units: RF chambers
Shielding materials

QA goals

QA MANAGEMENT GOALS

Better overall quality
Longer service life
Lower scrap speed
Less waste
Minor delivery delay

QA (quality assurance) plan
 

Define and implement traceability system
Map customer-specific requirements for IQC, QC and OQC system in the process
Comprehensive review of procedures, assembly capabilities and quality
Agreement with customer and EMS on programming, testing and QA process
Review ad implementation of QA system terms
Agreement with on safe production and test reliability

QA FOLLOW-UP AFTER PRODUCTION

Batch evaluation and production yield reports
Report product design errors and similar solution
Identify and remove root causes of process efficiency and product defects

NPI timeline


NPI timeline

ROOT-CAUSE ANALYSE


By doing special studies, we look for the root cause of problems in production.

PRODUCTION AUDIT


In order to identify inefficiencies and non-conformities in production, to identify the root cause for high failure rate, we suggest to start with an in-depth audit.


Audit plan and report are based on the industry's leading technology company.
Read our audit plan

On-site audit

1. Check the procedures of the IQC department for proper material.

2. Inventory inspection with adequate storage of ESD and MSD as well as equipment control.

Concentrate on the SMT department, quality assurance procedures, to avoid errors, for ESD and MSD management.

4. Evaluate machine and factory functions. Evaluate the process and quality of the ongoing order during the audit. Advice on actual cases of SMT problems, whose staff can compile a list of most common errors.

Assembly department (incl. HMT and DIP processes) inspected for overall quality, soldering competencies, process flow, documentation, ESD, QA system and control structure

6. Evaluate the factory IPQC and OQC. The IPQC department is often underestimated and not functioning well

Previous project has proven factories will achieve better optimization by working with SMATE than dealing with it alone.
Logically, many problems would not exist or have already been solved if the factory had these skills internally.

PRODUCTION OPTIMIZATION


Based on findings from audit report and client request, we assist clients implementing optimizations, covering:


1. Management Optimization
- Training managers and engineers, improving their understanding of quality
- Enabling teams to perform internal audits.
- Clarify responsibilities


2. Process optimization
- Optimize procedures for control of risks before and during production
- On-site support for root cause analysis
- Focus on SMT department and assembly line.
- Focus on details, e.g. appropriate handling of humidity and temperature


Smate recommends scheduling a small follow-up audit a few weeks later to ensure optimization is performed.

Kick-off scale up


Start your project with us by sending below information:

PCBA

  • Gerba data
  • PCBA BOM
  • Programming and testing specifications

Report, feedback and suggestions

Cosesy prepares an audit report and submits a report on observed deviations together with proposals and solutions for optimization.