Industrial

Manufacturers of industrial products often face unique challenges including extreme environmental operating conditions, variable demand which may include configure-to-order requirements, and requirements to maintain spares and/or legacy product.

From a global network of facilities, SigmaTron offers industrial electronics customers a number of advantages:

• The ability to nearshore for logistics convenience or migrate products to lower cost regions for cost reduction
• Product development and enhancement support via our Design Services team
• Ability to support manufacturing requirements over the full product lifecycle
• Ability to support high mix, low-to-medium volume production, as well volume production
• Configure-to-order production capability

Manufacturing Support over the full product lifecycle 

• Strong internal systems that support serialization, traceability and revision control
• Ability to support legacy product technology

Assembly Expertise

• Cable and harnesses
• Conformal coating
• Electromechanical
• In-house plastics injection molding
• Potting

Test Expertise

• AOI, X-ray
• ICT
• Functional and burn-in/ESS
• GPS/RF/Ethernet

Product Expertise

• Controls
  • Brushless DC motors
• Gaming
  • Joysticks
  • Slot machines
• Health Club Equipment
  • Cross trainers
  • Exercise bikes
  • Treadmills
• LED Lighting
  • Ballasts
  • Displays
• Scales

Security/Aerospace/Defense

• Avionics control systems
• Battlefield electronics
• Communications and data management

Semiconductor Equipment

Power Supplies, Smart Grid, IOT Connectivity

• Switching
• High voltage

Relevant Certifications ISO 9001:2015 (all facilities)

Ability to support third-party qualification efforts such as UL and CSA

Case Studies

New Product Introduction (NPI) and Test Support for Low Volume, Complex PCBAs

A semiconductor manufacturer needed an electronics manufacturing services (EMS) provider who could support low volume, high complexity reference board production. The printed circuit board assemblies (PCBAs) typically had short product development cycles and never reached the volumes that would justify signifi­cant test ­fixturing. These PCBAs typically had 5000-6000 components with BGA sockets on both sides of the board. SigmaTron’s engineering team performed design for manufacturability (DFM) analysis on each PCBA, identifying whether the stencil or solder mask needed modi­fication to support assembly as well as test point access for flying probe requirements. Following customer approval, defect opportunities were calculated and a test strategy was developed that utilized automated optical inspection (AOI), 5DX/AXI (automated x-ray inspection) and, where possible, the flying probe test.

Complex Box Build Production Transfer

An industrial manufacturing equipment OEM wanted to outsource a complex electromechanical box build project. SigmaTron’s New Product Introduction (NPI) team visited the customer’s manufacturing site to observe and document the manufacturing and test process to facilitate a smooth transfer. They then developed manufacturing assembly instructions and all required documentation, plus designed a training program for production operators.

The process was transferred over a six-month period and the business expanded to six separate products on two dedicated lines. There were no out-of-box failures over a 10-year period.