Introduction to the NPI Process in Electronics Manufacturing
The New Product Introduction (NPI) process is one of the most critical components in electronics manufacturing services (EMS). An EMS provider with a robust NPI process can consistently deliver high-quality products.
However, those that neglect this key phase or rely on outdated policies may struggle to maintain consistent manufacturing standards.
Many EMS providers emphasize the importance of their NPI process, but what steps do they take to ensure that new products are seamlessly integrated into their manufacturing operations? Additionally, does a product need to be “new” to receive this level of attention and care?
This blog post highlights four essential pre-build checks that should be performed before launching an NPI and seven crucial steps an EMS provider should follow to ensure a repeatable production process.
Four Pre-Build Checks Your EMS Provider Should Make
- Data Verification
NPI Engineers must have all the information needed to build the product, including a Bill of Materials (BOM) and a Gerber file. If CAD data is available, the EMS provider can create a surface mount pick and place machine program automatically. Without CAD data, the program must be created manually, increasing NRE charges and the risk of human error.
- Using the Right Tools for Electronics Assembly
Most electronic designs will include surface mount components and could, therefore, require a solder stencil. Before ordering the stencil, the NPI Engineer should check the stepped Gerber file for correct panelisation. Any issues may require additional time or result in PCB scrap. Once verified, the stencil can be ordered, and its specifications confirmed. A visual check should also be carried out on receipt to ensure no damage occurred during transit.
- Creating the Build Pack
The NPI Engineer is responsible for ensuring that the data in the build packs covers everything the production team needs. Any special build, handling, test or packaging instructions provided by the OEM can be added as dedicated care points.
- Checking the Programme
The NPI Engineer should review the surface mount program details, checking for ‘no fit’ components and ensuring component package size and polarity accuracy. Any discrepancies must be clarified with the OEM prior to the build commencing to avoid production errors and costly rework.
The Seven Crucial Steps of the NPI Process
- Internal Visibility
A robust system is essential for automatically flagging “new” builds to the engineering team. With new orders being loaded throughout the day from various customers, this shouldn’t be left to chance or rely on manual processes. Ideally, new builds would be highlighted to the engineering team through an automated overnight report. This report should include customer details, part numbers, batch quantities, unique work order numbers, request and acknowledgment dates. The engineering team should then assign a unique NPI number for the job, which can be referenced in subsequent reports or documentation.
- Data Verification
The engineering team must ensure they have all the necessary data and equipment for the initial build. Missing data, such as the latest revision software or customer-supplied test equipment, could halt the assembly. Once the NPI engineers are satisfied with the data, they can create bespoke build packs, order solder stencils or pallets, and write programs for the surface mount equipment. This data should be securely stored and updated in a controlled environment. Some EMS providers use a color-coded document system to make NPI build documents stand out, visually raising awareness of NPI builds to other departments.
- Batch Size
The EMS provider should determine the size of the initial batch. Running the entire production quantity upfront could lead to costly issues if problems are found. Best practice is to run a smaller NPI batch first, ensuring the remaining material is ready to follow once the first stage is approved. Factors like PCB panelisation, complexity, test requirements, and completeness of build data can all influence the batch size. Communication between the OEM and EMS provider regarding additional tests and checks is crucial to factor potential delays into the overall lead time.
- Overseeing Production
The NPI Engineer should, ideally, oversee all assembly stages, including test requirements. Any observations during these stages should then be recorded on some kind of ‘traveller’ document which follows the build around the shop floor, incorporating critical information into the original build pack to improve the quality or efficiency of the next batch.
- Sign Off and Shipment
The NPI engineer responsible for the project should sign off on the build before shipment. A system or process should be in place to prevent freshly built products from shipping without a final check. If issues arise, the NPI engineer should communicate these to the Key Account Manager responsible for the customer so they can look to resolve these.
- Status Change
Following shipment and sign-off, the EMS provider will want to change the production status of future builds for the same product. The status levels, such as NPI, pre-production, and volume build, should be clearly defined, with engineering support reducing as the product moves toward volume build. The system should be flexible enough to revert to NPI status if needed.
- Reporting
Best practise involves the EMS provider creating an NPI report which documents the build process and any issues found during assembly. These reports should include build details, top and bottom images of the PCBA, process flow, material or build observations, and potential design issues and recommendations. A thoroughly documented process ensures that new designs and mature products can be consistently produced.
Conclusion: Ensuring Success in Electronics Manufacturing with a Robust NPI Process
While pre-build checks and a robust NPI process require time and effort upfront, they minimise issues during production, keeping product costs on budget and delivery on time. If your EMS provider lacks a thoroughly documented process or uses it only on “special” occasions, you may want to challenge them on their manufacturing repeatability control.
