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80 SMT Magazine • March 2016 • Male connector housing with female terminal: While this mistake is easily fixable, it can generate significant non-value activity if not caught in documentation. • Incompatible materials on header and cable: For example, specifying a gold- plated header on the PCB connector, but using tin on the cable terminal, can create resistance issues immediately and corrosion longer term. • Cable documentation shows pinout but doesn't identify connector: If the pin- out only shows a single view and the connector isn't identified, in the best case it slows down the new product introduction process and in the worst case it can result in an incorrect con- nector being used. • Incomplete or missing wire list: This is a frequent mistake with two-wire connec- tions. It can cause quality issues. • Proper crimp tool not specified: The tools used to crimp wire are specifically sized for the cable. Failure to specify the correct tool size or specification of an incorrect tool can cre- ate quality issues. IPC-A-620 includes a require- ment for specification of crimp height and tool test. • Insufficient electromagnetic interfer- ence (EMI) shielding or placement issue: Insufficient EMI shielding or placement of sen- sitive cables near a power supply can create in- termittent product failures. From a business model standpoint, this lev- el of vertical integration offers benefits to EMS providers as well. Projects that start at the cable or board-level often grow to subassembly or complete unit builds as customers see the value of utilizing a single source for the full product. Additionally, the mix of board-level, cable and box-build assembly makes it easier to maintain full utilization of a highly trained staff by rotat- ing cross-trained production operators through areas experiencing the highest of level of de- mand. Some EMS firms choose to optimize this approach by fine-tuning sales focus on the types of projects likely to keep all three areas near ca- pacity. This varies from the typical regional EMS provider model of dealing with demand varia- tions by increasing and lowering production operator headcount primarily through the use of temporary staffing options. A strong focus on quality in all operations is a critical point of the business model. The focus on ensuring that cables and harnesses meet the requirements of IPC-A-620 is equal to the level of detail put into ensuring that PCBAs are com- pliant with IPC-A-610 requirements. SAI has in- vested heavily in training. For instance, there is an in-house trainer certified as an IPC trainer for J-STD-001, IPC-A-610 Rev. E, and IPC/WH- MA-A-620. Team leaders and select operators thE bEnEfItS of a vErtICally IntEgratEd aPProaCh to EMS Figure 1: SAI uses a "working smarter" philoso- phy in project launch, working with customers to ensure transfer of a manufacturable product. Figure 2: humidity-controlled towers are used to store components as part of line-side stocking programs.

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