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76 SMT007 MAGAZINE I JULY 2018 Article by Mike Baldwin SPECTRUM ASSEMBLY INC. Regional EMS providers typically provide greater flexibility and responsiveness to their box build customers via use of work-cell-based batch assembly processes. Production volumes are fairly low, so the creation of dedicated continuous flow paced assembly lines is rare. However, we often see larger footprints and more complex projects with higher volumes. Our cable, harness and PCBA manufacturing capabilities attract companies with products requiring complex subassemblies. As a result, it utilizes both work-cell-based and continu- ous-flow-line assembly in its box build assem- bly area. One recent project example illustrates why this flexibility is important. The customer develops sports therapy devices used by train- ers and professional sports teams. They had a next-generation product that increased func- tionality and, as a result, became mechanically much more complex. They needed a contract manufacturer capable of assisting them with development of mechanical manufacturing process instructions in addition to manufactur- ing the product. SAI helped develop the manu- facturing process instructions as part of its new product introduction (NPI) services. The customer's documentation for wire and cable assemblies, electronic assemblies, mechani- cal assemblies and cosmetics requirements is transmitted to the Aegis system and used to create visual work instructions that are utilized by the production team. This project included cables, harnesses, PCBAs, electro-mechanical, fluidic, air and water subassemblies as well as chassis, sheet metal, plastics and hardware compo- nents. Routing the tubing in a limited chas- sis space was a challenge. Our team used the same process templates used in develop- ing efficient wire and harness routing to route the fluidic, air and water lines. Trial builds were performed to ensure correct air pres-

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