PCB Assembly

Box Build Assembly: Best Practices for Quality Control

The box build assembly

Box build is a very famous and unique technique in the EMS industry. Box-build assembly means PCBs are enclosed in the box with the harness and cable. This type of assembly is done after fabrication and assembly boards.

What is Box build?

Box build assembly is an innovative process of assembly to secure PCBs. It combines all of the things of PCB like electricity, finished assembly, etc. This assembly requires more precautions due to placing all harnesses and assembly boards in a box. This is very hard to manage in a box. It needs the skill to manage all things in the box. Most companies do this assembly which is known as EMS (electronics manufacturing services).
Sometimes box-build assembly is the most complex assembly due to complex design, high number of parts, and design of enclosure and production capacity.

The basic steps of box build assembly

  • Preplanning
  • Wire and harness assembly
  • PCB assembly
  • Accessories
  • Quality check
  • Packaging

Here is the Explanation of the whole process of box-build assembly:

1. Pre-planning

Pre-planning of box-build means what type of materials and parts are required for projects. It includes parts like brackets, fasteners, harnesses, cables, keypads, handles, connectors, and many more electronic components and assembly vendors.

This stage is the most important part of box-build. Because it shows how many parts are needed and what is carried in the assembly house. If any parts are failing when fitting assembly then it needs to be purchased that time. So, it covers some extra parts for the future. This team makes sure whole things like how many parts are needed, lead time, labeling, parts tracking, etc.

2. Wire and Harness assembly

The box bulid assembly of wire and harness

Box build PCBs are connected to the I/O devices, and AC/DC drivers with the use of cables and harnesses. So these cables are connected in USB ports, connectors, strips, DIN type cable connectors of PCB. Small things are more complex in box-build assembly. So at this stage make sure how much we reduce those connections to make it easy for connections. All connections are properly inside the Box using cables and harnesses.

3. PCB assembly

Some SMT parts are already assembled on the PCB. Other box-build parts are installed at this stage. So this stage sets the way how to install box-build parts easily and quickly.

The whole PCB is enclosed in the box. But there needs to be some space between the box and the PCB. Otherwise, it needs some screws and fastener fittings to make a secure place in the box at the same time, this thing is ensured by the assembly production house. The box is fitted with fasteners and screws with the use of holes available in the box. Some extra portions are available on the box. But it’s for connecting box-build assembly to other circuits.

4. Accessories

In this stage, accessories are installed on the PCB like buttons, switches, displays, mounting brackets, handles, etc. Also, brand logo and graphic badges are assigned to the box-build. If air ventilation fans and air filters are installed then whether they are working or not ensures that. The accessories stage is done with proper installation and integration of whole accessories parts with branding logos of the product.

5. Quality check

After the whole mechanical assembly is done, it goes to Quality check and testing. It contains different types of testing in quality check and assurance like functional testing, burn-in testing, etc.

Functional testing tests whether the electrical connections are properly working or not. Functional testing confirms no short circuit and no leakage current are found. It’s making sure whole key features are working properly like the display on and off, switch on and off, buttons control, output data of sensors, etc.

Quality check also follows safety and compliance requirements on boards like UL, EMC, EMI, and all. All corrections and faults are verified and solved:

Special testing:

  • Manual visual inspection: It inspects the whole box build like fitting, finishing, labeling, and all. 100℅ final units are going off the production house.
  • Calibration testing is for measuring parts like generators.
  • Thermal temperature testing tests the temperature of the box using probes.

6. Packaging

The final key step of box build is packaging. The whole box build is covered with the chassis. The packaging team applies the plastic wrappings over the box build Packaging. Assembly vendors provide extra wires to the customer if any cables are faulty for some other reason.
Packaging teams add the whole assembly manual, warranty letter, labeling, and CDs in the box build package. So it’s easier for customers to learn how to fit exactly.

As we know bubble wrapping is the most popular wrapping method in which assembly vendors are used for packaging. Bubble wrapping secures the package from the damage. The packaging team packing the boards is individual and penalized as per customer requirements.
The advantages of box build assembly.

The advantages of box build assembly

1. Minimize the size
Box build assembly contains mostly small boxes. So this will be more beneficial to be easy to pick and install anywhere.

2. Reduce cost
Cost is very low due to fewer parts needed to be installed with lower charges to logistics. There are multiple vendors available on the market for sourcing the parts. So we can get low-cost parts due to competition from all parts distribution vendors in the market.

3. High quality
It gives high-quality assembly due to the small size of the assembly. It takes less time for quality checks. With the help of the Quality department, it verifies the different types of testing on the box build and gives the assurance that the whole assembly is good to go for shipping.
Easy to install: box build assemblies are very easy to install because only mechanical connections are made manually and all other connections are already made through the machine.

4. Reliability and mobility
Box build assembly has some portion of mechanical assembly. So all types of equipment are easily connected. We can schedule production lines across some other facilities. We can get a workforce on demand to meet requirements.

5. One-stop service
One-stop service means the whole assembly is provided by the assembly vendors with boxing. It provides design, prototypes, testing and verification, and supply chain management and distribution easily.

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