Company D was a fairly new emerging PCBA provider in Asia. Our team was called in because the operational metrics weren't meeting the owner's expectations. The major issues were:

• Poor Yields well below industrial expectations
• Too much rework
• Poor outgoing Quality
• Behind Schedule
• Rejected board inventories were getting out of control

The QE team worked with the company to create a pareto of the reasons for the various issues. Based on this pareto the team made the following improvements:

• Provided Supplier Management support to improve the incoming quality of the components
• Re-layout the line so that it was balanced
• Created a new training program for the operators, technicians, and outgoing inspectors
• Worked with the testers to increase test coverage
• Hired, equipped, and trained extra labor to get red of the rejected boards by reworking them

The results of the QE team's efforts were:

• PCBA Yields reached industrial standards of > 90%
• Cycle time was substantially reduced
• Substantially improved the product quality
• Increased profit