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Overview
Overview
Our client, a Tier 1 supplier of precision electronics for medical devices and aerospace, built its reputation on high-quality, high-reliability components. However, rising defects in their assembly process began threatening both profitability and customer trust.
The Challenge
The Challenge
Within six months, the defect rate for advanced sensor units climbed from 0.8% to 2.5%. The main issues—solder voids, solder bridges, and weak joints—caused costly rework, longer cycle times, and missed delivery commitments. Annual losses from these defects exceeded ₹9.6M, eroding margins and putting client relationships at risk.
The Solution
The Solution
AEM Consultancy conducted a deep-dive analysis using VOC, SIPOC, VSM, and 12 months of production data. The findings revealed that most defects stemmed from excessive idle time between solder paste application and reflow soldering, as well as inconsistent operator practices.
To resolve this, AEM:
Re-engineered processes to minimize non-value-added time and ensure continuous flow.
Updated and reinforced SOPs, followed by hands-on retraining for all operators.
Introduced cross-shift rotation and communication huddles to eliminate variability and align practices across teams.
Results
Results
The improvements are projected to:
Reduce defect rates below the previous 0.8% baseline.
Improve First Pass Yield and solder reliability.
Cut rework and scrap costs, directly improving profitability.
Eliminate the 2-day rework delay, restoring on-time delivery.
Strengthen OEM confidence, ensuring future contracts and market reputation.
For expert guidance on optimizing your manufacturing processes, enhancing quality, and driving operational excellence, please contact AEM Consultancy
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