START NEW START-UPS SAFELY WITH OUR NPI PROCESS

The start of production of new electronic assemblies is one of the most critical points in the product life cycle. This is where most errors can occur: incomplete production data, unstable process parameters or unclear test scopes.

To ensure that our customers receive reproducible and robust production from batch one, we at Baudisch Electronic rely on a clearly defined new product implementation (NPI).

Our aim is to identify technical risks at an early stage, minimize process fluctuations and set up production capable of series production – regardless of whether prototypes, pre-series, small series or large series are involved.

WHEN A PRODUCT IS CONSIDERED A NEW START

At Baudisch Electronic, every assembly that runs through our production line for the first time – including re-designs, variants or layout updates – is considered a new start. Special rules apply to these products:

Increased control density
Documented approvals
binding interfaces between work preparation, production and quality assurance

In this way, we ensure that quality is not “checked retrospectively”, but is built into the process from the outset.

FROM CUSTOMER INQUIRY TO PRODUCTION RELEASE

The NPI process does not begin with the first manufactured assembly, but rather with the customer inquiry.

1. labeling as a new product

2. the product is clearly marked as NPI in the ERP/MES. This makes it clear for all areas: initial start-up with extended testing and approval process.

3. all production bases are completely created and checked in the work preparation:
a. Parts list (BOM) / AVL comparison
b. Production data (Gerber, Pick&Place, CAD data)
c. Work plans and setup documents
d. IPC-compliant soldering and assembly specifications
e. Customer-specific requirements incl. CTQs

4. QA information and NPI accompanying document:
Quality management is involved before the start of production.
It creates the NPI accompanying document as a central protocol for all test steps and approvals during the initial start-up.

THE PRACTICAL PART OF THE NPI PROCESS IN PRODUCTION

The operational NPI phase begins with the start of the SMD line:

1.first article inspection (FAI)

As soon as the first assembly leaves the line, QA carries out an initial visual inspection in accordance with IPC-A-610. Among other things, the following are checked

Component identity and polarity/orientation

Solder joint quality (wetting, bridges, tombstoning, etc.)

Solder paste application / stencil image

Mechanical features, connector position

Critical distances (if relevant)

The results are recorded in the accompanying document and jointly approved by SMD production and QA. Only then are the results passed on.

2. process-accompanying releases per production stage

The same two-stage mechanism applies in all subsequent steps, e.g:

THT assembly / selective or wave soldering

Assembly / mechanical integration

Programming / Calibration

In-circuit test (ICT), functional test, burn-in or customer-specific tests

A QA check is carried out after every internal process check. The next step is only started if production and QA approve. This prevents errors from being “passed on”.

3. final logistics and packaging approval

At the end, the QS checks:

Packaging and ESD protection

Labeling, traceability requirements, serial number logic

Customized specifications

The accompanying document is then archived – as complete proof of the first run and a reliable basis for the series.

DEALING WITH DEVIATIONS

If a deviation occurs, standardized correction loops take effect:

1. documentation of the deviation

2. immediate action / rework

3. re-inspection by QS

4. repetition until conformity is achieved

5. CAPA/8D-compliant process or data record customization

This applies consistently to all areas.
Result: No faulty assembly leaves a stage without qualified approval.

NPI-CLOSE-OUT: TRANSITION TO THE SERIES

After the initial run, the new start is completed and the assembly is transferred to series production. The knowledge gained during the initial run is documented and incorporated into the existing production and test documents. Proven process parameters, test programs and workflows are defined and released for series production. This ensures that the assembly continues to be manufactured under stable and reproducible conditions.

WHY THE NPI PROCESS MAKES THE DIFFERENCE

A stable series process does not come about by chance – it is built up during a new start-up. Our NPI process ensures that:

Risks are recognized and eliminated at an early stage

process parameters are capable and mastered from the outset

Test concepts take hold

production becomes reproducible and scalable

later series runs benefit from clear data and standards

In short: quality from batch 1 – with seamless traceability and defined approvals.

Baudisch Electronic stands for controlled, transparent new start-ups – from prototype to mass production. If you are looking for an EMS partner who can safely transfer new products to production and consistently anchor quality in the process, please contact us.