Process innovation improves throughput and consistency

ADCO Circuits delivers higher quality faster

ADCO Circuits partnered with a customer in the military aerospace sector to improve the efficiency of a soldering process involving two ribbon cables connected to a printed circuit board assembly (PCBA). The project demonstrates how automation and process innovation can reduce costs and improve throughput while maintaining IPC Class 3 quality standards.

ADCO Circuits, a leader in the high-performance electronic assembly was contracted by a customer to manufacture/assemble a printed circuit board for an automotive application for a Belt Tensioning System (BTS).   The assembly’s current design consisted of surface mount and through technology for placement and soldering which resulted in multiple operations through the manufacturing process. 

Challenge:

Hand-soldering step becomes production bottleneck that extends lead times.

The PCBA design included two ribbon cables soldered directly to the board — a process traditionally completed by hand. While manual soldering ensured precise results, it was expensive, time-consuming, and dependent on skilled IPC Class 3 solderers. As production volumes increased, this hand-soldering step became a bottleneck, extending lead times and limiting overall throughput.

Solution:

Develop automated ribbon soldering process that meets IPC Class 3 specifications

ADCO Circuits identified an opportunity to automate the ribbon cable soldering process while adhering to IPC Class 3 specifications. Our engineering team proposed and validated the use of a specialized soldering machine that could replicate and even improve upon the quality of manual solder joints.

We sourced and tested sample units, produced prototype boards, and demonstrated superior solder joint consistency. The automated method met all IPC Class 3 requirements and delivered a faster, more repeatable process — ensuring quality without compromise.

specialized soldering machines

Result:

Higher quality produced faster
and less expensively

By transitioning to an automated soldering solution, the customer realized measurable improvements:

  • Increased throughput: Faster production cycles and reduced bottlenecks.
    Lower labor costs:
  • Eliminated the need for manual Class 3 hand soldering.
  • Enhanced quality: Reliable, repeatable solder joints that meet IPC Class 3 standards.
  • Scalable process: Supports higher production volumes with consistent results.

This project underscores ADCO Circuits’ commitment to continuous process improvement

Leveraging our expertise  through automation to help customers in the military and aerospace industries achieve the highest levels of reliability, efficiency, and performance.