Recent industry cases have shown that some manufacturers experienced functional failure across entire PCBA batches due to a missing buzzer (SPK reference) during the SMT process. As a leading one-stop PCBA solutions provider, Fully Hong has conducted an in-depth investigation into such failures and implemented robust mistake-proofing systems that eliminate these issues at the source.
1. Root Cause: Why Was the Buzzer Not Mounted?
The Fully Hong engineering team reverse-engineered the failure and traced it to a series of breakdowns across three critical stages: design, production, and quality control.
✅ Key Findings:
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Design Deficiency:
The PCB pad supported both SMT and DIP processes, but the preferred assembly method wasn’t clearly specified. -
Production Misinterpretation:
The English BOM description differed from the Chinese production interface, causing SMT operators to incorrectly assume the component was to be surface-mounted. -
Quality Control Oversight:
IPQC failed to verify the assembly route. The DIP workstation assumed the buzzer had already been mounted via SMT.
2. Fully Hong’s Preventive Mistake-Proofing Mechanisms
At Fully Hong, we’ve developed a multi-layered quality assurance framework that ensures zero component omission—especially for hybrid-process parts such as buzzers.
Triple-Layer Mistake-Proofing System
1. Smart Design Review System
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Automatically detects components that support both SMT and DIP
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Enforces mandatory designation of preferred process (예를 들어, “DIP ONLY”)
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Gerber files include auto-generated process-layer warning markers
2. Production Execution Safeguards
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Multilingual BOM auto-conversion system (supports 12 languages)
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MES system validates process routing in real-time
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SMT machines automatically ignore non-SMT component positions
3. Full-Process Quality Gating
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First Article Inspection follows “Triple Verification” (Bom / Drawing / Physical Sample)
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AOI program trained to detect hybrid-process components
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Handover checkpoints require dual-signature confirmation between stations
3. Why Choose Fully Hong?
We have systematized our manufacturing processes to ensure consistent, high-reliability results for all your PCBA projects:
✅ 100% identification accuracy for hybrid-process components
✅ <0.01% missing component rate — among the industry’s best
✅ 72-hour rapid response mechanism for issue resolution
📢 Experience Our Quality System for Yourself
➡️ Book a factory tour
➡️ Request our “High-Reliability PCBA Manufacturing White Paper”
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