When it comes to box build assembly, many of your options for reducing cost and production timelines exist prior to manufacturing. The configuration you select for your product enclosure, the types of fasteners you choose to use, and even the routing of your cables and wires all play a part in ensuring smooth assembly and minimal rework and delays.
By understanding how design decisions affect manufacturing, engineers and product designers can ensure they’re not only minimizing overall cost, but also accelerating time-to-market.
Below are a few of the primary design considerations that have an impact on box build assembly time and cost.
Why Design for Assembly Matters
During the box build assembly process, a variety of components are combined within an enclosure to create a functioning system or device. Products generally consist of a combination of printed circuit board assemblies (PCBAs), wire harnesses, power supplies, displays, switches, fans, and other electronic and mechanical components, all mounted within a box or enclosure.
Design for assembly (DFA) involves designing your enclosure and product so that assemblers can put it together as efficiently as possible. By prioritizing ease of assembly during the design process, companies can significantly reduce assembly time and cost. Assemblers may ultimately need to complete fewer steps when putting the device together.
What to Consider When Designing Enclosures for Box Build Assembly
A variety of elements must be taken into account when designing enclosures to facilitate an efficient assembly process:
Part Count and Complexity
One of the simplest ways to accelerate the assembly process is to reduce the number of parts. Each time an additional bracket, component, or other element is added, the potential for complications during assembly increases. Look for opportunities to combine parts, eliminate unnecessary brackets, or integrate features directly into the enclosure.
Standardized Hardware and Fasteners
Using a wide variety of screw sizes, lengths, and configurations can slow production and increase the risk of mistakes. By standardizing hardware, production can generally be accelerated by reducing the number of steps within the assembly process. Wherever possible, consider simplified fastening methods and reduce the amount of labor needed.
Enclosure Layout and Accessibility
The location of components within the enclosure should always be considered as you finalize the configuration. Designers must consider how each component will be accessed during assembly, as restricted space, accessibility issues, and an overly complex installation sequence can create significant manufacturing delays.
Additional considerations at this stage include ensuring easy access to critical connections between boards and components, providing adequate hand clearance in key areas, and considering overall accessibility for installation and future disassembly.
Cable and Wire Harness Design
Cabling and wire harnesses can be among the most labor-intensive parts of box build assembly. Cabling should be considered during box design, with specific routing planned to improve accessibility during installation and minimize cable lengths. Pre-wired harnesses can play an essential role in simplifying the box build assembly process.
Modular Design and Subassemblies
Subassemblies can help accelerate production during the box build process while also providing opportunities for quality control. Complex or multi-step assemblies can often be broken down into smaller subassemblies, which can often be built independently and later integrated into the full enclosure configuration.
Component Selection and Availability
Design choices also affect supply chain costs. Components with limited availability, extremely long lead times, or end-of-life status can create a significant delay in the assembly process, pushing up production costs. Selecting readily available and standardized components can be one of the simplest ways to reduce box build assembly costs.
Tolerances and Fit
While product designers will always seek to optimize the size and performance of a given device, it’s also important to leave sufficient tolerances to allow for easier assembly of various components. Excessively tight tolerances can significantly increase costs while also creating the need for additional adjustments and steps during assembly. At a minimum, tight tolerances can also require additional labor during assembly.
Designing For Testing
Testing is a key part of box build assembly. Products that are difficult to test or require complex steps can create significant delays in production. By factoring in considerations for accelerated testing and simplified test procedures, companies can greatly reduce assembly time and cost.
Clear Documentation
A well-designed product can streamline the assembly process, but adequate documentation, including bills of materials (BOMs), drawings, instructions, and revision control, is absolutely essential in reducing unnecessary delays during box build assembly. Assemblers who are faced with incomplete documentation or unclear guidelines may have to halt progress and wait for instructions.
Partner Early with Your Manufacturer
When it comes to reducing the cost and timelines of a box build project, working with a reputable and experienced contract manufacturer is arguably one of the best ways to simplify and accelerate the manufacturing process. Manufacturers can provide their expertise during the early design stages to help eliminate design issues and accelerate production timelines.
Frequently Asked Questions About Box Build Assembly
What is box build assembly?
Box build assembly is the process of integrating components such as circuit boards, wiring, power supplies, and hardware into an enclosure to create a finished electronic or electromechanical system.
What can companies do to reduce box assemble costs?
Reducing part count, standardizing hardware, simplifying cable routing, choosing readily available components, and involving your manufacturer early in the design process can all help lower costs.
When should you involve a manufacturer in your product design?
Manufacturers should be involved in your product design as early as possible to ensure that they can help identify issues which may delay production timelines.
Streamline Your Next Box Build Project with Sonic Manufacturing
Sonic Manufacturing is here to help you design your next great product. Our knowledgeable team of contract manufacturers and engineers can help you design products that are not only high-quality and high-performing, but also efficient and cost-effective to assemble. Contact Sonic Manufacturing today to learn more.