Reliability Matters

In this episode, we’re diving into a topic that’s rapidly reshaping our industry: Artificial Intelligence in PCB Design. Far from a futuristic concept, AI is already being integrated into advanced design tools—improving efficiency, reducing design iterations, and helping engineers tackle increasing design complexity with shrinking timelines.Joining me today are two thought leaders who are at the forefront of this transformation:First, we welcome back Stephen Chavez, a senior printed circuit engineer with more than 30 years of experience. Stephen serves as a Senior Product Marketing Manager at Siemens EDA, where he helps drive AI adoption in PCB design workflows. He’s also the Chairman of the Printed Circuit Engineering Association (PCEA) and a PCEA and IPC Certified Master Instructor Trainer. Stephen recently authored the article “AI in PCB Design: It’s Already Here”, which forms the foundation of today’s discussion.Also joining us is Dave Wiens, Product Marketing Manager for the Xpedition Enterprise portfolio at Siemens EDA. With decades of experience in electronic design automation, Dave is a recognized expert in digital transformation and design innovation. He brings deep insight into how AI-driven tools are streamlining everything from system-level design to manufacturability, while empowering engineers to focus on innovation rather than repetition.We’ll unpack the practical applications of AI in PCB workflows—covering predictive design, simulation acceleration, and how these advancements are improving both reliability and time-to-market.If you're wondering what AI really means for the future of design—and what it doesn’t—you’ll want listen to this episode!

As the electric vehicle market accelerates, the reliability of the charging infrastructure becomes increasingly vital. Chargers that are down or malfunctioning can hinder adoption and erode consumer confidence. But who ensures these chargers stay up and running?Today, we're diving into that very topic with a trailblazer in the EV service space. My guest is Kameale Terry, co-founder and CEO of ChargerHelp!, a company revolutionizing how we think about EV charger maintenance and reliability. Under her leadership, ChargerHelp! has pioneered Reliability as a Service, developed a highly trained and diverse technician workforce, and shaped industry policies aimed at improving charger uptime.Kameale’s journey is as inspiring as it is innovative, leading a national movement for a more reliable and equitable EV charging network. With backgrounds in workforce development, clean tech, and digital operations, she’s uniquely positioned to tackle the challenges facing this growing industry.In this episode, we’ll explore the common causes of EV charger failures, the role data plays in predictive maintenance, the impact of new regulations like the National Electric Vehicle Infrastructure (NEVI) standards, and how ChargerHelp! is creating pathways into the clean energy economy for workers from all walks of life.If you've ever wondered how reliability translates to the EV world, or how technology and workforce innovation go hand in hand, you won’t want to miss this conversation.Kameale’s Company:ChargerHelp!https://www.chargerhelp.com

Today we're diving into a topic that keeps many executives awake at night—ERP implementations. More specifically, why so many of them fail and, perhaps more importantly, how to fix them midstream before they derail your operations.Joining me today is someone who knows this space inside and out—Chintan Sutaria. Chintan grew up working in an EMS business from a young age, gaining firsthand experience in the unique challenges of our industry. His career path took him into the world of business process consulting at some of the largest Big 5 firms, and he has since worked with numerous EMS companies on a wide range of projects.Many of you may recognize Chintan as the founder and former CEO of CalcuQuote, a well-known supply chain management software solution for the EMS industry. Recently, he founded, OpenJar, a consultancy dedicated to helping electronics manufacturers navigate complex business challenges—including ERP implementations.We’ll discuss his new company as well as his recent blog post, "Why Your ERP Implementation Failed (and How to Fix It Midstream)", explore common pitfalls, and uncover strategies to steer your ERP project back on course.Chintan's CompanyOpenJarhttps://openjartech.com

Today we're turning our attention to a cornerstone of modern electronics manufacturing: pick and place technology.Joining me is Tim Kang, CEO of Hanwha Semitech Americas. With nearly two decades of experience in the electronics manufacturing space—starting as a mechanical engineer and now leading one of the top pick and place equipment providers—Tim brings a wealth of insight into what it takes to build reliable assemblies.In this episode, we’re covering best practices for selecting the most appropriate pick and place machine, how to get the most out of your equipment, and the common mistakes that can compromise productivity and long-term reliability.Whether you’re a process engineer, a line operator, or anyone involved in electronics manufacturing, this conversation is packed with practical advice you can use right away.Hanwha's Website:https://www.hanwha-pm.com/en/product/smt/index.asp

Today we're exploring a concept that has deep roots in process safety and infrastructure management, but also has meaningful applications in electronics manufacturing: Damage Mechanism Reviews, or DMRs.My guest today is Dheeraj Narang, a corrosion and reliability engineering specialist, process safety activist, and digital innovation researcher with an impressive track record across the energy sector.Dheeraj has spent his career developing and implementing asset integrity programs for more than nine global energy companies across the U.S., India, and the Middle East.He’s also a visionary advocate for using advanced technologies, industry best practices, and safety standards to uplift regions and workers where such systems are still under development. Whether it's through his service on global conference committees or his contributions to cutting-edge digital initiatives, Dheeraj is on a mission to blend technology, safety, and human rights into a unified vision of operational excellence.In this episode, we’ll discuss:What Damage Mechanism Reviews are and why they matter.How DMRs tie into reliability programs like FMECA.How DMR thinking could benefit industries outside of oil and gas—including electronics manufacturingand how emerging technologies like AI and machine learning can amplify the impact of these reviews.Whether you're in energy, electronics, or any industry where reliability and safety are paramount, this is a conversation you won’t want to miss.Dheeraj's Contact Info:dnarang1@my.harrisburgu.eduReferences:Narang, D. Dual Benefits of Damage Mechanism Reviews. 2024 AiCHE Spring Meeting and 20th Global Congress on Process Safety, New Orleans, LA, March 25-27, 2024.Narang, D. Application of FMECA Methodology in Reliability Assessment of Complex Assets in Process Plant Industries. Reliability, Maintenance & Managing Risk Conference (RMMR) by American Society of Quality (ASQ), Pittsburgh-PA, July 25-26, 2024.Narang, D. Feature Selection Methodology for Developing a Supervised Machine Learning Model for Risk Based Inspection Study on Process Plant Assets. 79th Instrumentation and Automation Symposium, Mary Kay O’Connor Safety & Risk Conference, College Station-TX, October 22-24, 2024.Narang, D. Application of Machine Learning Concepts in Inspection Data Management System at Process Plant Facilities. 27th Process Safety International Symposium, Mary Kay O’Connor Safety & Risk Conference, College Station-TX, October 22-24, 2024.

On this episode of the Reliability Matters podcast, I left my usual studio for the IPC APEX Expo in Anaheim California.I interviewed two subject matter experts on topics related to electronic assembly.My guests are:Gerald Gardner, Global Product Manager at Weller, a manufacturer of hand soldering equipment fume extraction systems, and precision tools.Mike Young – CEO OF SASinno Americas, a manufacturer of wave and selective soldering equipment.More information on my guest's companies is available here:SASinno Americashttps://www.sasinnoamericas.comWellerhttps://www.weller-tools.com/us/en

On this episode of the Reliability Matters podcast, I left my usual studio for the IPC APEX Expo in Anaheim California.I interviewed three subject matter experts on various topics related to electronic assembly. My guests are:Greg Beck, Director of Sales at Absolute EMS, a contract manufacturer.Brian Watson, Co-Founder OF HyRel Technologies, a global provider of quick turn semiconductor modification solutions.Keith Sweatman, Technical Advisor at Nihon Superior, a manufacturer of soldering materials.More information on my guest's company is available here:Absolute EMShttps://www.absolute-ems.comHyRel Technologieshttps://hyrel.techNihon Superiorhttps://en.nihonsuperior.co.jp

Today, we’re diving deep into the world of electronics manufacturing from a unique vantage point—that of the press.  My guest today is someone who has spent decades at the forefront of reporting on the electronics manufacturing industry. Mike Buetow, editor-in-chief of Circuits Assembly magazine, has covered everything from the latest technological advancements to the biggest challenges facing manufacturers today. If there’s a major trend shaping the industry, you can bet Mike has written about it, analyzed it, and spoken with the experts behind it. Mike is also the host of his own podcast, PCB chat, available at pcbchat.com. I am so proud to say Mike also syndicates this show at pcbchat.com.In this episode, we’ll explore the evolving landscape of electronics manufacturing, from supply chain disruptions and AI-driven automation to the future of ultra-high-density interconnects and the real impact of reshoring efforts. We’ll also get an inside look at what it takes to cover this ever-changing industry—how stories are chosen, what topics are making waves, and what challenges lie ahead.  Printed Circuit Engineering Association (PCEA)https://pcea.netCircuits Assembly Magazine:https://circuitsassembly.com/ca/

This episode is a little different in two ways. First, I didn’t record it in my studio. I recorded it at the SMTA Pan Pacific strategic Electronics symposium, affectionately known as PanPac, in beautiful Maui Hawaii.Each year, I record a Reliability Matters podcast at PanPac. Normally, the format of the show is I ask questions, and my guests provide answers. On this episode however, I decided to let my guest do all of the talking. The theme of this episode is Electronics: Down Memory Lane and a Vision for the Future. My three guests on this episode will share their view of the history of electronics from three different perspectives. My guests are Dr. Ron Lasky from Dartmouth College, Dr John Evans, and Dr. Tom Duval, both from Auburn University. They’ll share their perspectives on the history of the electronics industry in presentation format.

Today, we’re putting the spotlight on a critical component in surface mount technology, the stencil. These precision-engineered tools are the unsung heroes of electronic assembly, playing a pivotal role in ensuring accurate solder paste deposition and, ultimately, the reliability of your circuit assemblies.It's been long said that reliability begins at the solder print, and the print begins with the stencil.Joining us today is Elias Malfavon Jr, President of Metal Etch Services, Inc. a stencil manufacturer operating in San Marcos California. Metal edge services was founded 20 years ago in 2005. We’ll explore the fascinating journey of stencil production, from design and material selection to the advanced laser cutting technologies that ensure microscopic precision. We’ll also discuss the latest innovations in stencil technology, their impact on modern assembly processes, and how the industry is evolving to meet the challenges of ultra-high-density interconnects and miniaturization.So, sit back, relax, and let’s uncover the critical role of SMT stencils in today’s electronics manufacturing landscape.Elias Malfavon Jr's Contact Info:eliasjr@metaletchservices.comMetal Etch Services, Inc.https://metaletchservices.comThe D-Code Podcasthttps://www.youtube.com/@The-D-Code