Reliability Matters

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

Today, we're tackling a topic that has become increasingly vital in recent years: supply chain management. With global supply chains recently under immense pressure from disruptions, shortages, and growing complexity, the need for smarter, more efficient solutions has never been greater. And what better way to explore this than by discussing the cutting-edge role of AI-powered supply chain management software.My guest today is Sebastian Schaal, the founder and CEO of Luminovo, a company at the forefront of transforming how supply chains are managed in the electronics industry. Sebastian Schaal is the founder of Luminovo, a leading software provider revolutionizing the electronics supply chain. He holds two masters degrees—one in Electrical and Computer Engineering from the Technical University of Munich and another from Stanford University, where he was a Fulbright scholar focusing on Management and Computer Science. Before founding Luminovo, Sebastian gained diverse industry experience, working on AI algorithms for signal processing and computer vision at Intel and robotics companies NavVis and Magazino. Additionally, he served as a consultant at McKinsey, advising on data strategy.Sebastian and his team are leveraging artificial intelligence to streamline processes, enhance collaboration, and future-proof supply chain operations. In this episode, we'll explore how AI is reshaping supply chain management, the unique challenges facing the electronics industry, and what companies can do to stay ahead in an ever-changing global landscape. This conversation is packed with insights you won't want to miss. So, sit back, relax, and get ready to learn about the innovations that are revolutionizing supply chains worldwide. Luminovohttps://luminovo.comChapters:00:00:00 The Role of AI in Revolutionizing Supply Chain Management00:02:30 Innovation in Supply Chain Management: Origins and Vision00:04:56 The Unsung Heroes of the Electronics Supply Chain  00:07:25 The Impact of Supply Chain Challenges on Business Growth00:10:06 Challenges in Electronics Supply Chain Management00:12:28 Navigating the Complexities of Supply Chain Management  00:14:51 AI and Machine Learning in Modern Supply Chain Management  00:17:31 Enhancing Supply Chain Resilience with Digitalization and Collaboration00:20:03 Enhancing Collaboration with Digital Tools00:22:26 Automating Processes for Efficiency and Cost Optimization00:24:55 Choosing the Right Supply Chain Software: Industry-Agnostic Vs. Specific Vendors00:27:24 Advantages of Vertical Solutions in the Electronics Industry00:30:06 Challenges in Semiconductor Manufacturing and Supply Chain  00:32:35 Evolution of AI: From Engines to Intelligent Agents00:34:57 Transforming Manufacturing with Cloud and AI00:37:26 Overcoming Resistance to Digital Transformation in Supply Chains00:40:03 Overcoming Fragmented Data in Supply Chains00:42:36 Implementing New Systems and Avoiding Pitfalls00:45:08 Key Questions for Supplier Data Integration00:47:32 Common Mistakes in Selecting Supply Chain Management Systems00:50:04 Enhancing Supply Chain Integration and Automation00:52:23 Building a Global Supply Chain Network  00:57:19 Conclusion and Upcoming Podcast Schedule

Today we’re diving into a critical yet sometimes overlooked component that powers so many of the devices we rely on: batteries. Batteries are the heartbeat of countless electronic products, from medical devices and electric vehicles to consumer gadgets and industrial systems. Choosing the right battery is not a one-size-fits-all decision. It requires a keen understanding of the application, performance needs, and environmental demands. The right selection can make the difference between a product that excels in reliability and one that, quite literally, fails to deliver.  But there’s more to batteries than just selecting the right chemistry or capacity. Safety is paramount. Poor battery selection, design, or management can lead to performance issues, overheating, or catastrophic failures. As we’ve all seen in headlines, battery malfunctions can result in recalls, damage to brand reputation, or, worse, safety hazards for users.  To shed light on this vital topic, we’re joined by an expert in the field of battery technology. Alex Norman is a Battery Management System Designer at Pro Technologies, a well-established and trusted custom battery pack manufacturer, providing engineering capabilities from concept through production. Their leading edge manufacturing facility and headquarters is based in Pilot Mountain, North Carolina. Alex has deep experience in Printed Circuit Board Design, Product Development, Battery Management Systems and more. Alex is also a content creator, focusing mostly on electronics, battery, and BMS content available on his LinkedIn page and YouTube channel.Today, we’re going to explore how to choose the right battery for your assembly, best practices for integration, and how to mitigate potential safety risks.  So, if you care about keeping your products powered, reliable, and safe, don’t bolt just yet – this podcast on batteries is positively charged with insights! Stick around and top off your battery knowledge!Alex's Contact Info:Alex Normananorman@eetengineer.comProTechnologies, Inc.http://protechnologies.comAlex's YouTube Channel:https://www.youtube.com/@eetengineerChapters:00:00:00 Choosing the Right Battery for Electronic Assemblies00:02:44 Exploring Battery Technology and Safety Concerns00:05:21 Starting a YouTube Channel: Journey and Growth00:07:55 Performance and Safety: Alkaline vs. Lithium-Based Batteries00:10:28 The Future of Sodium-Ion Batteries vs. Lithium-Ion00:13:12 Causes of Samsung Phone Battery Fires00:16:01 Advancements in Solid State Battery Technology00:18:44 Dangers of Swollen Lithium Batteries and Battery Safety00:21:19 Battery Charging Myths and Optimization Techniques00:24:04 Importance of Battery Management Systems (BMS)00:26:51 Primary vs. Secondary Batteries Explained00:29:28 Comparing Performance: Alkaline vs Rechargeable Batteries00:32:11 Impact of Temperature on Battery Performance00:34:51 Optimizing Battery Performance in Extreme Cold00:37:28 Lead Acid vs. Lithium Iron Phosphate: Battery Safety and Advancements00:39:56 Optimizing Battery Performance in Electric Cars00:42:36 Advanced Lithium Iron Phosphate Cells  00:45:24 Battery Regulations Impact and Safety Standards00:48:05 Battery Safety and Standards in Consumer Electronics00:50:49 Quality and Safety in Consumer Vs. Industrial Battery Cells00:53:25 The Importance of Proper Battery Recycling00:56:05 Lithium Iron Phosphate vs. Nickel Metal Hydride Batteries00:59:51 Humor and Technology: Creating Engaging Content01:01:10 Get Involved with Reliability Matters Podcast