DFM Problem Resolution

Design for Manufacturability and Assembly remains the biggest nemesis for the electronic assembler. ITM has expertise and experience in resolving DFM problems. The effective PCB designer must be knowledgeable with respect to the characteristics and capabilities of the SMT assembly process including soldering, placement, cleaning and testing. Most aren’t !  We perform DFM for Assembly […]


Contamination Failure Analysis

Contamination issues can be both difficult for the manufacturer to track down and very costly with regard to yields and field failures (“escapes”). ITM has experience and expertise in identifying root cause(s) of contamination and recommending directions for mitigating the problem. ITM works on-site to examine the entire assembly process –from “dock to stock” –from […]


Expert Witness Services

Process and Product Defense Intellectual Property Protection Legally defending Process, Product and Intellectual Property is very important in maintaining a competitive position in the electronics assembly market. ITM consultants have significant experience supporting these efforts by acting as Expert Witnesses. We can provide broad technical expertise, long term historical knowledge of the electronics assembly industry, […]


10 Deadly Sins of SMT and Lead-free Assembly

The Deadly Sinse of SMT and Lead Free Assembly During the course of our assembly process audits and troubleshooting work, we tend to see trends in the types of errors and problems. In other words, a lot of people are making the same mistakes. The resulting process problems wreak havoc with an impact on assembly […]


Advanced On-Site Workshops

ADVANCED ON-SITE WORKSHOPS   These On-Site Workshops are intended for Process, Manufacturing and Quality Engineers and Management  (Level 2 Personnel).   Bleeding Edge Technologies:    An ITM signature workshop that addresses advanced component, material and process technologies. Printing/stencil characteristics and other aspects of processing micro-passives (0201s, 01005s), QFNs, and lead-free will be covered and discussed.   […]


Basics of Cleaning Electronic Assemblies

  Basics of Cleaning Electronic Assemblies   The complexion and complexities of cleaning electronic assemblies has changed drastically over the last few decades.  A plethora of flux chemistries and their associated soils prevail today presenting challenges with regard to the proper solvent and equipment.  In addition to fluxes, the composition of modern PCBAs  present major […]


Best Practices for Class 3 and High Reliability

    Best Practices for High Reliability (Class 3) Electronic Assembly Processes Where high reliability electronic products involved there is little or no room for error.  Whether manufacturing military, avionics, medical, automotive or other “mission critical” applications, “escapes” (defective product that fails for the end-user) can be anything from very bad to disastarous.  In addition, […]


Best Practices in SMT and Electronic Assembly

Understanding and Implementing Best Practices in Electronic Assembly Processes     Course Instructors:            Phil Zarrow, Joe Belmonte and/or Jim Hall                                                  ITM Consulting                                                   Course Duration:               1 Day or 2 Days   Objectives of the Course:   This is an important workshop that drives awareness and presents solutions to the adverse impact of non-optimal […]


Class 3 and High Reliability Best Practices

Best Practices in High Reliability (Class 3) Electronic Assembly Processes Where high reliability electronic products involved there is little or no room for error.  Whether manufacturing military, avionics, medical, automotive or other “mission critical” applications, “escapes” (defective product that fails for the end-user) can be anything from very bad to disastarous.  In addition, mistakes and […]


Considerations in On-Shoring /Regionalizing Electronic Manufacturing

  CONSIDERATIONS IN ON-SHORING / REGIONALIZATION ELECTRONIC MANUFACTURING Many electronic manufacturers are experiencing increasing difficulties with off-shoring their manufacturing.  These challenges include increasing supply-chain problems costs, loss of control of IP, delays in deliveries, problem resolution, and implementing design changes, inventory costs, among others.  As a result many OEMs are considering bringing their electronic assembly […]


High Reliability Lean Lead-free SMT Manufacturing

HIGH-RELIABILITY LEAN  LEAD-FREE SMT MANUFACTURING Environmental and economic demands have made electronic manufacturing more challenging than ever.  To be competitive In this day and age, the electronics assembler has to be both Lean and Green.  A daunting task perhaps, but it can be accomplished. Although many electronics manufacturers are still in transition to the production […]


Increasing Assembly Productivity and Profitability with Lean Techniques

Increasing Assembly Productivity and Profitability with Lean Techniques With the impressive arrays of enterprise software systems available, one would think that electronic assembly productivity would be at an all time high.  Unfortunately, that is not the case.  Assembly line uptime has stagnated for years at less than 25% in most facilities.  This situation has cost […]


Lead-Free for the Exemptee

Lead-Free for the Exemptee Surviving in a Lead-Free World RoHS is upon us and everyone is affected.   You’re exempt, deferred or “out of scope”  yet much of the industry is going to 100% Lead-free.  This inevitably affects a major portion of your supply chain.  Concurrently, competitive pressures can significantly impact that viability of long-term exemptions.  […]


LEAN Lite

Lean Lite LEAN Lite, presented by ITM Consulting, is a 2 day intensive practical course designed to provide an introduction and basic skills in LEAN 6-Sigma (LSS) implementation for Electronic Manufacturing and to facilitate initial improvement programs within the organization . It is targeted at leaders who can appreciate the benefits of significant improvements in […]


Lean Six-Sigma GREEN BELT

Electronics Manufacturing Industry Lean Six Sigma Green Belt Offered exclusively by ITM Consulting Lean Six Sigma is a combined process-improvement methodology that accelerates processes, increases efficiency, and reduces or eliminates variation. Whether you are a CEM or OEM, competition for the same customers is increasing throughout the electronics industry, putting company profits on the line.  […]


Low Volume – High Mix Electronic Manufacturing

Considerations in Low Volume – High Mix Manufacturing   Course Instructors:             Joe Belmonte, Phil Zarrow, Jim Hall, ITM Consulting Objectives of the Course: In many regards, Low Volume electronic assembly can be far more demanding than manufacturing high volume of a product.  Add to this a high mix of products and the challenges involved […]


On-Site Customized SMT Assembly Workshops

On-Site SMT Assembly Workshops Customized for the Client These workshops, performed on-site at your facility and oriented towards the products you build and the equipment, materials and processes you are using. Soldering Fundamentals: Soldering is the predominant assembly technique in the construction of all electronic products This course will present the fundamentals of soldering as […]


Outsourcing SMT To Contract Assembly

CONSIDERATIONS IN OUTSOURCING SMT TO CONTRACT ASSEMBLY COURSE             The Electronics Manufacturing Services Industry (EMSI) or contract assembly is the largest growing segment of the industry.  An ever increasing number of manufacturers are deciding to outsource all or a portion of their electronic assembly.  Based upon ITM’s experience in both Process Auditing as well as […]


SIX-SIGMA LIte: Continuous Improvement Plan for Quality (CIPQ)

Six-Sigma Lite:  Continuous Improvement Plan for Quality (CIPQ)   Course Title:  Six-Sigma Lite: Continuous Improvement Plan for Quality (CIPQ) Instructors:  Dr. Ron Lasky and Jim Hall,  Lean Six-Sigma Master Blackbelts Duration:       2 Days Course Description: CIPQ, presented by ITM Consulting, is a 2 day intensive practical course designed to provide a plan for a continuous […]


SMT Manufacturing – Introduction to the Assembly Process

                    SMT Manufacturing – Introduction to the Assembly Process This course is intended to provide the participant with a thorough yet practical overview of Surface Mount Technology manufacturing.  The SMT assembly process will be covered, step by step.  Instructors:           Phil Zarow, Jim Hall and/or Joe Belmonte Duration:                1 Day Topics Covered: I.  The SMT […]


SMT Process Training with ITM Certification

SMT PROCESS TRAINING  with ITM Certification   ITM Consulting is the only organization in the industry that offers Training and Certification on specific SMT processes.  These workshops are offered at two levels:    Level 2 is intended for Process, ManufacturingandQuality Engineers as well as Engineering Managementand is presented at the appropriate Engineer oriented level.   […]


SMT Solder Paste Evaluation and Qualification

SMT Solder Paste Evaluation and Qualification terials for most SMT assemblies, yet very few users know how to qualify and evaluate the solder paste appropriate to their process.  This course is intended to provide the participant with an understanding of how to evaluate and select the solder paste best suited for the application including circuit […]


SMT Stencil Printing and Inspection

SMT STENCIL PRINTING AND INSPECTION                                             Objectives of the Course: This  course is intended to give the participant an in-depth understanding of SMT soldering fundamentals.  The various aspects of solder paste including No-clean and water-soluble soldering processes. Fine pitch device and ball grid array requirements, conductive epoxies & adhesives and Reflow of Through-hole will also […]


Through-Hole and Mixed-Technology Wave Soldering

THROUGH-HOLE AND MIXED-TECHNOLOGY WAVE SOLDERING A critical issue for board level assemblers is forming through-hole interconnections on circuit boards of ever increasing densities. This course provides an overview of through-hole and mixed-technology soldering and describes the principles of wave soldering, key process variables, wave solder processing, alloy selection and flux requirements, alloy contamination and corrosion, […]


Advanced On-Site Workshops

ADVANCED ON-SITE WORKSHOPS   These On-Site Workshops are intended for Process, Manufacturing and Quality Engineers and Management  (Level 2 Personnel).   Bleeding Edge Technologies:    An ITM signature workshop that addresses advanced component, material and process technologies. Printing/stencil characteristics and other aspects of processing micro-passives (0201s, 01005s), QFNs, and lead-free will be covered and discussed.   […]


SMT Process Training with ITM Certification

SMT PROCESS TRAINING  with ITM Certification   ITM Consulting is the only organization in the industry that offers Training and Certification on specific SMT processes.  These workshops are offered at two levels:  Level 2 is intended for Process, ManufacturingandQuality Engineers as well as Engineering Managementand is presented at the appropriate Engineer oriented level. Level 1  […]


Understanding and Implementing Best Practices in Electronic Assembly

  Understanding and Implementing Best Practices in Electronic Assembly Processes   This is an important workshop that drives awareness and presents solutions to the adverse impact of non-optimal assembly practices and processes. A comprehensive perspective on problem issues is developed for the electronic assembly process, including design, materials (both existing and emerging), equipment, procedures, and […]


Proactive Defect Reduction

  PROACTIVE DEFECT REDUCTION   We often hear or use the terms “World Class Manufacturing” or “Best in Class Manufacturing” in reference to a manufacturing operation or perhaps a competitor’s or supplier’s manufacturing operation. However no formal industry recognized definition of “world class” or “best in class” manufacturing actually exists. There are certainly numerous industry […]


The 10 Deadly Sins of SMT Manufacturing

  The “10 DEADLY SINS” OF SMT AND LEAD-FREE ASSEMBLY And the 4 Horsemen of the Assembly Apocalypse    Everyone has heard of the “7 Deadly Sins” that will, supposedly, lead one to Hell.  There are also the “10 Deadly Sins” of SMT – and there are actually more than just 10 – and they […]


Failure Analysis – Assembly Processes

  Whether you are struggling with new technologies or a stubborn defect, ITM can help you resolve the problem expeditiously and economically. Whether lead-free or lead-inclusive, ITM’s experienced consultants, with our proven diagnostic routines and resources can help you determine the source(s) of yield lowering defects as well as improve processes believed to be under […]


Process Development and Implementation

  ITM can assist you in setting up any assembly process which may be new to your facility, expanding your current process or developing a new capability including: Any Standard Surface Mount Assembly Process Lead-free Process No-clean Process [*note] Reflow of Through-hole Direct Chip Attach Ball Grid Array [* note] No-Clean Implementation has been so […]


SIX-SIGMA Lite (CIPQ) and LEAN Lite (Lean Manufacturing)

  In today's difficult times, quality and profitability have never been so important and so challenging. Yet, it surprises many people to find that very small improvements in productivity can result in exponential improvements in profit. Here is an example. Let's say you were losing just 3 minutes per shift each day. Maybe you waited […]


Lean Six-Sigma GREEN BELT

Electronics Manufacturing Industry Lean Six Sigma Green Belt Offered exclusively by ITM Consulting Lean Six Sigma is a combined process-improvement methodology that accelerates processes, increases efficiency, and reduces or eliminates variation. Whether you are a CEM or OEM, competition for the same customers is increasing throughout the electronics industry, putting company profits on the line.  […]


PCB Fabrication Source Evaluation

  Finding good, capable sources for bare-PCB supply is difficult. Seldom does the capability to analyze PCB fabrication processes and sources exist in OEM or CEM operations. PCB fabrication is a complex combination of several processes, any one of which, if not properly controlled, can cause immediate or latent board failure, negatively effect assembly processes […]


CEM Assessment / Evaluation / Auditing

  Electronic manufacturing has always been and always will be demanding. With constant change, small margins and very challenging economic currents it is essential that the suppliers you trust your PCB assembly and fabrication to are the best and performing optimally. Do you really want to leave selection and ongoing assessment of your suppliers to […]



Process Audits

ITM's unique SMT Process Audit begins with us bringing our PC Board Fabrication and SMT Assembly expertise on-site to your facility. Unlike other audits, we don't just point out what you are doing wrong — we make positive and objective recommendations on how to do it right. We concentrate on improving your assembly process as […]


Telephone Consultation Service

ITM Consulting Telephone Consultation Service “Consultant on Tap”   Do you need some advice on a nagging defect causing problem?  Have questions about possible alternative technologies, materials or component packages?  Are you wondering about the impact a new methodology, component package or material might have on your process?   These and many other questions can sometimes […]


Equipment Development

For The Electronics Assembly Industry The design and development of process equipment for the Electronics Assembly industry is challenging for a number of reasons. The development cycle from concept to introduction is long The new equipment, over its expected lifetime (usually several years) must have the capabilities to meet future assembly and product requirements Product […]