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ProWorks offers a comprehensive suite of both board level and system level manufacturing and integration services. We operate four SMT lines on two shifts with a current capacity of 1.5 million placements per day. We not only excel at manufacturing less complex applications, but also are known as experts in dense, BGA-intensive PCBA’s where we routinely manufacture product with over 5,000 components and over 50,000 solder joints. We have outfitted our company to be able to be repetitively successful in situations where product complexity tests technological limits. Our expertise is derived from a combination of: |
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Comprehensive Manufacturing Service Offerings [back] |
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ProWorks is a full-service EMS provider with a breadth of manufacturing services, including:
- Advanced surface mount capability powered by Juki Pick and Place machines
- Chip Scale Packages
- 0201’s
- BGA’s of any size and density
- QFN’s
- PCB Form Factors up to 18” by 20”
- Full BGA rework capabilities including state-of-the-art Summit SRT-1100 LX with expert level process engineering support for distinct BGA profiling
- Expertise in lead-free and mixed chemistry manufacturing certified by the IPC and driven through dedicated lead free equipment
- Optical splicing and routing capabilities
- Dedicated and universal box build/system integration lines
- Static burn-in and ESS
- Rework of complex boards, including those in NPI phase
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Advanced Process Engineering Expertise [back] |
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In order to succeed at high-end, BGA-intensive PCB assembly, ProWorks has a strong team of process engineers with a strong body of knowledge and expertise, developed over many years of experience working on technologically challenging manufacturing solutions.
- We are Thermal Profiling experts. Using a combination of state-of-the-art thermal simulation equipment and software with leading edge reflow ovens, we engineer sophisticated and surgically accurate reflow profiles. We then use our extensive data collection systems to continually optimize these thermal profiles.
- We bring extensive experience and engineering to Stencil Design. We always use customized stencils with the benefit of carefully engineered modifications to optimize solder deposition, especially in situations where customer designs present manufacturing challenges.
- We are experts in Tooling & Fixture Design. With the benefit from strategic partnerships with a few carefully chosen vendors, we are able to quickly and accurately design and manufactures customized fixtures and tooling to optimize the manufacturing process.
- We use and have developed expertise in leading edge Design Software including CAM350 and Valor Trilogy. These tools represent a significant investment in process engineering horsepower and are keys to providing engineering expertise to our customers. Through the use of these tools, our engineers are able to bring a significant amount of Product Realization services to our customers. Furthermore, these tools are extremely powerful as ad hoc problem solving vehicles.
- We use some of the most powerful, advanced Process Validation Hardware including
- Ersascope
- 3D Hi Magnification (50X – 450X) Digital Microscope
- Xray for BGA verification
- Hand-held 70X Digital BGA Scope
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Tight Process Control Systems [back] |
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Through our Rhythm MES, the processes used by the manufacturing organization are documented in detail, measured continuously and controlled to ensure full adherence to the prescribed recipe. The scope of the process control mechanisms within Rhythm is all-encompassing and pervasive to our factories. A few of the key process control mechanisms delivered by Rhythm include:
- Routing Control – all products traveling through the factory must travel through a route prescribed by engineering. Steps in the manufacturing process cannot be skipped and the exact location of any serial number is known real-time all of the time.
- Solder Paste Control – All solder paste received is bar coded and tracked by Rhythm throughout its existence at ProWorks. Time into the refrigerator, time out of the refrigerator, thawing time, FIFO controls and chemistry controls to ensure its lead status is consistent with the build are all systematically controlled by Rhythm MES.
- Moisture Sensitive Devices (“MSD”) Control – All receipts of components are tracked in Rhythm for MSD warnings from the manufacturer. Based on these warnings, components that require curing are trapped by Rhythm and not allowed to be issued to the manufacturing floor until the proper oven curing period is exhausted. Rhythm automatically decodes the exact temperature and time frames for curing using the JEDEC standard for the component and completely manages the curing process including email queues for placing and removing components from the oven.
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Insistence on utilizing state-of-the-art equipment [back] |
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Since inception, ProWorks has always had the philosophy of investing in the most advanced manufacturing, test and support equipment that emphasize flexibility and breadth of capabilities. Below is a list of the key pieces of manufacturing equipment used by the company: |
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SMT |
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Description |
Manufacturer |
Model |
Qty |
SMT Pick and Place |
Juki |
750 |
4 |
SMT Pick and Place |
Juki |
760 |
4 |
SMT Pick and Place |
Juki |
2050 |
1 |
SMT Pick and Place |
Juki |
2060 |
4 |
SMT Pick and Place |
Juki |
FX-1R |
3 |
Solder Paste Printer |
Ekra |
E5 |
4 |
Reflow Oven |
Vitronics |
XPM 820 |
2 |
Reflow Oven |
Vitronics |
XPM2 1030 |
2 |
Epoxy Dispenser |
Asymtek |
D-555 |
1 |
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Through Hole/Wave/Wash |
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Description |
Manufacturer |
Model |
Qty |
Through Hole Prep Equipment |
Hepco |
Various |
5 |
Wave Solder Machine |
Electrovert |
Electra |
2 |
Flow Soldering System |
Hakko |
485 |
2 |
Air Fountain Soldering System |
Zephytronics |
ZT-6 |
2 |
Aqueous Wash |
Trek |
Lightning Elite |
1 |
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Process Validation |
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Description |
Manufacturer |
Model |
Qty |
Solder Paste Measurement System |
VisionMaster |
1150-A |
1 |
Hirox Hi Magnification (50X-450X) 3D Digital Microscope |
Caltex Systems |
Hirox - 3040 |
1 |
2D X-ray Inspection System |
Nicolet |
NXR1550 |
1 |
Handheld BGA Scope |
SMT Tools |
BGA-200 |
2 |
Digital BGA Microscope |
Ersa |
Ersascope 2 |
1 |
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Other/Specialty |
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Description |
Manufacturer |
Model |
Qty |
Viscometer |
Malcolm |
PCU-5 |
1 |
XRF System |
InnovXSystems |
Α-6500R |
1 |
Tape and Reel Machine with AOI |
V-Tek Inc |
TM-50 |
1 |
Nitrogen Generator |
O2N2 Site |
N-500 |
1 |
Arc Fusion Splicer |
Fujikura |
FSM-45PM |
2 |
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