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Kitting Guidelines for PCB Assembly

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Policy

Kitting in PCB assembly is driven by growing customization and usage of component variants essential for assembly. Following specific kitting guidelines is crucial to obtain high-quality products at competitive pricing.

What is kitting in PCB assembly?

Kitting is the process of putting together a set of components as a kit required to assemble circuit boards. Here the customer provides all the components that go on the board. Kitting brings all the materials/parts into one single package. It is extremely beneficial for the commencement of assembly since all the required components are available, verified, and placed in appropriate packaging.

Every board design and quantity requirements vary according to the customer. Hence, the kit criteria for each assembly project are different. In spite of there, there are particular rules to consider and follow as a standard. The analogy could be that of cooking a recipe when all the ingredients are collected either from the market or from the kitchen and pantry. All these ingredients are brought together on the kitchen table and then cooked.

Kit criteria for components

Below is the list of approximated kit guidelines for each component.

SMDs

packaging-of-smds-on-reels.jpg
Packaging of SMDs on reels

Leaded components or ICs

  • These parts should be sent in properly packaged containers (tubes, trays, or taps). Parts should be loaded in such a way that Pin1 should remain consistently in the same direction. Otherwise, it will cause directional placement issues resulting in compromised quality.
  • If the parts are handled manually, it can lead to coplanarity problems.

Digital signal processing chips (DSPs) and other ICs

  • Usually, these components require special handling. For example, moisture-sensitive components need baking. These should be sealed. If opened, they must be resealed according to specific techniques. In most cases, waffle trays are used for handling such parts.

Passive parts

  • Passive components like capacitors and resistors should be in proper pick and place format.
  • Include a few parts for attrition.

Connectors

  • For these parts, the original waffle packaging should be utilized to prevent damage to the leads.

Stencils

  • Engineers at Sierra Circuits will review the stencil supplied by the customer to ensure production and machine compatibility.

Through-hole components

Sockets

  • These sockets should be delivered in their original packaging to avoid damaged or bent leads. These parts will create several manufacturing and quality flaws if sent otherwise.

DIP packages

  • These components can be supplied in tubes or in loose form.

Leaded parts

  • Typically, these components should be packed on reels to maintain their quality. Loose parts are also acceptable if they are properly packed and not oxidized in any way.

Important guidelines for kitting

If you are asking for consigned assembly (partial turnkey) quote, make sure to send all the required components for assembly while placing an order. Here are some critical kitting guidelines:

1. Each SMD line item should be on a single continuous tape (a minimum of 12″ long cut tape/reel/mini-reel). If not placed on a tape or reel, they must be on trays or tubes.

smds-packaged-in-tape-for-assembly.jpg

2. Each item should have an additional quantity of components for attrition during assembly. Refer to the following specifications:

Discrete SMT passives

  • 01005 size: Additional 50% based on a minimum order of 100 pieces
    • Extra components should be greater than 100 pcs or 50% of the required quantity.
    • e.g. For 01005 size components, if required Qty = 70, 50% extra = 35, min Qty = 100. Total quantity required = 70 + max (35,100) = 70 + 100 = 170.
  • 0201size: 50% extra subject to a minimum of 50 pieces
    • Extra components should be greater than 50 pcs or 50% of the required quantity.
    • e.g. For 0201 size components, if required qty = 70, 50% extra = 35, min Qty = 50. Total quantity required = 70 + max (35, 50) = 70 + 50 = 120.
  • 0402 size: Additional 25% based on a minimum of 20 pieces
    • Extra components should be greater than 20 pcs or 25% of the required quantity.
    • e.g. For 0402 size components, if required Qty=70, 25% extra= 17.5, min Qty=20. Total quantity required= 70+ max(17.5+20)= 70+20= 90.
  • 0603 size: 15% extra subject to a minimum of 20 pieces
    • Extra components should be greater than 20 pcs or 15% of the required quantity.
  • 0805 size: 10% extra subject to a minimum of 10 pieces
    • Extra components should be greater than 10 pcs or 10% of the required quantity.
  • 1206 size or larger: 10% extra subject to a minimum of 5 pieces
    • Extra components should be greater than 5 pcs or 10% of the required quantity.

Active devices

  • Component width of 0.6 mm or smaller: 20% extra subject to a minimum of 20 pcs
    • Extra components should be greater than 20 pcs or 20% of the required quantity.
  • Component width of 0.6-1 mm: 10% extra subject to a minimum of 10 pcs
    • Extra components should be greater than 10 pcs or 10% of the required quantity.
  • Component width of 1-1.6 mm: 10% extra subject to a minimum of 5 pcs
    • Extra components should be greater than 5 pcs or 10% of the required quantity.
  • Component width of 1.6- 2 mm: 5% extra subject to a minimum of 5 pcs
    • Extra components should be greater than 5 pcs or 5% of the required quantity.
  • Component width larger than 2 mm: 5% extra subject to a minimum of 2 pcs
    • Extra components should be greater than 2 pcs or 5% of the required quantity.

3. Through-hole (DIP) ICs should be supplied in trays, tubes, or continuous tapes.

Through-hole components

  • Small devices: 5% extra subject to a minimum of 2 pcs
    • Extra components should be greater than 2 pcs or 5% of the required quantity.
  • Other devices: 2% extra subject to a minimum of 1 piece
    • Extra components should be greater than 1 piece or 2% of the required quantity.

Hardware (screws, nuts, washers, etc.)

  • Hardware costing less than $.50: 10% extra subject to a minimum of 5 pcs
  • Hardware costing $.50-$2.00: 5% additional subject to a minimum of 2 pcs
  • Hardware costing more than $2.00: 2% extra subject to a minimum of 1 piece

4. Lack of attrition will be interpreted as parts shortage.

5. Make sure to ship all consigned parts in a properly kitted form (each line item of BOM in a separate bag, correctly marked for identifying the component unambiguously).

6. Kits for multiple jobs must be in separate bags recognized by the appropriate assembly order number.

7. All shipments must include the order number or quote number. Check FAQs for kitting.

Maintain a balance between material planning and handling to manage kit components effectively. This will help to overcome many challenges associated with handling, shipping constraints, and document control. If you are raising a quote for full turnkey assembly, we will take care of kitting requirements so you don’t have to.

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