Introduction and Industry Context
Printed circuit boards power almost every modern electronic device—from cars and solar inverters to medical equipment and everyday consumer tech. Modern PCBs often feature six, eight, or more layers of copper and insulation, incorporating components such as BGAs, fine-pitch ICs, RF transceivers, and power management modules. As product complexity increases, so do engineering change requests (ECRs), quality regulations, and supply-chain risks for long-lead items.
Many PCB manufacturers still rely on spreadsheets, paper documents, and disconnected systems for BoM (bill of materials) control, shop-floor tracking, and compliance record-keeping. This fragmented approach creates opportunities for errors, mid-cycle production stoppages, and “surprise” cost overruns at month end.To resolve these issues, Clockwork Business Solutions deployed SAP Business One with a configuration tailored for PCB environments—optimizing workflows across high-mix, low-volume builds as well as high-speed mass production.
Key Challenges
- Complex Multi-Layer PCB BoMs
- Lack of Real-Time Production Visibility
- Disparate Quality & Compliance Documentation
- Costing Inaccuracy & Inventory Risks
Our Solutions
- Smart BoM Control & Integrated ECR Workflow
- Real-Time Shop-Floor Production Oversight
- Digital Quality & Compliance Management
- Live Costing, Predictive Planning & Inventory Precision
Implementation Approach
- Discovery & Blueprinting: Workshops to map current processes, define target workflows, roles, and data governance.
- System Configuration: Configured SAP B1 modules and built custom features like BoM locking, dashboards, and compliance tools.
- Integration & Testing: Integrated PLCs/MES/barcode/QA tools, migrated legacy data, and completed all testing cycles.
- User Training & Change Management: Delivered role-based training for 120 users and set up super-users and helpdesk support.
- Go-Live & Hypercare: Launched in pilot lines, scaled facility-wide, and provided on-site support with continuous improvements.
Results & Business Impact (90 days)
| Metric | Improvement | Baseline | Post-Implementation |
|---|---|---|---|
| Rework Rate | 41 percent | 8% | 4.7% |
| Average Audit Preparation Time | 85 percent | 40 hours | 6 hours |
| Month-End Cost Variance | 100 percent | ₹2.5 million | ₹0 |
| Engineering-to-Production Lead Time | 25 percent | 20 days | 15 days |
Why Clockwork Business Solutions?
Clockwork brings SAP B1 expertise and deep PCB manufacturing knowledge for seamless digital transformation.
- Domain-Specific Customizations: Ready extensions for BoM control, multilayer PCB costing, and ECR/ECN management.
- Seamless SMT & MES Integration: Real-time shop-floor visibility across SMT, coating, assembly, and testing processes.
- End-to-End Traceability: Complete serial/lot tracking with automated quality checkpoints.
- Scalable Architecture: Effortlessly supports both low-volume prototypes and large-scale PCB production.
Conclusion
By deploying a specialized SAP Business One solution, the PCB manufacturer achieved significant efficiency gains, quality improvements, and risk mitigation. The transformation journey underscored the importance of integrating engineering, production, quality, and finance in a single digital platform.