1. Background

A European client in the industrial automation sector aimed to develop a compact, stable, and interference-resistant PLC programmer. Their previous supplier struggled with delivery delays and inconsistent quality, leading the client to seek a more reliable PCBA partner. KKPCB was selected for its strong manufacturing capabilities and engineering support.

2. Application Scenario

The PLC programmer is used for programming, parameter configuration, diagnostics, and system testing across industrial production lines, building automation, water treatment stations, and smart grid systems. It requires high electromagnetic compatibility, compact layout, and robust communication stability.

3. Product Specifications (Table Format)

Specification	Value / Description
Operating Voltage	9~30V DC
Communication Interfaces	RS232 / RS485 / USB
Transmission Rate	Up to 115.2kbps
EMC Standard	IEC61000-4-2/3/4 compliant
PCB Size	120mm x 80mm
PCB Stack-up	4-layer FR4, 1oz copper
LED Indicators	3 (TX / RX / PWR)
Mounting Method	DIN rail / panel mount

4. Results Achieved

KKPCB’s tailored PCBA solution delivered the following improvements:

• Lead Time: Reduced from 18 days to within 12 working days
• Cost: Assembly cost lowered by approx. 15% through BOM optimization
• Performance: Communication reliability improved by 20+%
• Quality: EMC passed IEC61000-4-4 Level IV, and batch defect rate kept below 0.5%, far better than previous supplier’s 2.3%

5. KKPCB’s Value in This Project

KKPCB provided one-stop PCB and PCBA services including high-precision SMT, BGA rework, AOI and X-ray inspection, and functional testing. Our engineering team supported DFM analysis and BOM selection. With MES traceability and ISO-certified processes, we ensured consistent quality from prototypes to volume production. Our responsive communication and engineering involvement helped the client reduce risks and improve product manufacturability.

6. Manufacturing-Focused Customized Solution

KKPCB focused on solving manufacturing challenges with a reliable and production-ready approach:

• PCB Design: Recommended 4-layer high-TG FR4 with optimized ground shielding for EMI reduction
• Process Control: Applied conformal coating to key components for anti-vibration protection
• Functional Testing: Designed custom FCT fixtures for 100% outgoing inspection
• Component Alternatives: Offered verified local replacements for long-lead-time parts
• Export Packaging: Provided anti-static, foam-protected packaging suitable for air/sea shipping to Europe

7. Real-World Performance

With KKPCB’s solution, the client shortened development time by ~20% and achieved a 98.6% first-pass yield during the pilot-to-mass transition. On-time delivery reached 100% in Q4 2024, and post-sale issues dropped by over 80%. The client is now planning to outsource their entire PLC controller series to KKPCB.