SOLUTIONS

Whizz Systems provides solutions from concept to completion.

SOLUTIONS

Whizz Systems provides solutions from concept to completion.
MANUFACTURING

MATERIAL SOURCING & PROCUREMENT

Through our world class supply chain partners, we provide global sourcing, materials management and logistics tailored to meet your business’ unique needs.

Issues that our dedicated project manager facilitate
-Identify 2nd and 3rd sources for developing BOM

-Facilitate critical sourcing issues with procurement groups

-Pre-screen preliminary BOM for invalid/obsolete components

-Analyze the potential impact of new revisions of components

-Coordinate design team, evolving BOMs, suppliers, and supply chain teams

-Established on-shore and off-shore supply chain

-Optimize unit cost by facilitating architectural and sourcing trade-offs

-Facilitate the timely obtaining of material unit cost data

-Lead time reduction by synchronizing supply and demand and (VMI)

We have developed sophisticated tools to help manage our inventory, generate customized reports, handle MRP functions and manage our proto and production builds. Coupled with our capability to add new functions, improvements and customer required formats to our MRP system, we also work with engineering BOMS without part numbers, and produce a production BOM with specs for all parts chosen with your approval. We have an extensive inventory of commonly used parts in-house, and are closely tied with Tier 1 distributors and brokers all over the world to get the parts in time for quick turns. This is what makes us cost competitive and cost-efficient.

Board and System Design

Our supply chain team is set up to support New Product Engineering, Prototyping as well as Medium volume projects.  Our focus on working closely with our chosen vendors gives Whizz the time-to-market edge and helps our clients get products to market faster and more efficiently.  Our process is proven and repeatable.  We have the right team, tools, equipment and experience to get the job done.

PCB Fabrication
We work with the highest quality, local PCB factories to source our circuit boards.  With a well-defined model in place to identify the right fit for our clients, including technology, turnaround requirements, and quantities needed, we are experienced at matching your needs and getting the most value from our chosen partner.

Parameters that helps us to identify the right fabrication partner
-Layer count
-Stackup
-Hole sizes and tolerances
-Material requirement
-Quantity and turnaround time
-Complexity
When the design is finalized, our fabrication partner is prepared for the project, and will successfully complete the product with an efficient and speedy turnaround time.

Material Procurement
While most companies have the manufacturing equipment necessary, very few actually have a materials team that performs well on quick-turns. Whizz has both. Our materials team closely interfaces with our in-house design team during the design phase to identify long lead time parts, recommend packages readily available, and raise the flag on EOL parts. Our process is setup to track the daily changes made by engineers during the design phase, and transmit the BOM changes to the materials team. This precise coordination is crucial to the successful delivery of quick turn prototypes and a smooth transition into production. Our long term relationships with key suppliers allow us to circumvent long lead time and secure critical components.
We have developed sophisticated tools to help manage our inventory, generate customized reports, handle MRP functions and manage our proto and production builds. Coupled with our capability to add new functions, improvements and customer required formats to our MRP system, we also work with engineering BOMS without part numbers, and produce a production BOM with specs for all parts that we choose with your approval. We have an extensive inventory of commonly used parts in-house, and are closely tied with Tier 1 distributors and brokers all over the world to get the parts in time for quick turns. This is what makes us cost competitive and cost-efficient.

PCB Assembly
We have 3 State of the Art SMT lines in-house and are RoHS compliant. Our team at Whizz has extensive experience assembling very complex boards with over 16,000 components, 2800 pin count BGA packages and equipment capable of placing 0201 0105 components and .3 mil pitch IC’s. You will not be required to find a different house for these needs, nor will you be asked to purchase the fixture to get the job done. Whizz Systems will handle everything for you.
Our assembly processes include the following:
-RoHS compliant process
-BGA packages down to .3mm pitch
-QFN Packages
-Straddle mount high pincount connectors
-Press fit connectors
-0105 component placement capability
Quick turn is a norm in our business. We have delivered boards with over 4600 components in 24 hours. Our yields are well above industry average and we have steadily improved the yields of well-known customers from the high 80’s to 99%. With proper DFX during the design phase and good manufacturing processes, we are hitting 99% yields on most of our programs. All boards during proto builds are 100% inspected. For production, we address all the variables up front to improve your product yields.

Rework
We understand the importance of debugging, and support all of your rework requirements on a quick turn basis. During this phase, we routinely support requests for the following items:
-BGA removal, reball and replace
-Cuts/jumps
-QFN Packages
-Incrementally populating/depopulating boards
-Custom adaptors to address different pin-outs

PRODUCTION

Whizz Systems offers consigned and turnkey production services from small to large sized production orders. We are also a good fit for customers whose orders are large enough to require more than prototype capabilities, but not large enough to require the attention of large CMs. We produce parts either locally in the us for small to mid sized orders or off shore for high volume production.

We have the tools to manage production builds of various sizes, ranging from a few boards to thousands. While we are cost competitive, we deliver only the highest quality products to our customers. Additionally, we have experience handling a board level product and system level products that involve box builds. We also handle any custom cables, packaging and contents that go along in the final packaging. We can ship a fully functional product directly to your distribution center or end customer if required.

Offshore Production:

For our customers with higher volume production and price point goals, our facility in Malaysia and other Tier 2 offshore partnerships allow us to successfully fulfill those production needs. Our dedicated offshore QC and technical support team not only keeps high quality intact, but their expertise minimizes offshore risks. We address the overall product-build plan during the design phase, and refine the design accordingly, achieving the best yields while keeping overall costs low.

COMPLETE BOX BUILD EMS SERVICE

Whizz systems offers comprehensive EMS service. We offer design, prototypes, assembly and test services for board level assemblies, sub-assemblies, box build, and finished products. Our turnkey solutions extend to product procurement, panel wiring, electrical cabling, conformal coating and functional testing.

We specialize in manufacturing a range of sub-assemblies, including Electro-Mechanical Assembly and machined parts (through our partners) as well as PCBs with different fitments and brackets. Whether you are seeking simple PCB enclosures or complex metal card frames, Whizz offers complete integration services ranging from procurement and warehousing to shipping. Our industrial, medical and commercial box build assembly services help OEMs save system integration cost and time. We have dedicated work cells and private production capabilities to focus on customer specific needs and privacy/secrecy concerns.

We encapsulate the final assembly with acrylic or polyurethane based materials for protecting the PCB from extreme temperatures and other environmental conditions. Functional testing can be performed using our custom designed test fixtures or customer provided test fixtures. All assemblies produced at Whizz Systems comply with industry standards, including ISO 9001, 14001, RoHS, ITAR.

MANUFACTURING

MATERIAL SOURCING & PROCUREMENT

Through our world class supply chain partners, we provide global sourcing, materials management and logistics tailored to meet your business’ unique needs.

Issues that our dedicated project manager facilitate
-Identify 2nd and 3rd sources for developing BOM

-Facilitate critical sourcing issues with procurement groups

-Pre-screen preliminary BOM for invalid/obsolete components

-Analyze the potential impact of new revisions of components

-Coordinate design team, evolving BOMs, suppliers, and supply chain teams

-Established on-shore and off-shore supply chain

-Optimize unit cost by facilitating architectural and sourcing trade-offs

-Facilitate the timely obtaining of material unit cost data

-Lead time reduction by synchronizing supply and demand and (VMI)

We have developed sophisticated tools to help manage our inventory, generate customized reports, handle MRP functions and manage our proto and production builds. Coupled with our capability to add new functions, improvements and customer required formats to our MRP system, we also work with engineering BOMS without part numbers, and produce a production BOM with specs for all parts chosen with your approval. We have an extensive inventory of commonly used parts in-house, and are closely tied with Tier 1 distributors and brokers all over the world to get the parts in time for quick turns. This is what makes us cost competitive and cost-efficient.

Board and System Design

Our supply chain team is set up to support New Product Engineering, Prototyping as well as Medium volume projects.  Our focus on working closely with our chosen vendors gives Whizz the time-to-market edge and helps our clients get products to market faster and more efficiently.  Our process is proven and repeatable.  We have the right team, tools, equipment and experience to get the job done.

PCB Fabrication

We work with the highest quality, local PCB factories to source our circuit boards.  With a well-defined model in place to identify the right fit for our clients, including technology, turnaround requirements, and quantities needed, we are experienced at matching your needs and getting the most value from our chosen partner.[/accordion_item

Parameters that helps us to identify the right fabrication partner
-Layer count
-Stackup
-Hole sizes and tolerances
-Material requirement
-Quantity and turnaround time
-Complexity
When the design is finalized, our fabrication partner is prepared for the project, and will successfully complete the product with an efficient and speedy turnaround time.

Material Procurement
While most companies have the manufacturing equipment necessary, very few actually have a materials team that performs well on quick-turns. Whizz has both. Our materials team closely interfaces with our in-house design team during the design phase to identify long lead time parts, recommend packages readily available, and raise the flag on EOL parts. Our process is setup to track the daily changes made by engineers during the design phase, and transmit the BOM changes to the materials team. This precise coordination is crucial to the successful delivery of quick turn prototypes and a smooth transition into production. Our long term relationships with key suppliers allow us to circumvent long lead time and secure critical components.
We have developed sophisticated tools to help manage our inventory, generate customized reports, handle MRP functions and manage our proto and production builds. Coupled with our capability to add new functions, improvements and customer required formats to our MRP system, we also work with engineering BOMS without part numbers, and produce a production BOM with specs for all parts that we choose with your approval. We have an extensive inventory of commonly used parts in-house, and are closely tied with Tier 1 distributors and brokers all over the world to get the parts in time for quick turns. This is what makes us cost competitive and cost-efficient.

PCB Assembly
We have 3 State of the Art SMT lines in-house and are RoHS compliant. Our team at Whizz has extensive experience assembling very complex boards with over 16,000 components, 2800 pin count BGA packages and equipment capable of placing 0201 0105 components and .3 mil pitch IC’s. You will not be required to find a different house for these needs, nor will you be asked to purchase the fixture to get the job done. Whizz Systems will handle everything for you.
Our assembly processes include the following:
-RoHS compliant process
-BGA packages down to .3mm pitch
-QFN Packages
-Straddle mount high pincount connectors
-Press fit connectors
-0105 component placement capability
Quick turn is a norm in our business. We have delivered boards with over 4600 components in 24 hours. Our yields are well above industry average and we have steadily improved the yields of well-known customers from the high 80’s to 99%. With proper DFX during the design phase and good manufacturing processes, we are hitting 99% yields on most of our programs. All boards during proto builds are 100% inspected. For production, we address all the variables up front to improve your product yields.

Rework
We understand the importance of debugging, and support all of your rework requirements on a quick turn basis. During this phase, we routinely support requests for the following items:
-BGA removal, reball and replace
-Cuts/jumps
-QFN Packages
-Incrementally populating/depopulating boards
-Custom adaptors to address different pin-outs

PRODUCTION

Whizz Systems offers consigned and turnkey production services from small to large sized production orders. We are also a good fit for customers whose orders are large enough to require more than prototype capabilities, but not large enough to require the attention of large CMs. We produce parts either locally in the us for small to mid sized orders or off shore for high volume production.

We have the tools to manage production builds of various sizes, ranging from a few boards to thousands. While we are cost competitive, we deliver only the highest quality products to our customers. Additionally, we have experience handling a board level product and system level products that involve box builds. We also handle any custom cables, packaging and contents that go along in the final packaging. We can ship a fully functional product directly to your distribution center or end customer if required.

Offshore Production:

For our customers with higher volume production and price point goals, our facility in Malaysia and other Tier 2 offshore partnerships allow us to successfully fulfill those production needs. Our dedicated offshore QC and technical support team not only keeps high quality intact, but their expertise minimizes offshore risks. We address the overall product-build plan during the design phase, and refine the design accordingly, achieving the best yields while keeping overall costs low.

COMPLETE BOX BUILD EMS SERVICE

Whizz systems offers comprehensive EMS service. We offer design, prototypes, assembly and test services for board level assemblies, sub-assemblies, box build, and finished products. Our turnkey solutions extend to product procurement, panel wiring, electrical cabling, conformal coating and functional testing.

We specialize in manufacturing a range of sub-assemblies, including Electro-Mechanical Assembly and machined parts (through our partners) as well as PCBs with different fitments and brackets. Whether you are seeking simple PCB enclosures or complex metal card frames, Whizz offers complete integration services ranging from procurement and warehousing to shipping. Our industrial, medical and commercial box build assembly services help OEMs save system integration cost and time. We have dedicated work cells and private production capabilities to focus on customer specific needs and privacy/secrecy concerns.

We encapsulate the final assembly with acrylic or polyurethane based materials for protecting the PCB from extreme temperatures and other environmental conditions. Functional testing can be performed using our custom designed test fixtures or customer provided test fixtures. All assemblies produced at Whizz Systems comply with industry standards, including ISO 9001, 14001, RoHS, ITAR.

FIRMWARE AND SOFTWARE
Whizz Systems offers firmware and software support as it relates to board bring up and debugging. We work with your team to identify critical paths, scrutinize issues and implement changes that lead to robust product performance.

Our Embedded Software Design services and capabilities include:

Micro Controller Software

 

IC Sensors

Chip Interfaces

User Interfaces

DSP Software

 

Audio / Video

Custom Algorithms

RF/Wireless Software

 

Bluetooth® / WiFi / ZigBee™

Custom Protocols

USB Software

 

Audio / HID / CDC / MSDC

Vendor Defined

Operating Systems

 

Embedded Linux / Android™

Embedded SF

Windows® Embedded

PC Software

 

User Application Software

Test Software

Programmable Logic

 

FPGA

CPLD

Connected Products

 

Windows®

Android™

iOS / MFi 

TESTING

TEST (FP, ICT, FCT, Burn-In)

Testing is a very important aspect of a successful product launch. That is why we pay special attention to the test details during the design phase. During the design phase, we will maximize the test point coverage. We will give you the report of all the nets that are not being covered, so that we can cover those nets in a functional test.

We have several testing options in-house, and will offer you the right choice depending on your product plan.

The following are some of the test options we offer.

Flying Probe Test
We have a brand new Seica S40 Pilot LX Tester in-house. It is an extra large flying probe system well-suited to test any type of electrical board on any type of production run from a single board to a high volume of boards. The 24’x24” board area is particularly suited to larger PCBs. Our tester features a full suite of test capabilities, ranging from the simple MDA testing of passive components to complete, powered up in-circuit and functional analog tests, static and dynamic digital tests and vectorless testing, boundary scan and custom techniques and OpenFix vectorless testing methods. The system is equipped with two high resolution CCD cameras for performing tasks such as the automatic centering of the board, optical inspection of component placement and the creation of digitized images of the UUT. The advantage of the flying probe test is that it has a small up front NRE expense, because it does not require a test fixture. The disadvantage is that it takes longer than ICT test, so the test cost per board is higher than ICT test. We will recommend the right test plan based on your build quantities.

ICT Test
For high volume production runs, this is the correct choice. We will develop the program and fixture for all of your ICT test requirements. Although the NRE expense on this test is much higher, the ROI for production boards will be easily shown when you compare the speed and cost per board with those of the flying probe test.

Functional Test
We have the engineering capability and a proven track record to develop a functional test for your product. We can also utilize your own test procedure, plan and set up. Our functional test plans range from simple GO/NO-GO tests to very detailed testing where each register and each function is tested with memory read-writes. We will provide you these detailed test results to further improve the future yields of similar products in your product family. We can also automate the test setup to improve the test efficiency and lower your test cost.

Burn-In
We also offer burn-in services. Burn-In can be a simple power on burn-in to temperature cycling and stress test.

REWORK & ECO

Whizz Systems is well known for its ability and receptive attitude towards reworking assemblies. Whether the rework is simple or difficult, caused by a faulty component or an Engineering Change Order (ECO), we are ready. We understand that it is difficult and stressful to deal with these types of issues. Rather than paying more to scrap and rebuild, Whizz will offer you a rework solution that is effective and cost-efficient. In one instance of rework, we received failed units from a customer’s field. We took the boards apart and installed a number of cuts and jumpers in order to repair a serious layout error discovered after the boards were completed at an offshore facility. Though this rework was tedious and demanding, we shipped back the functional assemblies, ready for installation within weeks. We constantly provide these kinds of services to many manufacturers, service centers, major electronics retailers and repair centers.

Whizz supports all of your rework requirements with quick turnaround.

Routinely Supported Items

-Through-hole or SMT Rework

-CO Implementation

-Cuts and Jumpers

-Components Soldering/Desoldering

-BGA Removal and Replacement or ReBalling

-Incrementally populating/depopulating boards

-Custom adaptors to address different pin-outs

TESTING

TEST (FP, ICT, FCT, Burn-In)

Testing is a very important aspect of a successful product launch. That is why we pay special attention to the test details during the design phase. During the design phase, we will maximize the test point coverage. We will give you the report of all the nets that are not being covered, so that we can cover those nets in a functional test.

We have several testing options in-house, and will offer you the right choice depending on your product plan.

The following are some of the test options we offer.

Flying Probe Test
We have a brand new Seica S40 Pilot LX Tester in-house. It is an extra large flying probe system well-suited to test any type of electrical board on any type of production run from a single board to a high volume of boards. The 24’x24” board area is particularly suited to larger PCBs. Our tester features a full suite of test capabilities, ranging from the simple MDA testing of passive components to complete, powered up in-circuit and functional analog tests, static and dynamic digital tests and vectorless testing, boundary scan and custom techniques and OpenFix vectorless testing methods. The system is equipped with two high resolution CCD cameras for performing tasks such as the automatic centering of the board, optical inspection of component placement and the creation of digitized images of the UUT. The advantage of the flying probe test is that it has a small up front NRE expense, because it does not require a test fixture. The disadvantage is that it takes longer than ICT test, so the test cost per board is higher than ICT test. We will recommend the right test plan based on your build quantities.

ICT Test
For high volume production runs, this is the correct choice. We will develop the program and fixture for all of your ICT test requirements. Although the NRE expense on this test is much higher, the ROI for production boards will be easily shown when you compare the speed and cost per board with those of the flying probe test.

Functional Test
We have the engineering capability and a proven track record to develop a functional test for your product. We can also utilize your own test procedure, plan and set up. Our functional test plans range from simple GO/NO-GO tests to very detailed testing where each register and each function is tested with memory read-writes. We will provide you these detailed test results to further improve the future yields of similar products in your product family. We can also automate the test setup to improve the test efficiency and lower your test cost.

Burn-In
We also offer burn-in services. Burn-In can be a simple power on burn-in to temperature cycling and stress test.

REWORK & ECO

Whizz Systems is well known for its ability and receptive attitude towards reworking assemblies. Whether the rework is simple or difficult, caused by a faulty component or an Engineering Change Order (ECO), we are ready. We understand that it is difficult and stressful to deal with these types of issues. Rather than paying more to scrap and rebuild, Whizz will offer you a rework solution that is effective and cost-efficient. In one instance of rework, we received failed units from a customer’s field. We took the boards apart and installed a number of cuts and jumpers in order to repair a serious layout error discovered after the boards were completed at an offshore facility. Though this rework was tedious and demanding, we shipped back the functional assemblies, ready for installation within weeks. We constantly provide these kinds of services to many manufacturers, service centers, major electronics retailers and repair centers.

Whizz supports all of your rework requirements with quick turnaround.

Routinely Supported Items

-Through-hole or SMT Rework

-CO Implementation

-Cuts and Jumpers

-Components Soldering/Desoldering

-BGA Removal and Replacement or ReBalling

-Incrementally populating/depopulating boards

-Custom adaptors to address different pin-outs

INTERNET OF THINGS DESIGN
Whizz Systems offers an expansive choice of engineering services pertaining to Internet of Things Networks that are sensor-driven in nature, ranging from IoT architecture designing and development to manufacturing.

EDGE DEVICES

  • -Single or Multi-Functional Custom Sensor Development
  • -Integration of Acoustic, Motion, Temperature, Moisture etc. Sensors
  • -Power Management
  • -Security – Video, Data Capture etc
  • -Integrated Wireless and Wired Networks

BASE STATION DESIGN

-Development and Solutions for sensory data collecting Embedded Software
-Latency Management for timely and precise performance
-Data Flow Solutions and Management for sizable data sets
-PCB design and input/output (I/O) integration (Ethernet, USB)
-Power Management
-Cloud Connectivity (Cellular, Ethernet, Wi-Fi)

SENSOR NETWORKING

  • -Development and Cross Platform Integration of Communications Firmware
  • -Secure Device Identification and Communications Encryption
  • -Wireless Protocol Support ( Bluetooth 2.1 and Bluetooth Smart, Wi-Fi, 802.xx.x, Sub-1GHz, 2.4 GHz, Custom Radio Protocols)
  • -RF Design
    • •Colocation Testing
    • •Certifications such as FCC part 15, ETSI, EN60251 etc.
    • •RF Tuning and Optimization
    • •4GHz Industrial, Scientific, and Medical (ISM) Bands
    • •868MHz/915MHz (Custom point to point and broadcast protocols for Sensor Data, Status Messages, Distributing Firmware Upgrades and Media Content)

CLOUD CONNECTIVITY

-‘Heartbeats’, forwarded through the base station to the cloud server which confirm the active and healthy status of the Sensor Network.
-‘Pushed’ Commands, Configurations and Software Update, received by the Base Station and Edge Devices.
-Application Level System Management and Analytical Software Support