Reliability Matters

Today, we’re going to explore a topic that doesn’t always get the attention it deserves, but has a direct impact on product quality and long-term reliability.I’m joined by Mehdi Nahali, founder of PCB Revision Control PRO. His platform is designed to replace spreadsheets, emails, and disconnected systems with a centralized approach to PCB revision lifecycle management and factory intelligence. We’re going to talk about how revision control, data integrity, and process discipline impact reliability, and where manufacturers are still getting it wrong.PCB Revision Control Prohttps://www.pcbrevisionpro.com

What if your factory could predict failures before they happen, capture decades of human expertise, and make better decisions than ever before—without replacing the people who run it?Today’s guest sits right at the intersection of innovation and industry. Bryan DeBois, Director of Industrial AI at RoviSys, is helping reshape what manufacturing looks like in the age of intelligent machines.From predictive analytics that catch problems before they happen, to data-driven systems that optimize production in real time, Bryan’s work is transforming how factories think, learn, and produce. But this isn’t about replacing people, it’s about amplifying human expertise and capturing decades of industrial knowledge before it disappears.In this episode, we’ll explore how smart factories are changing the game, what it really takes to begin a digital transformation, and why trust and transparency are just as critical as algorithms and code.What stands out most is Bryan’s ability to make advanced technology practical. He’s not talking about theory, he’s helping real manufacturers integrate AI in ways that improve safety, efficiency, and sustainability.I speak with Bryan about how artificial intelligence is redefining manufacturing, the challenges of digital transformation, and the future of smart factories.RoviSyshttps://www.rovisys.com

Artificial intelligence is being promoted as the next revolution in electronics manufacturing, but what happens when the people evaluating it aren’t traditional AI experts, aren’t software vendors, and aren’t selling anything? Today’s conversation brings together engineers and professors who live at the intersection of education, reliability, and real-world manufacturing to separate meaningful progress from speculation.Each episode brings together engineers, researchers, and industry leaders to examine best practices, emerging technologies, and real-world lessons, always with a focus on data, physics, Best practices, and long-term performance.Today’s episode is a little different—and the setting couldn’t be better. I’m recording live from the Big Island of Hawaii, in Kona, at the SMTA Pan Pacific Strategic Electronics Symposium, better known as PanPac.At PanPac, academia meets industry in a way that’s truly unique. Leading international universities join forces with CEOs, inventors, senior engineers, and decision-makers from around the world. This is where the brightest research collides with the most pressing industry challenges — and sparks solutions that drive the future of electronics. I’m honored to be the conference chair, especially on this 30th anniversary of PanPac.This episode is all about “AI in Action: Progress, Pitfalls, and the Future of Electronics.”Artificial intelligence is becoming a frequent topic in electronics manufacturing—from inspection and process optimization to predictive maintenance and reliability modeling. But rather than approaching this conversation from the standpoint of AI evangelists or software developers, we’re taking a different path.My panelists are: Eva Hymes, Hayden Lee, Dr. Ron Lasky, Dr. John Evans, and Dr. Pradeep Lall. None of today’s panelists claim to be AI experts. Instead, they are engineers and professors who sit at the intersection of education, engineering, and real-world manufacturing challenges. Their perspective is grounded in physics, data, reliability science, and decades of experience teaching the next generation of engineers—many of whom will be working alongside AI-driven tools whether they choose to or not.Because all of our panelists come from academia, this conversation intentionally steps back from hype and buzzwords. We’ll focus on how AI is actually being used, where it shows promise, where it introduces risk, and where critical gaps still exist—especially in high-reliability electronics manufacturing. And because PanPac serves the electronics manufacturing community, we’ll keep this discussion connected to the factory floor, workforce readiness, education, and long-term product reliability. We’ll also touch on broader societal questions, including how AI is shaping engineering education and professional intuition.So if you’re looking for a grounded, thoughtful discussion on AI—one rooted in engineering reality rather than marketing claims—this episode is for you.

When you talk to one manufacturer, you hear a story. When you talk to hundreds, patterns emerge. Today, we step back and examine what those patterns tell us about the real state of electronics manufacturing.Today’s episode takes a step back from individual processes and technologies to look at the electronics manufacturing industry through a broader, editorial lens. My guest is Trevor Galbraith, publisher of Global SMT & Packaging—one of the industry’s valuable trade publications.As a publisher, Trevor speaks with manufacturers, suppliers, technologists, and industry leaders from around the world. That gives him a unique vantage point—not just on where the industry is investing, but where it’s struggling, where expectations and reality diverge, and how issues like reliability, workforce challenges, supply chain pressure, automation, and standards are truly playing out on the factory floor.In this Meet-the-Press–style conversation, we’ll explore the current state of electronics manufacturing, how reliability is being prioritized—or deprioritized—amid cost and speed pressures, whether manufacturing processes are keeping pace with design complexity, and what Trevor sees ahead for the industry over the next five to ten years.This episode isn’t about promoting solutions. It’s about understanding the landscape, asking hard questions, and gaining perspective from someone who hears unfiltered voices across the entire electronics manufacturing ecosystem.Global SMT & Packaging Magazinehttps://www.globalsmt.net

Today, I’m joined by someone who has spent more than three decades at the intersection of materials science, automation, and high-reliability manufacturing. Jon Urquhart is the Director of Global Applications Engineering at Precision Valve and Automation — one of the world’s leading developers of dispensing, coating, and industrial motion-automation systems. Since joining PVA in 1993, Jon has become widely recognized for his expertise in fluid material processing, precision dispensing, and the engineering-to-manufacturing handoff that so often makes or breaks product reliability.Jon holds multiple patents and has helped shape advanced processes used in industries where the stakes couldn’t be higher — from aerospace and EV battery systems to semiconductor packaging, medical devices, and high-density electronics assembly. His work spans everything from protective coatings that safeguard electronics in extreme environments, to next-generation thermal interface material (TIM) deposition, to automation strategies that reduce human error, improve consistency, and dramatically scale production.We’ll discuss the real-world challenges of protecting critical electronics and batteries, the latest advances in TIM materials and deposition, sustainable precision-coating techniques, and the power of a strong collaboration model between vendors, manufacturers, and lab technicians.PVA Website:https://www.pva.netJon Urquhart:jurquhart@pva.net

Today, we’re continuing our dive into the world of contract manufacturing—a vital piece of the electronics ecosystem.Joining me are two industry leaders who know this space inside and out. First, we have Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, and alongside him, Sean Kincaid, President of K & F Electronics. Both Daniel and Sean represent companies that provide contract manufacturing services to a wide range of customers, helping turn design concepts into dependable, production-ready circuit assemblies.In this conversation, we’ll explore what makes for a successful relationship between contract manufacturers and their customers. We’ll talk about the types of customers they look for, the challenges they face in today’s manufacturing environment, and the common mistakes that can derail a project if not addressed early on. Most importantly, we’ll dig into best practices that can help customers and manufacturers work together more effectively.You may recognize Daniel and Sean. In addition to their day jobs, Daniel and Sean, along with Elias Malfavon Jr. are also co-hosts of the d-code podcast, where they share candid conversations and insights from across the electronics industry. We’ll hear what inspired them to launch the show and how it ties into their mission of building stronger connections in this field.So whether you’re an engineer, a buyer, or anyone working with contract manufacturers, this episode is packed with advice to help you navigate the process with confidence. Daniel is an SMT Process Engineer at:Aurora Boardworkshttps://auroraboardworks.comSean is President of:K & F Electronicshttps://www.circuitboards.com

This is the fourth of four episodes on the subject of soldering materials.Today, we're diving into a topic that's reshaping how we think about thermal management, energy efficiency, and long-term performance in electronics manufacturing—low temperature soldering.Joining me is Dr. HongWen Zhang, Principal Metallurgist and R&D Manager of the Alloy Group at Indium Corporation. Dr. Zhang is not only a seasoned materials scientist with a Ph.D. in materials science and engineering, a Master’s degree in materials science and engineering and in mechanical engineering and a Bachelor’s degree in metallurgical physical chemistry he’s also the co-inventor of Durafuse, a groundbreaking family of solder alloys that are redefining what's possible at low reflow temperatures—which, reportedly, does not compromise reliability. In this episode, we’ll explore how low temperature solders are helping manufacturers lower energy consumption, protect heat-sensitive components, and still meet the rigorous mechanical and environmental demands of today’s electronics—from wearables to wafer-level packaging.We’ll also talk about the challenges of brittleness, drop shock resistance, activation and encapsulation of no clean activators, and how cutting-edge materials research is solving problems that used to be considered trade-offs.Whether you’re a reliability engineer, a process expert, or just solder-curious, this episode is packed with insights you won’t want to miss.Indium's Website:https://www.indium.comDurafuse ®:https://www.indium.com/products/alloys/solder-alloys/durafuse-lt/

This is the second of four episodes on the subject of soldering materials.In today’s episode, continuing the subject of soldering materials, diving deep into the science, strategy, and subtleties behind one of the most foundational elements of electronic assembly: soldering materials. Joining me are two experts from KOKI Solder—Shantanu Joshi, Head of Customer Solutions and Operational Excellence, and Greg Starrett, General Manager of North American Operations. Together, they bring decades of experience in solder chemistry, process engineering, and real-world reliability. We’ll explore how soldering materials influence long-term performance, how material and process decisions interact, and what assemblers should consider when aiming for high-reliability outcomes.From surface finishes and flux residues to void mitigation and future trends in solder formulation, this episode offers practical insights that go well beyond the datasheet.So whether you’re on the factory floor, in the lab, or managing quality and reliability at scale—this conversation is for you.Shantanu JoshiHead of Customer Solutionsshantanu@kokiamerica.comGreg StarrettNational Sales Managergreg@kokiamerica.com

This is the first of four episodes on the subject of soldering materials.In this episode, I’m joined by Chris Ward, founder and Managing Director of Solderking Assembly Materials Limited, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies.Chris brings decades of experience in soldering materials and chemical formulations—and he’s built a company committed to performance, consistency, and innovation.Earlier this year, Chris and his company were honored with the prestigious King’s Award for Enterprise in International Trade, recognizing their exceptional export growth. That recognition earned him an invitation to Windsor Castle, where he had the distinct honor of meeting King Charles III.Today, we’ll explore the evolving world of soldering materials—from the realities behind “no-clean” flux, to reliability challenges in harsh environments, to innovations in solder chemistry that support today’s miniaturized and mission-critical electronics.Whether you're on the production floor, in the design lab, or managing quality and reliability, this is a conversation that brings valuable insight into the materials behind the mission.SolderKing:https://solderking.com

Today, I’m joined by two of the most respected names in the electronics manufacturing industry, Phil Zarrow and Jim Hall. Together, they bring decades of hands-on experience and unparalleled insight into the challenges and solutions within our field.Jim and Phil are the driving forces behind ITM Consulting, where they help manufacturers around the world improve processes, solve complex problems, and build more reliable products. Whether it’s soldering, cleaning, reflow profiling, process control, or failure analysis, these two have seen it all, fixed it all, and taught it all.In this episode, we tackle some of the most pressing issues facing the industry today, from the challenges of miniaturization, the reality of voiding, to the rise of electronics deployed into harsh environments, to IPC standards, and the role of process control in ensuring long-term reliability.Whether you're a process engineer, a quality manager, or simply passionate about electronics manufacturing, this is a conversation you won’t want to miss.ITM Consulting:https://itmconsulting.com

As the electric vehicle market accelerates, the reliability of the charging infrastructure becomes increasingly vital. Chargers that are down or malfunctioning can hinder adoption and erode consumer confidence. But who ensures these chargers stay up and running?Today, we're diving into that very topic with a trailblazer in the EV service space. My guest is Kameale Terry, co-founder and CEO of ChargerHelp!, a company revolutionizing how we think about EV charger maintenance and reliability. Under her leadership, ChargerHelp! has pioneered Reliability as a Service, developed a highly trained and diverse technician workforce, and shaped industry policies aimed at improving charger uptime.Kameale’s journey is as inspiring as it is innovative, leading a national movement for a more reliable and equitable EV charging network. With backgrounds in workforce development, clean tech, and digital operations, she’s uniquely positioned to tackle the challenges facing this growing industry.In this episode, we’ll explore the common causes of EV charger failures, the role data plays in predictive maintenance, the impact of new regulations like the National Electric Vehicle Infrastructure (NEVI) standards, and how ChargerHelp! is creating pathways into the clean energy economy for workers from all walks of life.If you've ever wondered how reliability translates to the EV world, or how technology and workforce innovation go hand in hand, you won’t want to miss this conversation.Kameale’s Company:ChargerHelp!https://www.chargerhelp.com

Today we're turning our attention to a cornerstone of modern electronics manufacturing: pick and place technology.Joining me is Tim Kang, CEO of Hanwha Semitech Americas. With nearly two decades of experience in the electronics manufacturing space—starting as a mechanical engineer and now leading one of the top pick and place equipment providers—Tim brings a wealth of insight into what it takes to build reliable assemblies.In this episode, we’re covering best practices for selecting the most appropriate pick and place machine, how to get the most out of your equipment, and the common mistakes that can compromise productivity and long-term reliability.Whether you’re a process engineer, a line operator, or anyone involved in electronics manufacturing, this conversation is packed with practical advice you can use right away.Hanwha's Website:https://www.hanwha-pm.com/en/product/smt/index.asp

On this episode of the Reliability Matters podcast, I left my usual studio for the IPC APEX Expo in Anaheim California.I interviewed two subject matter experts on topics related to electronic assembly.My guests are:Gerald Gardner, Global Product Manager at Weller, a manufacturer of hand soldering equipment fume extraction systems, and precision tools.Mike Young – CEO OF SASinno Americas, a manufacturer of wave and selective soldering equipment.More information on my guest's companies is available here:SASinno Americashttps://www.sasinnoamericas.comWellerhttps://www.weller-tools.com/us/en