Overview of Sub Assembly and Contract Assembly
Assembling products, or components of products, is a key process in many manufacturing applications. Companies looking for assistance with their assembly processes may be looking for contract assembly or sub assembly services. These terms are often used interchangeably, although there are key differences when referring to sub-assembled and assembled products and/or sub-assembly and contract assembly services.
Let’s review what each term means, the differences between subassembly and assembly, the benefits of each, and the advantages to manufacturers that outsource these services. Learn how sub assembly companies like Peoria Production Solutions, PPS, help manufacturers increase revenue and sustainable growth.
Sub Assembly & Contract Assembly: What Exactly Do They Mean?
Sub-Assembly
Sub-assembly process: Sub-assembly refers to the process of assembling smaller components into sub-components, which are then used in the final assembly of a larger product. This intermediate step is crucial for creating complex products that require multiple assembly stages. Subassemblies are essential building blocks of the final product, and their accuracy and quality significantly impact the overall assembly process. Sub-assembly helps streamline production by breaking down complex assembly tasks into more manageable parts.
Subassembly product: A subassembly, or subassemblies, refers to partially assembled products, composed of two or more already assembled components, that are part of a larger product. Picture the face of a car radio, with knobs and buttons already assembled, slated to fit into a larger assembly, a dashboard panel, for example. Or an electro-mechanical switch, consisting of buttons assembled in a housing, that fits into a larger assembled product, like a door panel. These assembled products are called “subassemblies”.
To retain sub-assembly services, a manufacturer might look for a contract assembly company with the experience and capacity to take numerous parts and assemble them together so they are ready for the next stage in an assembly line or a manufacturing process. These sub-assembled components could then be shipped back to the manufacturer for their next stage in the production process, or the contract assembly provider may further assemble these parts into larger components for a final assembly.
Many manufacturers find great value in outsourcing these assembly services to experienced sub assembly companies.
Contract Assembly
Contract assembly involves hiring an assembly company to perform subassembly or final assembly of a product. Contract assembly companies may create subassemblies and ship them back to a manufacturer, or they may perform final assembly, quality inspections, and packaging.
Assembly services include integrating various components and sub-assemblies into a final product. Assembly is often required for various products in various industries and applications, such as automotive OEMs, mechanical part production, electrical part assembly, medical devices, and various miscellaneous components.
Contract assembly companies often utilize sophisticated techniques and equipment to achieve the desired product outcome and ensure that all parts fit together seamlessly, function as intended, and meet quality standards.
Key Differences of Sub Assembly and Contract Assembly
Subassembly and contract assembly are critical services provided by experienced contract assembly companies. These assembly companies typically provide various secondary production services such as assembly, kitting, and packaging for various industries.
Contract assembly involves the complete assembly of a product, making it ready for packaging and distribution. This service includes integrating various components and sub-assemblies into a final product.
On the other hand, sub-assembly refers to the process of assembling smaller components into sub-components, which are then used in the final assembly of a larger product. This process is crucial for creating complex products that require multiple assembly stages. Subassembly processes are essential for manufacturing complex products efficiently and accurately.
The primary difference between sub-assembly and contract assembly lies in the scope of the assembly process:
- Sub Assembly deals with the creation of intermediate sub-components that are later integrated into the final product during the contract assembly process.
- Contract Assembly focuses on the complete assembly of the final product, integrating all components and sub-assemblies to produce a ready-to-distribute item.
Benefits of Sub-Assembly
Sub-assembly provides numerous benefits that can significantly enhance manufacturing processes and outcomes. Here are the key advantages of utilizing sub-assembly in your production operations:
- Enhanced Efficiency
Sub-assembly can greatly improve overall efficiency in the manufacturing process. By breaking down the assembly into manageable sub-components, each stage of production becomes more streamlined. This division of labor allows specialized teams or machines to focus on specific tasks, reducing the complexity and time required for the final assembly. Consequently, the entire manufacturing process becomes faster and more efficient. - Improved Quality Control
One of the significant benefits of sub assembly is the ability to implement detailed quality control measures at each stage of the production process. By inspecting and testing sub-assemblies before they are integrated into the final product, manufacturers can identify and rectify issues early on. This approach ensures that only high-quality components move forward to the final assembly stage, resulting in a more reliable and defect-free finished product. - Flexibility and Scalability
Sub assembly offers greater flexibility in the production process. It allows manufacturers to easily adapt to changes in design or production requirements without disrupting the entire assembly line. This flexibility is particularly beneficial for custom orders or products that require frequent updates. Additionally, sub assembly enables scalability, making it easier to ramp up production in response to increased demand or scale down during slower periods. - Cost Savings
By optimizing the assembly process, sub assembly can lead to significant cost savings. The streamlined production process reduces labor costs and minimizes the need for extensive in-house assembly facilities. Additionally, focusing on subassemblies can reduce waste and improve resource utilization, further driving down costs. - Simplified Inventory Management
Managing inventory becomes more straightforward with subassemblies. By organizing components into subassemblies, manufacturers can keep better track of parts and materials, reducing the risk of shortages or overstocking. Several SKUs could be combined into one, simplifying the inventory process. This improved inventory management leads to more efficient use of storage space and resources. - Enhanced Customization
Sub assembly allows for greater customization in the manufacturing process. Manufacturers can easily modify components of sub-assemblies to meet specific customer requirements or adapt to new design specifications. This capability is particularly valuable in industries where personalized products, new models, or frequent design changes are common. - Reduced Production Time
By focusing on sub-assemblies, manufacturers can significantly reduce the overall production time. The streamlined process allows for quicker assembly of final products, enabling faster delivery to market. This reduction in production time can be a critical competitive advantage, especially in industries with high demand and rapid product cycles.
Importance of Assembly in Manufacturing
Sub assembly manufacturing and contract assembly are vital to many production applications:
- Sub Assembly Manufacturing – streamlines the production process by creating sub-components that can be easily integrated during the final assembly. This division of labor enhances efficiency, reduces production time, and allows for better quality control at each assembly stage.
- Contract Assembly – alleviates the burden from the manufacturer, and ensures that final products are assembled correctly, meet quality standards, and are ready for the market. It allows manufacturers to produce high-quality products efficiently and cost-effectively.
Together, these processes enable manufacturers to produce complex products with precision, ensuring that every component works together seamlessly in the final product.
Advantages and Disadvantages of Contract Assembly
Outsourcing sub assembly and contract assembly play vital roles in manufacturing, allowing companies to focus on their core competencies while ensuring high-quality production. By outsourcing these services to a sub assembly company, businesses can achieve greater efficiency, cost savings, and scalability.
Contract assembly and sub assembly services help streamline production processes, reduce the time and effort required to assemble complex products, and ensure high-quality standards are met. This approach allows companies to optimize their resources, enhance operational efficiency, and remain competitive in their respective industries.
Advantages:
Here are some of the most important advantages of outsourcing to a contract assembly company:
- Increased Internal Capacity Outsourcing the assembly process allows companies to free up valuable floor space and labor resources. This shift enables businesses to increase their internal capacity, as they no longer need to allocate significant space and personnel for assembly tasks.
- Savings on Labor and Benefits By opting for contract assembly, companies can avoid the costs associated with hiring, training, and maintaining an in-house assembly workforce. This approach reduces labor expenses and eliminates the need for employee benefits and ongoing training related to staff turnover.
- More Resources to Focus on Niche Production When assembly tasks are outsourced, companies can redirect their freed-up floor space and labor towards their core manufacturing activities. This enables them to concentrate more on their niche markets and specialized products.
- Increased Productivity Receiving pre-assembled products on time allows companies to enhance their productivity. This improvement enables them to produce more products internally, which can lead to increased sales and revenue.
- Improved Profitability Partnering with a reputable contract assembly provider helps companies manage their budgets more effectively while ensuring the timely delivery of quality products. This combination of factors contributes to increased productivity and profitability.
- Enhanced Quality and Delivery Outsourcing to an experienced assembly provider can help companies struggling to meet in-house assembly demands. Working with a quality-focused assembly house, particularly one certified to ISO9001:2015, can improve both the quality and timeliness of product delivery.
- Insight from Experienced Assembly Providers Experienced assembly providers offer valuable insights into efficient assembly methods. They can provide manufacturers with suggestions to enhance the quality and delivery of their assembled products, leveraging their expertise to optimize the assembly process.
By outsourcing assembly services, companies can enjoy these numerous benefits, leading to more efficient operations, cost savings, and improved product quality. By leveraging the benefits of sub assembly, manufacturers can enhance their production processes, improve product quality, and achieve greater operational efficiency. Sub assembly not only streamlines the manufacturing process but also provides the flexibility and scalability needed to adapt to changing market demands.
Disadvantages
While contract assembly offers numerous benefits, companies should be aware of potential disadvantages and take steps to mitigate them. Key concerns include communication errors, less control over the project, intellectual property risks, and potential quality and delivery issues.
Communication Errors
Outsourcing assembly to a third party can sometimes result in communication errors if either party does not clearly relay assembly or quality requirements. It is crucial to ensure that your assembly provider is responsive and communicates effectively to avoid misunderstandings. PPS mitigates this challenge by maintaining open and transparent communication channels with our clients, ensuring that all specifications and requirements are clearly understood and met.
Less Control Over the Entire Project
Using the services of a contract assembly provider means having less direct control over the process. Trusting an experienced provider with a track record of delivering quality assembled products can alleviate concerns. PPS addresses this by developing detailed work processes with quality checks and audit requirements to meet client specifications, ensuring that every project adheres to the highest standards.
Intellectual Property Risks
For companies that assemble proprietary products or government projects, protecting intellectual property is paramount. A reliable assembly provider will sign nondisclosure agreements and take steps to safeguard intellectual property. PPS ensures the protection of your intellectual property through stringent confidentiality measures and secure handling practices.
PPS mitigates these challenges with more than 80 years of experience, complete transparency, and responsiveness to our customers’ needs. Our commitment to quality, open communication, and rigorous security measures ensures that we deliver exceptional contract assembly services while addressing potential disadvantages.
Key Considerations for Outsourcing Assembly Services
Choosing the Right Sub-Assembly Company
Selecting the right sub assembly company is crucial to the success of your outsourcing strategy. Here are some key factors to consider:
- Experience and Expertise: Look for a company with extensive experience in your industry and a proven track record of successful projects. The provider should have the technical expertise to handle your specific assembly needs.
- Quality Control: Ensure the company has robust quality control measures in place. Check if they are certified to standards such as ISO9001:2015, which indicates a commitment to maintaining high-quality standards.
- Technology and Equipment: The assembly provider should utilize advanced technology and equipment to ensure precision and efficiency in their processes. This can lead to better product quality and faster turnaround times.
- Scalability: Choose a provider that can scale their operations to meet your changing needs. Whether you need to ramp up production during peak times or scale down, the company should be able to accommodate your requirements.
- Reputation and References: Research the company’s reputation and ask for references or case studies. Speaking with other clients can give you insights into their reliability, quality of work, and customer service.
Critical Questions to Ask Before Outsourcing
Before finalizing your decision to outsource assembly services, it’s essential to ask critical questions to ensure you are making the right choice. Consider the following:
- What is your experience with projects similar to ours?
- Can you provide references or case studies from similar industries?
- What quality control measures do you have in place?
- Are you certified to any industry standards, such as ISO9001:2015?
- What technology and equipment do you use for assembly processes?
- How do you handle scalability and changes in production volume?
- What are your lead times for assembly projects?
- How do you ensure on-time delivery of assembled products?
- What is your approach to managing and mitigating risks?
Asking these questions will help you evaluate the potential assembly provider’s capabilities and ensure they align with your business needs. Considering these factors should help you make an informed decision and choose the right partner for your assembly needs.
Sub Assembly and Contract Assembly Services Offered by PPS
Peoria Production Solutions (PPS) offers comprehensive sub assembly and contract assembly services customized to meet the diverse needs of various industries. With over 80 years of experience, PPS leverages advanced technology and a skilled workforce to deliver high-quality assembly solutions. Our capabilities encompass a wide range of assembly processes, ensuring precision, efficiency, and reliability in every project we undertake.
Specific Assembly Services and Industries Served
Mechanical Assembly
PPS specializes in mechanical assembly, providing services that include the assembly of complex mechanical systems and components. Our team has the expertise to handle projects of varying complexity, ensuring that all mechanical assemblies meet stringent quality standards and function flawlessly.
Electronic Assembly
Our electronic assembly services cater to the needs of the electronics industry, including the assembly of circuit boards, wiring harnesses, and electronic devices. PPS utilizes state-of-the-art equipment and follows industry best practices to ensure the highest level of accuracy and reliability in electronic assemblies.
Medical Device Sub Assembly
Peoria Production Solutions (PPS) offers a wide range of sub assembly services for medical devices, ensuring adherence to the highest quality and regulatory standards with our ISO9001:2015 certification and FDA-certified clean room. We specialize in assembling and packaging single-use, disposable medical products, face shields, and sneeze guards. Additionally, we provide packaging for OEM and private label products and secondary packaging for items already in compliant packaging, including swab testing kits.
While we do not handle the initial packaging of sterile devices, we excel in secondary packaging and the assembly and kitting of non-sterile medical instruments, such as certain home health machines. Our capabilities ensure that medical products are assembled accurately and efficiently, making PPS a reliable partner for your medical device assembly needs.
Component Assembly
We provide component assembly services for a variety of industries, assembling individual components into ready-to-use sub-assemblies and final assemblies. Our streamlined processes and quality control measures ensure that each component assembly is completed to the highest standards, facilitating seamless integration into final products.
Automotive Sub Assembly
PPS supports the automotive industry with specialized sub assembly services, including the assembly of automotive components and systems. Our expertise in handling automotive assemblies ensures that all parts are assembled accurately and efficiently, contributing to the production of high-quality vehicles.
PPS is committed to delivering top-tier assembly solutions to a wide range of industries. Please contact us with any questions about our assembly service capabilities.
Increasing Revenue and Sustainable Growth Through Outsourced Assembly
Outsourcing sub assembly services can significantly contribute to business growth by enhancing efficiency, reducing costs, and allowing companies to focus on their core competencies. By partnering with an experienced contract assembly company like PPS, businesses can benefit from streamlined production processes, improved product quality, and faster time-to-market.
Benefits of Outsourcing for Business Growth
Outsourcing also reduces the need for substantial capital investments in equipment and labor, freeing up resources that can be redirected toward innovation and market expansion. Additionally, outsourcing provides scalability, enabling companies to easily adjust production volumes in response to market demands without the constraints of in-house capacity limitations.
Contact PPS to learn valuable information on the benefits and practical outcomes of outsourcing assembly services.
Innovation and Technology in Assembly Services
Incorporating advanced technology and automation in assembly services is crucial for achieving high efficiency and maintaining consistent quality. Peoria Production Solutions (PPS) leverages state-of-the-art equipment and cutting-edge technologies to streamline the assembly process. Automation tools such as robotic arms and precision assembly machines enable us to perform complex assembly tasks with high accuracy and speed.
These technologies reduce manual labor, minimize errors, and ensure that each product meets stringent quality standards. By continuously investing in the latest technology, PPS stays at the forefront of innovation, providing our clients with top-tier assembly solutions.
Impact on Efficiency and Quality
The implementation of advanced technology and automation has a profound impact on both the efficiency and quality in assembly services. Automated systems enhance production speed and consistency, allowing for higher output rates without compromising quality. This efficiency translates into faster time-to-market for our clients, giving them a competitive edge.