In 2020, Zero Mistake Solutions managed and delivered the LED lighting PCBA for Doha Corniche project.
It is about 100 thousand LED lighting PCBA manufactured and delivered by ZMS within 1 month. We would like to share the difficulties we have encountered in this project and how we get through it.
The LED Price is far beyong client's budget
Our client is also the first time designing this project and they have chosen quite an expensive LED, but the budget is only 1/3 of the original LEDs. Thus, to help our client reaching their budget, ZMS has recommened Chinese alternative which could hit their target and bring the cost down. But for maintaining the quality, client still choosing part-number which is also from the famous brand SAMSUNG recommened by ZMS, and we reach an agreement on the LEDs Costing.
Soldermask Issue
The PCB quality and soldermask color are very important for this project. In the first prototyping stage, the aluminum PCB factory applied common white soldermask with cooler tone, while client expect for milky white (Warmer tone) which will be better for the light reflection color standard.
After sampling and selection with more than 10 local factories, Zero Mistake Solutions found the ideal milky white soldermask color for customers, because most manufacturers would choose ink with blue tone for production due to price issues, ZMS sucessfully convinced our supplier join us with this project by using prettier soldermask while maintaining the price within client's budget.
LED stocks are not available in the market
In this project, ZMS was required to deliver this project within 1 month. Besides, our clients have specific requirements for the LED Ra/CRI value, while the project demand for 5 million LEDs is far beyond the stock supply in the Chinese market.
In a very short time, our sourcing team started contact as much as possible with the SAMSUNG and their agent to see how much stock we can collect from them, not only in China, but also in oversea, we have ability to search and collect for the large demand when our client need them in urgent situation and finally, we have achieved our goal and the production is able to gose into production.
Thermal Adhesive Tape for the PCB
Because the LED lighting PCBA must be installed on the metal casing and there are no screw holes for it, clients require strong adhesive thermal tape to be applied to the back of the lighting board.
You can see below picture, we have capability to help our clients do this job perfectly.
Quality Testing and Functional Testing
In each step, we must perform the functional testing to see if all LEDs is ble to be lighten up.
LED lighting Aging test
The LED PCBA Package
LED PCBA is very dedicated, especially the LEDs on the board. Our package must be able to protect the PCBA and LEDs very well. So ZMS chose ESD proof foam to protect the PCBA inside of the box and make sure they are fixed.
Outter box, we use 5 layers of carton to make sure the strong structure of our goods is safe in air or sea cargo.
After our PCBA was successfully delivered to our client, we are excited to see they were using the Light Poles of Doha Corniche project. ZMS Team managed well and perfectly delivered this project on time and quality is verified by the Doha engineering team of our client.
