Not every electronics project involves mass-producing identical devices. For many businesses, production means small batches of varied products—different circuit board designs, unique PCB layouts, and custom assemblies, often in quantities ranging from a few units to a few hundred. This is high mix low volume (HMLV) production, a method that prioritizes flexibility over repetition. It’s common in industries like automotive, industrial automation, IoT, and consumer electronics, where customization and quick turnarounds matter more than sheer volume. Let’s explore what it takes to make HMLV work, including the technical setup and supply chain essentials, based on real-world manufacturing capabilities.
Understanding High Mix Low Volume Production
HMLV is about variety. One day, a production line might handle PCB assembly for an IoT sensor; the next, it’s assembling circuit boards for an industrial controller. Each run has its own components, design files, and testing needs, unlike high-volume production where everything stays consistent. The challenge lies in managing this diversity efficiently—switching setups fast, maintaining quality across designs, and keeping costs in check for small batches. It’s a practical solution for prototyping, niche markets, or tailored electronics, but it requires a different approach than traditional manufacturing.
Technical Requirements for HMLV
To handle HMLV effectively, the manufacturing process needs specific tools and systems. Here’s what’s essential:
1. Adaptable Assembly Lines
A facility needs flexible equipment to switch between PCB designs without long delays. Multiple surface-mount technology (SMT) lines—say, seven—can place components on various circuit boards, from tiny chips to larger parts. Adding five through-hole (THT) lines allows for hybrid SMT-THT assemblies, common in complex electronics. High-speed SMT machines ensure quick transitions, keeping production moving across diverse runs.
2. Soldering and Quality Control
Soldering options must match the mix. Wave soldering handles THT components, while robotic soldering offers precision for detailed PCB assembly. Quality is critical in small batches—3D Automated Optical Inspection (AOI) checks surface issues, and X-ray inspection verifies hidden joints, especially on high-density interconnect (HDI) PCBs. Conformal coating protects boards for tough environments like automotive or industrial use, ensuring reliability.
3. Traceability and Monitoring
With frequent design changes, tracking every step is vital. Real-time statistical process control (SPC) collects data during PCB assembly, spotting trends or errors instantly. Full traceability links components to their origins, helping troubleshoot issues in low-volume runs—a must for industries demanding accountability.
4. Complex Design Support
HMLV often includes advanced electronics like HDI PCBs with fine traces, rigid-flex circuits blending rigid and flexible sections, or mixed-technology assemblies. These require precise handling, from solder paste application to thermal management, to meet quality standards across small batches.
Key Supply Chain Considerations
In HMLV, the supply chain isn’t about bulk orders—it’s about agility and precision. Here’s what matters:
1. Component Sourcing
Small runs mean ordering limited quantities of many parts, like specific sensors for an IoT circuit board or connectors for an automotive PCB. Lead times can delay projects, and minimum order quantities (MOQs) might exceed needs. A well-managed supply chain sources these efficiently, often pooling requirements to reduce costs and wait times.
2. Inventory Control
Stocking too many components wastes money, but too few stops production. HMLV relies on lean inventory—enough for immediate runs, adjusted as orders shift. Systems that track usage and predict needs keep electronics projects on schedule without excess.
3. Supplier Coordination
Low volumes don’t always get priority from suppliers. Strong connections—or a manufacturing partner with established ties—ensure timely delivery of critical parts. If a component runs dry, fast alternatives (approved by engineers) maintain momentum.
4. Logistics Efficiency
Shipping small batches of electronics components can add up, and managing multiple vendors complicates things. A turnkey system, where one team oversees sourcing, PCB assembly, and delivery, simplifies logistics and adapts to changing demand without hassle.
Benefits and Applications
HMLV suits specific needs: prototyping new circuit board designs, serving custom orders, or supporting emerging fields like IoT. It reduces upfront investment compared to mass production and lets businesses respond to market shifts quickly. The trade-off is complexity—more setups, tighter supply chain oversight—but the payoff is flexibility and precision for diverse electronics.
Karkhana.io: Your HMLV Contract Manufacturing Partner
For businesses tackling high mix low volume production, Karkhana.io offers a practical solution. Operating from a 100,000 sq. ft. facility, they run 7 SMT lines and 5 THT lines, equipped with high-speed SMT machines, wave and robotic soldering, 3D AOI, X-ray inspection, and conformal coating. This setup delivers high-quality PCB assemblies with 100% traceability and real-time SPC, handling everything from HDI PCBs to rigid-flex circuits for automotive, industrial automation, IoT, and consumer electronics.
Karkhana.io’s turnkey approach—covering component sourcing, PCB assembly, testing, validation, integration, and logistics—addresses HMLV challenges head-on. They manage supply chains to secure parts, control inventory, and streamline delivery, helping businesses scale efficiently. Whether it’s a prototype or a small production run, Karkhana.io provides the technical backbone and flexibility needed for successful circuit board production.
Closing Thoughts
High mix low volume electronics production balances variety with quality, demanding adaptable tools and a responsive supply chain. It’s about getting the right PCB design built, tested, and delivered—without the overhead of mass production. With a partner like Karkhana.io, businesses can navigate this complexity, turning diverse circuit board needs into reliable results. Ready for your next HMLV project? It starts with the right strategy and support.
