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Elexon Electronics is aiming high with its Elexon2Zero program, targeting zero defects, zero delays, and zero returns.

We spoke with John White, Elexon’s Business Development Manager and a key leader of this initiative, to understand the benefits Elexon2Zero brings to customers, the inspiration behind the program, and the innovative strategies being used to achieve its goals.

Zero defects, zero delays, and zero returns… Elexon Electronics’ ambitious program aims to grow not only bigger but BETTER.

Elexon Electronics is aiming high with its Elexon2Zero program, targeting zero defects, zero delays, and zero returns. We spoke with John White, Elexon’s Business Development Manager and a key leader of this initiative, to understand the benefits Elexon2Zero brings to customers, the inspiration behind the program, and the innovative strategies being used to achieve its goals.

Elexon2Zero Program seems to be the flavour of the month. What initiated this bold activity?

The fire event forced us to rebuild the factory and during that process we took the opportunity to significantly enhance our manufacturing capabilities. We have all new equipment, a facility twice the size of our previous one, and we’ve been producing more products than ever. We’ve also been hiring a range of staff, from assembly workers to engineering and technical personnel. We knew it was now or never that we have a chance to redevelop our processes and bring better outcomes for our customers. That’s how Elexon2Zero came about, and it is very exciting to be part of it.

What specifically did you do differently with your new manufacturing set-up?

We’ve introduced additional inspection equipment, including advanced solder paste inspection. Our upgraded pick-and-place machines are now more accurate and faster, and we’ve integrated automatic optical inspection (AOI) equipment from the same manufacturer, Mycronic. This uniformity across our equipment enables even stronger Industry 4.0 capabilities, allowing for precise adjustments to solder paste and enhanced overall quality.

Additionally, we’ve added a second production line designed for prototyping and small runs. This line uses compatible equipment, making it easier to introduce new products to the manufacturing process. As volumes increase, we can seamlessly transition products to the main production line.

These improvements are important steps towards achieving our Elexon2Zero goals. They allow us to collect more data throughout the production line, which will support analysis and help us make targeted actions to set milestone targets and reach our E2Zero objectives.

While E2Zero is focused on Zero defects, delays and returns, there will also be a benefit of waste reduction.  From this perspective, the Elexon2Zero program is closely aligned with Australia’s net-zero goal by implementing sustainable practices such as reducing emissions and increasing energy efficiency, but mainly by minimizing waste.

What is the reaction of the industry to Elexon2Zero?

Our larger corporate and defence clients are especially receptive to the concept of zero defects, zero delays, and zero returns. It aligns with their key metrics of improving outgoing quality. The Elexon2Zero initiative aims to enhance on-time delivery, improve product quality, and ultimately reduce costs. By improving the quality of the finished product, we also lower the overall cost of ownership, which is a major advantage for our customers.

What are the new Industry 4.0 features in your upgraded manufacturing capabilities?

The upgrades to our facility has significantly enhanced our capabilities. The improvements span multiple levels of our operation. Materials are stored in automated robotic towers or control towers. These systems manage the materials needed for each job, automatically providing them to allow machine setup and the machines call up for additional supplies as needed. This creates immediate feedback between machines and ensures a continuous, efficient operation with minimal manual intervention and reduction is human error related issues.

We’ve also integrated advanced inspection stations into the line. Our new solder paste inspection station measures the volume of solder applied to circuit boards, providing precise data on solder quality. This information is fed back to the solder paste jet printer, enabling real-time adjustments to maintain optimal quality. At the end of the line, our automatic optical inspection (AOI) system measures soldering quality and offers recommendations for adjustments to process. These adjustments can be applied to improve solder quality, ensuring it meets the IPC standards we aim for. Overall, these upgrades enable us to maintain high efficiency and quality throughout the production process, aligning with Industry 4.0 principles.

Are there any methodologies that you find helpful in accelerating the implementation of your recent process changes?

Six Sigma helps us identify and address process variations by creating measurement systems to achieve our targets. We use Six Sigma tools to implement these systems, allowing us to monitor critical points on the production line. By analyzing data from our equipment, we can make real-time adjustments and continuously improve quality.

Lean methodologies focus on optimizing our processes by eliminating waste and enhancing efficiency. Through Lean, we streamline workflows, reduce unnecessary steps, and ensure that every part of the process adds value, contributing to the overall success of the Elexon2Zero initiative.

Agile practices are applied across our business, particularly in project management. Agile allows us to adapt quickly to changes and manage projects more efficiently. By using Agile, we ensure that our initiatives are flexible, responsive, and aligned with our goals, which supports the dynamic nature of the Elexon2Zero program.

What are the key milestones of the Elexon2Zero program, and how do you plan to achieve them?

We have implemented rigorous quality control systems. At this stage, we are developing a new set of metrics and measurements specifically targeted around identified issues that we need to address. They are risk assessment-based. It’s still early days for us, but we anticipate a natural decline in the number of manufacturing process related returns, with improvements in our outgoing yield or first-time yield serving as initial indicators of progress. This is a complex project involving many parts of the production process. We are not expecting to see significant results in about six months or so, however, we are already seeing some early positive changes.

What challenges have you faced in implementing the Elexon2Zero program, and how have you addressed them?

One major challenge has been collecting accurate data to measure our processes. We need to ensure that data from manufacturing equipment is captured and integrated automatically. We are still working on perfecting this integration.

Another important topic is securing full staff engagement. Achieving our ambitious goals requires complete involvement from the entire team. Effective communication and collaboration across teams have been essential in addressing these challenges. Our staff wants to take pride in the work they produce. And because they strive to deliver perfect products to our customers, they are eager to participate, are engaged with the initiative, and clearly understand our goals. So far, we’re doing well on both counts.

How does Elexon Electronics distinguish itself from other electronics manufacturers, particularly with the Elexon2Zero program?

Mainly it is our commitment to quality, innovation, and sustainability, but also it’s a company culture that makes us unique and strong. In electronics manufacturing, having really great control over the right amount of solder paste being put on PCBs, is the root of most quality problems. If you get that right, then that brings good quality into the day.

Our cutting-edge manufacturing equipment, including a solder jet printer and vapor phase reflow oven, gives us superior quality. We’re always looking for incremental improvements through this new Elexon2Zero program.

And I mentioned the great company culture within our business. That means that we attract employees who stay for the long term, much longer than the average tenure rate you see today. The fact that we’ve designed the product and manufactured it for the customer is something that people take great pride in.

About John White

John White brings over 30 years of experience in electronics design, particularly in RF radio design, to Elexon Electronics. Having transitioned into operations and local management roles, including serving as Product Development Director with a US-based company working with businesses in San Francisco and Vancouver, John has a wealth of experience.

For the past eight years, he has specialized in delivering products for industrial wireless communications and machinery control. More recently, he held general manager roles in Australia, managing small to medium-sized businesses. Wanting to return to a more technical role, he joined Elexon to reconnect with his technical roots.

At Elexon, John handles customer engagement from initial contact to New Product Introduction, overseeing the entire product lifecycle. He’s also a key part of our Elexon2Zero program, educating customers about its benefits and positive impact.