ShenTech Electronics: zero audit findings, 20-minute defect response
A high-mix PCBA contract manufacturer with 8 SMT lines in Shenzhen. Customer audits were failing — they needed traceability and SPC visibility fast.
0
Audit findings across 3 audits
20 min
Defect response (was 4 hours)
92%
First pass yield (was 87%)
8
SMT lines connected
The challenge
ShenTech runs 8 SMT lines producing boards for automotive, medical, and industrial customers. Each customer audit required weeks of manual data compilation — and the results weren't always passing.
- 1Incomplete component traceability. Panel serial-to-component lot linkage was manual and error-prone. Auditors found gaps in 2 of 5 sampled products.
- 2SPC data in offline spreadsheets. Solder paste inspection (SPI) and AOI data existed but wasn't connected to production events. No real-time control charts.
- 3Defect response was slow. When a customer reported a field failure, the quality team needed 4+ hours to reconstruct which boards were produced on which line, with which solder paste lot, at what reflow profile.
The solution
ShenTech deployed DFI Digital Twin to ingest real-time data from all 8 SMT lines — SPI, pick-and-place, reflow, and AOI machines — via OPC UA and MQTT.
The Quality & Traceability module provided SPC control charts connected to live production data, with automatic alerting when processes drifted. Panel-level genealogy linked every board to its component lots, solder paste batch, stencil ID, and operator.
The results
3 consecutive audits — zero findings
Automotive and medical device customers audited ShenTech in Q3, Q4 2025, and Q1 2026. All three passed with zero major or minor findings. The audit report generator produced complete traceability packages in minutes.
Defect response: 4 hours to 20 minutes
When a customer reported a solder joint failure, the quality engineer searched the serial number in DFI, pulled the full genealogy, identified the solder paste lot and reflow profile, and narrowed the affected batch — all in 20 minutes.
First pass yield: 87% to 92%
Real-time SPC on paste volume and placement offset caught drift before it produced defects. The team now addresses process shifts within minutes of detection, not at end-of-lot review.
“Our customers used to question our traceability. Now they hold us up as the benchmark.”
Quality Director, ShenTech Electronics
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