Reliability Matters

This is the second of four episodes on the subject of soldering materials.

In today’s episode, continuing the subject of soldering materials, diving deep into the science, strategy, and subtleties behind one of the most foundational elements of electronic assembly: soldering materials. 

Joining me are two experts from KOKI Solder—Shantanu Joshi, Head of Customer Solutions and Operational Excellence, and Greg Starrett, General Manager of North American Operations. Together, they bring decades of experience in solder chemistry, process engineering, and real-world reliability.
 
We’ll explore how soldering materials influence long-term performance, how material and proc...

This episode is all about SMTAI, surface mount Technology International, taking place OCTOBER 19 - 23, 2025 at the DONALD E. STEPHENS CONVENTION CENTER in ROSEMONT, ILLINOIS. 

SMTA International is the premier gathering for innovation and collaboration in electronics assembly, surface mount technology, and advanced manufacturing.

This year, SMTAI is more than just a conference and expo. It’s an opportunity for experts, newcomers, industry leaders, and rising professionals to come together, exchange ideas, showcase breakthroughs, and shape the future of electronics manufacturing. 

Over several days, you’ll see deep-technical sessions, the latest research, hands-on exhibits, and, co-loc...

This is the first of four episodes on the subject of soldering materials.

In this episode, I’m joined by Chris Ward, founder and Managing Director of Solderking Assembly Materials Limited, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies.

Chris brings decades of experience in soldering materials and chemical formulations—and he’s built a company committed to performance, consistency, and innovation.

Earlier this year, Chris and his company were honored with the prestigious King’s Award for Enterprise in International Trade, recognizing their exceptional export growth. That recognit...

On this episode of Reliability Matters, we’re diving into a deceptively simple but incredibly important topic, humidity, and the massive impact it can have on electronic assembly reliability.

Joining me is Viktoria Rawinski, a seasoned expert in materials science and reliability engineering, whose career spans decades of hands-on experience in failure analysis, process optimization, and design-for-reliability practices. 

Viktoria is not only a respected voice in the industry, but also a passionate educator, known for breaking down complex technical issues into actionable insights.

In her two-part LinkedIn technical series, “Humidity – A Small Cause with a Huge...

Today, I’m joined by two of the most respected names in the electronics manufacturing industry, Phil Zarrow and Jim Hall. Together, they bring decades of hands-on experience and unparalleled insight into the challenges and solutions within our field.

Jim and Phil are the driving forces behind ITM Consulting, where they help manufacturers around the world improve processes, solve complex problems, and build more reliable products. 

Whether it’s soldering, cleaning, reflow profiling, process control, or failure analysis, these two have seen it all, fixed it all, and taught it all.

In this episode, we ta...

In this episode, we’re diving into a topic that’s rapidly reshaping our industry: Artificial Intelligence in PCB Design. Far from a futuristic concept, AI is already being integrated into advanced design tools—improving efficiency, reducing design iterations, and helping engineers tackle increasing design complexity with shrinking timelines.

Joining me today are two thought leaders who are at the forefront of this transformation:

First, we welcome back Stephen Chavez, a senior printed circuit engineer with more than 30 years of experience. Stephen serves as a Senior Product Marketing Manager at Siemens EDA, where he helps drive AI ado...

As the electric vehicle market accelerates, the reliability of the charging infrastructure becomes increasingly vital. Chargers that are down or malfunctioning can hinder adoption and erode consumer confidence. But who ensures these chargers stay up and running?

Today, we're diving into that very topic with a trailblazer in the EV service space. My guest is Kameale Terry, co-founder and CEO of ChargerHelp!, a company revolutionizing how we think about EV charger maintenance and reliability. 

Under her leadership, ChargerHelp! has pioneered Reliability as a Service, developed a highly trained and diverse technician workforce, and shaped industry policies a...

Today we're diving into a topic that keeps many executives awake at night—ERP implementations. More specifically, why so many of them fail and, perhaps more importantly, how to fix them midstream before they derail your operations.

Joining me today is someone who knows this space inside and out—Chintan Sutaria. Chintan grew up working in an EMS business from a young age, gaining firsthand experience in the unique challenges of our industry. His career path took him into the world of business process consulting at some of the largest Big 5 firms, and he has since worked with nume...

Today we're turning our attention to a cornerstone of modern electronics manufacturing: pick and place technology.

Joining me is Tim Kang, CEO of Hanwha Semitech Americas. With nearly two decades of experience in the electronics manufacturing space—starting as a mechanical engineer and now leading one of the top pick and place equipment providers—Tim brings a wealth of insight into what it takes to build reliable assemblies.

In this episode, we’re covering best practices for selecting the most appropriate pick and place machine, how to get the most out of your equipment, and the common...

Today we're exploring a concept that has deep roots in process safety and infrastructure management, but also has meaningful applications in electronics manufacturing: Damage Mechanism Reviews, or DMRs.

My guest today is Dheeraj Narang, a corrosion and reliability engineering specialist, process safety activist, and digital innovation researcher with an impressive track record across the energy sector.
Dheeraj has spent his career developing and implementing asset integrity programs for more than nine global energy companies across the U.S., India, and the Middle East.

He’s also a visionary advocate for using advanced technologies, industry best pr...

On this episode of the Reliability Matters podcast, I left my usual studio for the IPC APEX Expo in Anaheim California.

I interviewed two subject matter experts on topics related to electronic assembly.

My guests are:
Gerald Gardner, Global Product Manager at Weller, a manufacturer of hand soldering equipment fume extraction systems, and precision tools.

Mike Young – CEO OF SASinno Americas, a manufacturer of wave and selective soldering equipment.

More information on my guest's companies is available here:

SASinno Americas
https://www.sasinnoamericas.com
Weller

ht...

On this episode of the Reliability Matters podcast, I left my usual studio for the IPC APEX Expo in Anaheim California.

I interviewed three subject matter experts on various topics related to electronic assembly. My guests are:

Greg Beck, Director of Sales at Absolute EMS, a contract manufacturer.

Brian Watson, Co-Founder OF HyRel Technologies, a global provider of quick turn semiconductor modification solutions.

Keith Sweatman, Technical Advisor at Nihon Superior, a manufacturer of soldering materials.

More information on my guest's company is available here:

Absolute EMS
https...

Today, we’re diving deep into the world of electronics manufacturing from a unique vantage point—that of the press.  

My guest today is someone who has spent decades at the forefront of reporting on the electronics manufacturing industry. Mike Buetow, editor-in-chief of Circuits Assembly magazine, has covered everything from the latest technological advancements to the biggest challenges facing manufacturers today. 

If there’s a major trend shaping the industry, you can bet Mike has written about it, analyzed it, and spoken with the experts behind it. Mike is also the host of his own podcast, PCB chat...

This episode is a little different in two ways. First, I didn’t record it in my studio. I recorded it at the SMTA Pan Pacific strategic Electronics symposium, affectionately known as PanPac, in beautiful Maui Hawaii.

Each year, I record a Reliability Matters podcast at PanPac. Normally, the format of the show is I ask questions, and my guests provide answers. On this episode however, I decided to let my guest do all of the talking. 

The theme of this episode is Electronics: Down Memory Lane and a Vision for the Future. 

My thre...

Today, we’re putting the spotlight on a critical component in surface mount technology, the stencil. 
These precision-engineered tools are the unsung heroes of electronic assembly, playing a pivotal role in ensuring accurate solder paste deposition and, ultimately, the reliability of your circuit assemblies.

It's been long said that reliability begins at the solder print, and the print begins with the stencil.

Joining us today is Elias Malfavon Jr, President of Metal Etch Services, Inc. a stencil manufacturer operating in San Marcos California. Metal edge services was founded 20 years ago in 2005. 

We’ll explor...

Today, we're tackling a topic that has become increasingly vital in recent years: supply chain management. 

With global supply chains recently under immense pressure from disruptions, shortages, and growing complexity, the need for smarter, more efficient solutions has never been greater. 
And what better way to explore this than by discussing the cutting-edge role of AI-powered supply chain management software.

My guest today is Sebastian Schaal, the founder and CEO of Luminovo, a company at the forefront of transforming how supply chains are managed in the electronics industry. Sebastian Schaal is the founder of Luminovo, a l...

Today we’re diving into a critical yet sometimes overlooked component that powers so many of the devices we rely on: batteries. Batteries are the heartbeat of countless electronic products, from medical devices and electric vehicles to consumer gadgets and industrial systems. 

Choosing the right battery is not a one-size-fits-all decision. It requires a keen understanding of the application, performance needs, and environmental demands. The right selection can make the difference between a product that excels in reliability and one that, quite literally, fails to deliver.  But there’s more to batteries than just selecting the right chemistry or capa...

On this episode, we’ll dive into the world of electronics testing with an expert within the electronics testing industry, Robert Boguski,  President and Owner of Datest. 

Robert brings 44 years of experience in the design, fabrication, assembly, and testing of printed circuit boards (PCBs) and electronic systems. Under his leadership, Datest has become a premier provider of advanced, integrated PCBA testing and inspection services, serving both contract manufacturers and original equipment manufacturers since its founding in 1984. 

Robert's extensive background includes active participation in industry associations such as APICS, SMTA, and IPC, reflecting his commitment to advancing the f...

Today, we’re exploring a transformative topic: AI-based inspection technologies. 
 
Artificial intelligence is revolutionizing how we detect, analyze, and address defects in the electronics assembly process, combining precision with unparalleled speed to unlock new possibilities for efficiency and reliability.

Our guest today is a leading innovator in this field. Priyansha Bagaria is the founder and CEO of Loopr AI, a company at the forefront of AI-powered solutions for manufacturing inspection. 

Priyansha holds an MBA in International business and Global management, a bachelors of engineering degree in computer Science, and she held a fellowship in data s...

Today, we’re diving into one of the most transformative innovations of our time: electric vehicles and the vast infrastructure needed to support their growth. 

Joining us is Brian O’Leary, Global Head of of e-Mobility & Infrastructure at Indium Corporation, a leading expert with deep insights into the electronic assembly industry and its critical role in the EV revolution.

As electric vehicles continue to redefine the future of transportation, the reliability and scalability of the infrastructure that powers them—particularly public EV charging stations—have become pivotal challenges. 

The electronic assembly industry is at the heart...

Today we’re celebrating the end of another incredible year. 

This isn’t just any episode—it’s a time to reflect on the journey we’ve been on together, highlight some milestones, and share a heartfelt thank you to everyone who has made this podcast such a success. Can you believe it? 

Reliability Matters has now released 159 episodes! It feels like just yesterday we started this podcast with the mission to explore how industry experts and their knowledge contribute to the reliability of electronics. And here we are—growing, learning, and making a real impact in our field.<...

Today, I’m excited to introduce the hosts of the D-Code podcast, a dynamic trio of young professionals making waves in the electronics manufacturing industry. 

With experience rooted in contract manufacturing and stencil fabrication for electronic assemblies, they bring a fresh perspective to the table. Although they’re at the start of their podcasting journey, D-Code has already begun to attract attention, tackling industry insights with a unique lens that up-and-coming voices can uniquely offer. 

My guests today are Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, a contract assembler located in Aurora, Nebraska, Sean Kincaid, Presid...

On today’s episode, we’ll be exploring the critical steps to avoid contamination on circuit assemblies during the rework process with our expert guest, Gayle Towell. 

Gayle is the Content Marketing Specialist at AIM Solder, a leading global manufacturer of solder assembly materials for the electronics industry. She holds master's degrees in both mathematics and physics from the University of Oregon and has nearly two decades of experience in higher education, technical writing, and creative writing. 

In her role at AIM Solder, Gayle is instrumental in producing technical and research-based materials, while also collaborating with indust...

On today’s episode, we’re turning our focus to a pivotal innovation that has transformed design and manufacturing processes: flexible circuits.

Flexible circuits have emerged as a game-changer in the manufacturing and design of electronic assemblies. With their unique ability to bend, twist, and conform to complex shapes, they offer unparalleled advantages in applications where space is at a premium and reliability is paramount. 
From wearable technology and medical devices to aerospace systems and consumer electronics, the use of flexible circuits has expanded rapidly, bringing with it both opportunities and challenges.
In this episode, we’ll expl...

Today, I’m in Rosemont Illinois at SMTAI, Surface Mount Technology International. I’m in the Ultra-HDI Pavilion on the trade show floor. And what are we going to talk about here in the Ultra-HDI pavilion? Ultra high density interconnects, of course.

As the demand for smaller, faster, and more powerful devices grows, the need for innovative solutions in circuit design has never been greater. UHDI's represent a significant leap forward, allowing for more connections in a smaller space, pushing the boundaries of what's possible in electronic assemblies.

But what exactly are UHDI's? Essentially, they refer to c...

One of the most critical aspects of manufacturing high-reliability circuit assemblies is thermal profiling during the reflow process. 

Whether you're designing, engineering, or troubleshooting circuit assemblies, understanding how temperatures during the reflow process influences the quality and performance of your assemblies is essential. 

In this episode, we’ll break down what thermal profiling is, why it’s important, and how it affects everything from solder joint integrity to component placement. 

We’ll also explore the challenges and solutions involved in getting your thermal profile just right, ensuring your circuit assemblies are built to last in a comp...

If you're part of the electronics landscape, you've likely encountered the role contract manufacturers play — and it's a critical one. These specialized partners bridge the gap between design innovation and full-scale production, bringing efficiency, expertise, and flexibility to the table.

As companies seek to meet growing demand for advanced electronic products, contract manufacturers are increasingly relied upon to provide cost-effective, high-quality assembly services. Whether it's managing supply chains, ensuring compliance with industry standards, or accelerating time to market, their contributions have become indispensable. In today's episode, we'll explore how contract manufacturing works, why it's so vital, and what tr...

As the demand for more durable and dependable electronics continues to rise across industries, the choice of soldering materials, such as solder paste, plays a pivotal role in determining the reliability of these devices. We'll discuss how selecting the right solder paste can influence performance and longevity, and we'll hear from an industry expert about the latest advancements and best practices in soldering material technology. 

I guest today is Ebad Rehman, Regional Product Manager at MacDermid Alpha Electronics Solutions. He has a Master's degree in Technology from Illinois State University and has led multiple technical and strategic projects f...

Two episodes ago, episode 149, we talked all about automated optical inspection. Today we're exploring the impact of less automated inspection Technology, that being optical microscopes.
From commercial, class 1 electronics to high reliability class 3 electronics, the intricate electronic devices we rely on daily are assembled with astonishing precision. This precision wouldn't be possible without the aid of advanced optical microscopes. These remarkable instruments allow technicians and engineers to inspect, analyze, and ensure the quality of electronic components down to the minutest detail.

In this episode, we'll uncover how optical microscopes have impacted electronic assembly, enhancing productivity, ensuring reliability...

Statistics, at its core, is the science of making sense of data. From predicting trends and making informed decisions to ensuring quality control and optimizing processes, the applications of statistics are vast and varied. In the electronic assembly industry, where precision and reliability are paramount, statistical techniques become indispensable tools for engineers, manufacturers, and quality assurance professionals alike.

Join us as we unravel the complex yet captivating connections between statistics and the truth. We'll delve into real-world case studies, and uncover the statistical principles that ensure the decisions we make every day are based on facts, accurate data...

In today's episode, we're exploring automated optical inspection (AOI) and x-ray inspection technology within the electronic assembly industry.

Joining us are two experts who bring a wealth of knowledge and experience to the table.
Joel Scutchfield is the General Manager of SMT and Semicon Business Operations & Director of Sales at Koh Young, manufacturers of automated inspection and precise measurement systems with its headquarters in Seoul South Korea and R&D centers around the world. Joel has been with Koh Young for just under 10 years.

Jesper Lykke is the CEO at Viscom, a manufacturer of inspection...

Just like the famous line from the 1984 film, The Terminator, “I’ll be back”, SMTAI is back. Back to the Chicago area.

We’re back in Rosemont, co-located with the Assembly Show, at the Donald E. Stephens Convention Center, October 20-24.

Between SMTAI and the Assembly Show, there will be thousands of engineers and industry professionals in attendance.

The exhibit floor features hundreds of exhibitors showing off the latest technology. But the topic we're discussing today is the Technical conference and other planned events taking place at this year’s SMTAI.

This year, ther...

Recorded live in Anaheim California during the IPC Apex Expo.

This episode features three interviews including:
• Kimberly Fagan from PVA
• Taylor Wagan from CETEC ERP
• Neil Hubble from Akrometrix

Recorded live in Anaheim California during the IPC Apex Expo.

This episode features four interviews including:
• David Chiu from Test Research, Inc.
• Michael Dolan from South-Tek
• Dalton Dodge from Brooks Automation 
• Michelle Ogihara from Seka Machinery, Inc.

Recorded live in Anaheim California during the IPC Apex Expo.

This episode features three interviews including:
• Gus Mavrou from Seho
• Mark Stansfield from Solderstar
• Jesper Lykke from Viscom

The challenging world of electronics becomes even more challenging when the end product is destined for harsh environments. For high reliability products operating in a harsh environment, the quest for reliability is not just a goal—it's an imperative. These are not your everyday gadgets; often they're critical components of systems designed to operate under extreme conditions, where failure is not an option. From the scorching heat of desert landscapes to the unyielding cold of arctic tundras, from the high-pressure depths of our oceans to the radiation-filled expanse of space, the demands on these electronic products are as varied as th...

We’re the best, we’re number one, we’re better than them, we’ve won more awards than our competitors, we’ve all seen those ads. While this form of advertising isn’t unique, when’s the last time it caused you to buy a product based on the ad. I think we all know that answer.

There was a time when we relied heavily on print advertising to determine what products were available and from whom. The two primary methods to gain product awareness were print advertising and trade shows. While advertising and trade shows still exist, they ar...

We’ve discussed the silver tsunami on the show numerous times, the unprecedented rate of which employees are retiring. When engineers and other employees retire from companies, they take with them more than a set of gold cufflinks or an engraved plaque. In many cases, they also take with them wisdom and knowledge.

Perhaps this is never more true than in the case of my guest today. And who is that? My friend and colleague Doug Pauls.

Doug Pauls holds a B.A. in chemistry and physics from Carthage College, Kenosha, Wisconsin, and a B.S. in...

This episode was recorded at SMTA's Pan Pacific Strategic Electronics Symposium on the big island of Hawaii.

My guests on this episode are Dr. Chuck Bower, founder of PanPac, Keith Bryant, and Dr. Ron Lasky.

We discussed the history of PanPac, technologies introduced at PanPac, and what makes PanPac so unique. We also discuss Dartmouth College's unique engineering innovations program.

Optimization has become an important goal within the electronic assembly industry. While modern electronic assembly techniques utilize a variety of equipment, one specific type of equipment often consumes a disproportionate percentage of the overall equipment budget, that is the place machine. The cost of the machine, associated conveyors and feeders, require that the machine is running as often as possible.

The airline Industry refers to this as “wheels up” time. Airlines make money when the aircraft is in the air “wheels up”. On the other hand, anytime the wheels are down, the aircraft is not making money for the airl...