Part 1. Box Build Overview & Planning
This is the culmination of manufacturing—where components become the final, customer-ready product. It’s high-risk because functional, safety, and cosmetic quality converge here.
We cover the fundamentals for predictable flow:
- Complexity: Defined by interconnect density, sealing, and testing, not just part count.
- Readiness: Transforming the BOM into kits with traceability to eliminate shortages.
- Clarity: Using Work Instructions and Visual Aids to standardize manual assembly.
Mastering this stage turns complexity into a predictable, efficient production rhythm.
5.1 What is Box Build (System Integration)
Box Build, often referred to as System Integration or Final Assembly, is the manufacturing stage ...
5.2 Box Build Complexity Tiers and Risk Mandates
Classification of Box Build products by complexity is a mandatory exercise for accurate resource ...
5.3 BOM, Subassemblies & Kitting
Effective management of the Bill of Materials (BOM), sub-assemblies, and kitting is the most crit...
5.4 Work Instructions and Visual Aids
Effective Work Instructions (WIs) are the backbone of a high-quality Box Build operation, standar...
5.5 Assembly Flow Design
Assembly flow design is the process of structuring the physical sequence of work and allocating l...