Problems We Solve

When the problem crosses departments, the solution usually has to as well.

T&M Electronics helps small and midsize manufacturers improve struggling production and solve difficult electronics and assembly problems. We connect what happens on the factory floor with the engineering and implementation needed to make the improvement work.

Describe Your Problem See Common Problem Types

Common problem families

Find the cause—or get the known fix implemented.

Production is not hitting the numbers

The line or cell misses output targets, needs too much labor, or keeps losing time to the same problems.

  • Recurring stoppages, rework, or slow changeovers
  • One machine or operation holds back the whole line
  • Parts shortages interrupt an otherwise workable schedule
  • New products struggle to reach a stable production rate
What we investigate: actual cycle times, SMT programs and setups, equipment arrangement, product mix, material flow, and recurring quality or downtime losses.
What the project can deliver: a focused Kaizen effort, implemented program or layout changes, revised setup and replenishment methods, and a before-and-after review against an agreed production baseline.

Useful equipment has unsupported electronics

The machine still does its job, but a board, controller, or interface is becoming unavailable or difficult to maintain.

  • Replacement boards are discontinued or hard to source
  • Failures keep returning despite repairs
  • A purchased module or interface is no longer available
  • Replacing the whole machine would be a major expense
What we investigate: required functions, interfaces, documentation, component availability, firmware dependencies, and how a proposed change could be validated.
What the project can deliver: a feasibility assessment, a component or module substitution plan, or a scoped replacement assembly with agreed verification and documentation. The assessment establishes whether a practical replacement is possible.

The same awkward assembly is repeated on every unit

Each machine needs a collection of relays, timers, converters, terminal blocks, and hand wiring to perform a repeatable function.

  • Too much time is spent wiring and checking connections
  • Configuration or workmanship varies between builds
  • Troubleshooting requires tracing many individual wires
  • Small product options create large assembly differences
What we investigate: the repeated function, build time, connectors and interfaces, configuration needs, expected quantities, and assembly cost.
What the project can deliver: a simpler harness, interconnect PCB, or tested assembly using commercial modules, custom electronics, or both. Consolidation is proposed when its benefits justify development and support costs.

The prototype works, but only its developer can build it

The idea is proven, but repeat production still depends on individual adjustment, undocumented decisions, or parts chosen one build at a time.

  • Units need individual tuning or troubleshooting
  • The BOM, wiring, or build instructions are incomplete
  • There is no repeatable acceptance test
  • The next batch needs to be consistent and supportable
What we investigate: design readiness, component sourcing, assembly methods, critical adjustments, and the checks needed to accept a finished unit.
What the project can deliver: PCB/PCBA and harness definition, a controlled BOM, build documentation, functional test instructions, and prototype or low-volume assemblies within the agreed scope.

Kaizen and production improvement

Make a focused improvement. Keep building on it.

A defined improvement effortFocus on a specific line, cell, changeover, or recurring loss. Observe the work with operators and technicians, identify the constraint, implement agreed changes, and measure the result.
Sustained follow-throughUse scheduled reviews to address remaining losses, track actions, refine replenishment and setup methods, and keep quality, output, and material availability visible.
Measures that remain meaningfulAgree on the baseline and track output, labor per unit, downtime, or quality as appropriate. Record changes to production standards so improvement is not confused with a change in the target.

Good project fit

The best first projects usually have something concrete to investigate.

Existing equipment or productThe real system can be inspected, measured, photographed, or documented.
A measurable consequenceDowntime, labor, scrap, missed output, replacement cost, or support burden can be estimated.
A defined first scopeWe can agree on an investigation or an implementation task, the expected deliverables, and how the result will be evaluated.
A practical implementation pathThe solution can become a process change, released assembly, manufacturing package, or repeat part.

How an engagement starts

Agree on the work, the cost, and the next decision.

1

Show us the problem

Start with a nonconfidential description, business impact, quantities where relevant, and timing. We discuss confidentiality before reviewing sensitive technical files.

2

Scope the assessment or implementation

If key questions remain, we propose a paid assessment with an agreed scope, price or spending cap, schedule, and documented findings. If the work is already defined, we can scope implementation directly.

3

Implement, verify, and hand off

Further work is a separate decision. Agree on acceptance criteria, documentation, ownership, and support. The result may be an improved process, repeat assembly supply, or a manufacturing package for your team.

Practical delivery

Match the build and schedule to the project.

Prototype and low-volume assemblyCurrent in-house work centers on manual assembly, rework, and troubleshooting. Package types, quantities, and test requirements are reviewed before quoting. Machine assembly and packages such as BGA or QFN require an outside assembly plan.
Testing defined with the workInspection and functional checks are specified around the assembly and its intended use. Specialized equipment, fixtures, or external testing are identified during project definition.
Scheduled engagementBased in southeast Minnesota, T&M works remotely where practical, with onsite visits and follow-up arranged to suit the agreed scope. Availability is confirmed before a project is accepted.

Have one of these problems now?

Tell us what the equipment or product is, what is happening, and what the problem is costing you. You do not need to know the solution before contacting T&M.

Describe Your Problem