One Stop PCB Turnkey Solutions Turnkey Assembly Services For High Mix Orders
High-mix orders are the ultimate test of manufacturing agility. One order may contain 10 different board types—each with its own BOM, its own component set, its own assembly instructions, and its own delivery deadline. Traditional EMS providers reject these orders or impose punishing surcharges because their lines are optimized for single-product, high-volume runs. At Studio, we embrace high-mix orders. Our one-stop turnkey PCB assembly for high-mix orders is engineered specifically to handle multiple board types within a single order—efficiently, accurately, and cost-effectively. We consolidate BOM management, synchronize component procurement, and orchestrate production sequencing across multiple variants—delivering every board type together, on time, with full traceability. One order. Multiple board types. One delivery. One accountable partner.
| Characteristic | Example |
|---|---|
| Multiple board types in one order | 5 variants of control boards + 3 variants of sensor boards + 2 power boards |
| Diverse component sets per variant | Each variant has unique BOM; shared components across variants optimized for sourcing |
| Different assembly technologies | Mixed SMT/THT on some boards; pure SMT on others |
| Varying quantities per variant | 100 units of Variant A, 50 of Variant B, 20 of Variant C — all in one purchase order |
| Common delivery deadline | All variants required for a single shipment to the customer's facility |
| Unique test requirements per variant | Each board type requires its own test program, fixture, and acceptance criteria |
| High-Mix Challenge | How Studio's One-Stop Model Solves It |
|---|---|
| Coordinating multiple suppliers | One point of contact manages all variants — no vendor proliferation |
| Component overlap mismanagement | We pool demand across variants to negotiate better pricing and secure supply |
| Inefficient changeovers | Intelligent sequencing minimizes setup time between variants |
| Different lead times per variant | Synchronized scheduling ensures all variants complete together |
| Traceability across variants | MES tracks each variant uniquely under the same order umbrella |
| Complex packaging and labelling | We pick, pack, and label per variant — customer receives organized, sorted shipment |
We treat high-mix as a single order, not multiple independent jobs:
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All BOMs consolidated into a single material planning view
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Shared components identified for volume purchasing leverage
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Variant-specific components flagged and sourced individually
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Production scheduling optimized across the entire order
Sourcing components for 10 different boards is more efficient when managed together:
| Sourcing Strategy | How It Works |
|---|---|
| Volume pooling | Shared passives and standard ICs consolidated across variants for better pricing |
| Variant-specific sourcing | Unique components sourced per BOM |
| Single receiving point | All components arrive at our facility together |
| Unified inspection | Incoming verification performed on all parts simultaneously |
| Kitting per variant | Components organized by variant before production begins |
The order in which variants are produced directly impacts efficiency:
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Setup-minimizing sequence – Variants with similar component sets produced consecutively
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Priority-based scheduling – Highest-volume variants first, or deadline-critical variants prioritized
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Changeover optimization – Shared stencils and programs used where possible
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Real-time line balancing – Production adjusted dynamically if a variant faces unexpected delay
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In-process buffers – Completed variants held in staging until all variants are ready
Each variant receives its own quality verification, independent of others:
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Variant-specific inspection criteria – AOI and SPI programs loaded per board type
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Dedicated test fixtures – ICT/FCT fixtures for each variant, already developed and validated
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Individual yield tracking – Quality metrics captured per variant, not averaged across the order
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Defect segregation – Rework and repairs handled by variant
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Separate certification – Each variant receives its own CoC and test reports
The final step ensures your order arrives organized and ready for use:
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Per-variant packaging – Each board type packaged separately with clear labeling
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Consolidated shipment – All variants shipped in a single, coordinated delivery
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Master packing list – Complete inventory of all variants, quantities, and serial numbers
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Customer-ready arrival – Variants arrive sorted and identified—no sorting required at your dock
| Additional Service | How It Supports High-Mix Orders |
|---|---|
| BOM consolidation support | We help you identify component commonality across variants before sourcing begins |
| Variant-level costing | Transparent cost breakdown per variant for accurate product profitability analysis |
| SKU management | We manage your entire product portfolio's SKU database within our ERP |
| Future repeat optimization | Historical variant data stored for even faster turnaround on repeat high-mix orders |
| Kit-in-place programs | Pre-kitted components for each variant for next-order readiness |
| Your Scenario | Why One-Stop High-Mix Service Works |
|---|---|
| You manage a product family with multiple models | Different configurations for different markets — all assembled in one order |
| You support legacy and current products | Old board versions and new designs requiring parallel production |
| You are building systems with multiple PCB types | A single device may contain main board, power board, and sensor board — all needed together |
| You are testing multiple design variations | Different prototypes in one order for side-by-side comparison testing |
| You need consolidated inventory for a new product launch | All variant boards for initial production run shipped together |
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✅ One Order, One Schedule, One Shipment – No piecemeal deliveries or partial shipments
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✅ Consolidated Sourcing – Pooled purchasing power across variants reduces component costs
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✅ Intelligent Changeovers – Production sequencing minimizes downtime between variants
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✅ Unified Accountability – One team owns the entire order from sourcing through shipment
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✅ Per-Variant Traceability – Each board type tracked independently; full records for every variant
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✅ SKU Management – We manage your product portfolio's BOMs and assembly instructions
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✅ Repeat Order Efficiency – Once we've built your high-mix order, repeat orders are faster and cheaper
Stop treating multiple board variants as separate sourcing projects. With Studio's one-stop turnkey PCB assembly for high-mix orders, you get all your variants managed, manufactured, and delivered as one unified order—backed by a single accountable partner who understands the complexity of mixed-product assembly.
Contact us today. One order. Multiple boards. One delivery. Done
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