Resource Category: Best practices

Supply chain resilience has become a priority across high-reliability industries. Tier 1 organisations across Defence, aerospace, MedTech, and industrial technology are reassessing how manufacturing models affect operational risk, business continuity, and long-term supply stability. 

The difference between single-site and multi-site manufacturing is attracting greater attention as organisations look beyond production capacity and cost. Increasingly, the focus is on how quickly manufacturers can respond to disruption, maintain consistent production across locations, and reduce exposure to single-site risk. 

With global supply chains under pressure from geopolitical instability, freight disruption, labour shortages, and component shortages, procurement teams are placing greater emphasis on continuity planning and sovereign manufacturing capability during vendor evaluation. 

For Circuitwise Group, this reflects growing demand across Australia and New Zealand for regional manufacturing capability supported by consistent quality systems, responsive engineering support, and reduced exposure to offshore supply chain risk. 

Why single-site manufacturing still appeals 

Single-site manufacturing remains the right model for many programs, particularly where a trusted facility already delivers strong quality performance, clear accountability, and dependable service. Running production through one site can simplify communication, governance, inventory management, and quality control, while keeping engineering, production, testing, and logistics closely aligned.  

For many organisations, that model is entirely appropriate when supply chain exposure is manageable, continuity risks are low, and the product is not so mission critical that production interruption would create significant operational or regulatory consequences.  

The key point is that single-site manufacturing is not inherently a weakness. Where a supplier is performing well and the risk profile supports it, a one-site model can remain efficient, stable, and commercially sensible. 

Why multi-site manufacturing is gaining traction 

Many Tier 1 organisations are placing greater emphasis on manufacturing models that improve flexibility and continuity. Organisations increasingly view multi-site manufacturing as part of a broader resilience strategy rather than additional production capacity.  

For many high-reliability businesses, partnering with a manufacturing group that has multi-site capability can offer a stronger resilience model than relying on two separate suppliers. It provides added continuity and flexibility while retaining a consistent commercial relationship, scalable production, aligned quality systems, common governance, and reduced operational variability. 

Greater operational resilience 

If additional continuity support is required, organisations may also distribute production capability across multiple sites within the same manufacturing group. This can reduce downtime and speed up recovery during unexpected events. 

That continuity matters, especially for organisations managing long product lifecycles or critical infrastructure programs. Programs can continue to operate through a primary site and client team, with additional site capability brought in only when agreed as part of continuity or scale planning. 

Circuitwise Group has expanded its regional manufacturing footprint specifically to strengthen this type of resilience, with facilities operating across Sydney, Brisbane, Auckland, and Christchurch. This regional footprint gives the Group greater manufacturing flexibility, deeper engineering capability, and stronger continuity planning across Australasia. 

Increased supply chain flexibility 

Multi-site operations provide greater flexibility across logistics, scheduling, and customer support. Regional manufacturing capability can also reduce dependence on international freight networks and offshore production hubs. 

This has become increasingly important for organisations seeking local manufacturing partners that can support design collaboration, responsive communication, and reliable delivery across Australia and New Zealand. 

Circuitwise Group supports this through a connected manufacturing network spanning Australia and New Zealand. By combining the capabilities of Circuitwise Electronics, IntelliDesign, Nautech Electronics, and ASL, the Group provides electronics manufacturing, embedded design, PCBA, box-build assembly, testing, and product development services under shared quality standards and engineering-led processes. 

Scalable production support  

Multi-site models can support growth more effectively. As production requirements increase, manufacturers with broader operational capability are often better positioned to manage changing workloads without overloading a single facility. 

For high-reliability sectors, scalability is not just about volume. It is about maintaining quality, traceability, and process control as production evolves. 

Multi-site manufacturing only works when systems stay consistent 

Despite the advantages, some organisations remain cautious about multi-site manufacturing arrangements. Concerns often centre on quality consistency, documentation control, pricing complexity, and process alignment across facilities. 

These concerns are valid; however, multi-site manufacturing can actually improve resilience when quality systems, documentation control, and engineering processes remain aligned across every location. 

For high-reliability sectors, consistency matters just as much as redundancy. Without aligned systems, additional sites can introduce variability instead of reducing risk. 

Shared quality frameworks, standardised manufacturing processes, aligned inspection procedures, and controlled documentation help maintain consistency across ANZ operations. 

Supporting this approach are ISO 9001, ISO 13485, ISO 14001, and AS 9100D-certified systems that help maintain: 

• standardised manufacturing processes 
• controlled change management 
• full traceability 
• aligned inspection and testing 
• consistent documentation controls. 

This operational alignment helps customers reduce single-site risk without compromising quality, traceability, or regulatory expectations. 

Resilience is becoming part of manufacturing strategy 

As organisations reassess supply chain exposure, they’re finding that flexibility, continuity planning, and regional manufacturing capability are increasingly important. 

Organisations recognise that manufacturing resilience is part of long-term business and supply chain strategy and risk mitigation. 

Circuitwise Group helps customers reduce single-site risk through a connected ANZ manufacturing network that combines consistent quality systems, traceability, and engineering support across multiple facilities. 

The Group, consisting of Circuitwise Electronics, IntelliDesign, Nautech Electronics, and ASL, supports high-reliability sectors that require operational resilience and manufacturing consistency. 

If you are scaling production, entering new markets, or formalising continuity planning, speak with Circuitwise Group about how its connected ANZ manufacturing network can support your long-term production requirements.

Circuitwise specialises in scalable manufacturing solutions for complex electronics, supporting growth from early builds through to sustained production. We collaborate closely with a group of valued partners who need precise manufacturing, full traceability, and to meet regulatory requirements across long and complex product lifecycles. These clients develop technologies that must function over time reliably, withstand scrutiny from auditors and regulators, and align with strict engineering and documentation standards. Many of them operate in MedTech, Aerospace, Defence, or Industrial sectors, where device failure carries significant consequences and production missteps cost time and money. A supplier focused on short-term throughput or one-off builds introduces too much risk. 

Circuitwise takes a different approach. We form long-term partnerships that let both sides operate with clarity, stability, and trust from the start. Here are five ways Circuitwise builds partnerships—not transactions—to deliver better outcomes: 

1. We start with in-depth onboarding 

Circuitwise treats onboarding as a structured process that defines how we work together; it’s not a simple box-ticking exercise. We invest time to understand your product, user environment, regulatory landscape, and full production context so we can anticipate risks early and align expectations before we start production. 

Our onboarding process includes: 

• reviewing design documentation for manufacturability, testability, and sourcing feasibility 
• evaluating your bill of materials (BOM) for availability, lifecycle status, and risks such as single-source parts 
• understanding how we’ll test the product and document the results 
• clarifying responsibilities, especially in programs with multiple development partners 
• agreeing on a change management process and communication expectations 
• identifying specific regulatory and quality system requirements, including compliance with ISO 9001, ISO 13485, and AS 9100D frameworks
• confirming applicable workmanship standards, such as IPC Class II or IPC Class III, based on the product’s reliability and performance requirements.

We use this information to build a solid foundation for production, and we avoid assumptions and address any misalignment at the beginning. That saves time later, reduces the risk of delays, and gives both teams confidence in how we’ll manage the project. 

2. We work with fewer clients on purpose 

Our team focuses on fewer programs so we can stay responsive, accessible, and consistent. That means you speak with someone who knows your project in detail when you call us.  

This approach suits clients who care about reliability and risk reduction. Our clients often deal with regulators, internal compliance teams, or downstream partners who require proof that our manufacturers build devices correctly and consistently. That level of accountability needs a different kind of supplier relationship, and we are structured to provide it. Our proven systems, certified processes, and a track record of successful audits and launches reinforce our capability to meet scalability and regulatory compliance needs when our clients need to pivot or increase their workloads. 

3. Our compliance systems guide how we operate  

Circuitwise is certified to ISO 9001, ISO 13485, and AS 9100D standards, with each one defining a specific role in how we work. ISO 9001 supports consistent quality across all our systems, ISO 13485 applies to our MedTech projects and supports regulatory compliance in Australia and international markets, and AS 9100D includes additional requirements for aerospace and Defence, such as stricter documentation, traceability, and configuration controls. 

We apply these standards at every stage as we build, test, and deliver reliable electronics. For each project, we track: 

• all components, including batch numbers and supplier traceability data
• process steps, inspection outcomes, and test reports  
• operator IDs, equipment calibration records, and environmental conditions 
• any deviations, non-conformances, or rework with appropriate root cause and resolution documentation. 

We use a dedicated document control system that aligns all records to the correct version, and we never build against outdated specifications. We log and review every update, and provide full traceability data, so you can complete your device history file, support internal audits, or respond to regulator queries. 

We avoid temporary workarounds and undocumented changes by following a controlled process for every update that protects both you and us. 

4. We support the full product lifecycle  

Circuitwise’s involvement doesn’t stop once you approve a design. We support clients across early prototyping, pre-production, certification runs, and long-term manufacturing. We also provide sustained support when parts become unavailable or when regulatory frameworks change. 

We can help with: 

• transitioning from design to production 
• managing component obsolescence and finding compliant alternatives 
• updating documentation to reflect real-world learnings 
• supporting design changes based on field feedback or audit outcomes 
• providing advice on new product variants, test coverage, or documentation improvements. 

This continuity matters. You shouldn’t have to re-explain your product every time you make a product update, so we stay involved to implement updates faster and with lower risk. 

5. We act as a technical manufacturing partner 

You already have engineers, designers, or development partners; Circuitwise isn’t here to replace them. Our role is to bring a manufacturing perspective to every decision that affects production. 

That includes: 

• reviewing layouts for solderability, inspection access, and component placement 
• flagging test coverage gaps or ambiguity in test specifications 
• raising concerns about component tolerances or supplier reliability 
• helping validate design changes before we move them into production. 

We treat this as a collaborative process, with a goal to identify risks before they affect outcomes. We don’t push back without reason, and we provide specific input based on experience and evidence. A more stable and predictable manufacturing process results when both teams follow this approach. 

We focus on programs where quality matters most 

We work best with clients who value reliability and long-term collaboration. The companies we partner with usually need: 

• proven traceability and well-maintained documentation 
• flexibility across development and production ramp-up 
• fast responses to quality issues, design changes, or supplier risks 
• a relationship focused on long-term outcomes, not short-term throughput.

We don’t treat manufacturing as a handover. We stay involved to bring stability, predictability, and insight to every phase of your program. Our team is structured, trained, and resourced to support complex, high-value programs from early development through to long-term production.

We’re prepared to support what comes next if you see quality as non-negotiable. Get in touch to discuss your next build. 

The term “Australian made” can be a powerful driver of a manufacturing company’s brand, especially when your value proposition involves something more than being the cheapest product around. Many products are functionally equivalent and smart companies look for some sort of emotional selling strategy rather than just relying on purely functional or logical selling points.

Commercial and operational factors will always be powerful drivers of a purchase decision, when all other attributes of a product are roughly equal, promoting your product as Australian-made can be the key differentiating factor. Following are some key brand related reasons to manufacture locally and emphasise with your customers:

1. Supporting the Local Economy
   By choosing Australian manufacturers, you help stimulate the local economy by creating jobs, supporting businesses in your supply chain, and contributing to the country’s GDP. This investment fosters broader community development and supports families. Manufacturing domestically helps retain specialized manufacturing skills in Australia. This ensures that Australia maintains a competitive and innovative manufacturing ecosystem, which benefits the entire industry. You help maintain a strong industrial base within Australia, which benefits all businesses by ensuring access to high-quality suppliers and services. In addition, money spent on local manufacturing has a ripple effect, as it flows back into the community through employee wages and business-to-business transactions, supporting a vibrant local economy.
2. Align with the sovereign capability agenda
   The Australian government is actively encouraging the growth of a sovereign capability in many strategic industries, including semiconductors and related products. Being seen to support national priorities can only enhance your brand in the Australian market. Some government departments, such as Defence, insist on Australian manufacture for reasons related to national security.
   An even larger number of Australian companies are now asking for at least one of their manufacturing sources to be in Australia, to ensure their supply chain stability. Being Australian made enables you to target this strategically important market segment.
3. Be part of the social good movement
   Social good companies are on the rise and Australian manufacturers adhere to strict labor laws that ensure fair wages, safe working conditions, and workers’ rights. By manufacturing locally, your business avoids the reputational risks associated with poor labor practices in some overseas markets. Supporting ethical practices through local production demonstrates your company’s values, building trust with customers and stakeholders.
4. Preserving Industry Expertise and Skills
   By manufacturing locally, you contribute to the development and preservation of critical manufacturing skills within Australia’s workforce. This is vital for fostering innovation and maintaining the competitiveness of the manufacturing industry. Local manufacturing ensures that specialized knowledge remains accessible, allowing for ongoing advancements in technology and production processes. Combating the long term decline in our manufacturing sectors starts with choosing to manufacture locally.
5. Be seen as the safe bet
   Another powerful element of brand is being seen as the safe bet. The COVID-19 pandemic highlighted the vulnerabilities of global supply chains and local manufacturing significantly mitigates the risks of relying on an overseas supplier. Local suppliers are not subject to sudden policy changes or tariffs imposed by foreign governments, providing more predictable and secure operations.
   In the past, manufacturing overseas was seen as the smart move but that is changing as more companies see the value of choosing the safest option for critical partners in their supply chain.

Manufacturing locally in Australia enhances more than just your bottom line—it builds your reputation, strengthens your brand, and contributes to community and national resilience. Supporting the local economy, aligning with consumer values, upholding ethical practices, and reducing sovereign risks all contribute to a narrative of trustworthiness and forward-thinking. These benefits make local manufacturing an excellent strategic choice for businesses committed to long-term success and sustainable practices.

Contact us to discuss the benefits of manufacturing in Australia.

This is the 4th article in a four-part series highlighting the benefits of local manufacturing.
Part 1 – The commercial case for manufacturing locally
Part 2 – Operational agility requires local collaboration
Part 3 – The environmental imperative for local manufacture
Part 4 – Why local manufacture matters for your brand – this post

Increasingly stakeholders in every stage of a product’s value chain are demanding environmentally sustainable manufacturing practices – from customers to government regulators. Local manufacturing aligns with sustainable practices by reducing environmental impacts associated with production and distribution. Following are five key reasons to manufacture locally:

• Reduced shipping emissions: Producing goods locally reduces the need for long-distance transportation for products sold or assembled in Australia, thereby decreasing greenhouse gas emissions. While components still need to be shipped to Australia and NZ, as we generally don’t manufacture such items here, these are largely shipped in bulk, translating to environmental efficiencies.
• Reduced travel emissions: Managing foreign suppliers requires at least a few visits to get your production quality up to speed. Typically, you will conduct on-site inspections for initial assessment, contract negotiations, and expectations setting. If your product’s value proposition is based on high reliability, you may need to visit the manufacturing site frequently for audits, product development collaboration and troubleshooting. Periodic follow-up visits are advisable to maintain a good working relationship and communication. Keeping your travel local within your city or country dramatically reduces emissions from air travel.
• Energy-efficient equipment: At Circuitwise, we install the most advanced manufacturing technologies possible to remain competitive with foreign manufacturers. The latest technology is also the most energy-efficient, as equipment suppliers are constantly under supply chain pressures to improve their technology’s environmental footprint. Low-cost Asian manufacturers, on the other hand, are incentivised to minimise their capital expenditure to maintain their low-margin profits.  These practices minimise energy consumption and reduce the overall environmental footprint of production activities.
• Environmentally friendly components: Some substances are so environmentally toxic that they have been banned in some jurisdictions, such as the European Union’s Restriction of Hazardous Substances (RoHS) Directive. In addition, some of the minerals used in semiconductors are so rare that they have driven the development of hazardous mining practices in countries with poor or no regulation, as in some African countries. These so-called “conflict minerals” include Tantalum, Tin, Tungstun and Gold. Circuitwise audits its component suppliers to ensure they comply with RoHS rules. By contrast, in Asia, substituting counterfeit parts for the original RoHS-compliant component is common, especially among the cheapest manufacturers. For assurance of original componentry and environmental compliance, Australian or NZ-made is a must.
• Responsible management of e-waste: Australian and NZ companies are strictly bound by local regulations to responsibly manage e-waste. In addition, the European Directive on Waste Electrical and Electronic Equipment (WEEE) and the REACH Regulation on chemical waste disposal and recycling demand companies marketing products in the European Union ensure their manufacturers follow stringent environmental guidelines. Circuitwise’s quality management system is set up to ensure compliance with these. It’s hard to be sure how strictly Asian suppliers follow these directives, even if they say they are. By contrast, Circuitwise aims to minimise the production of any waste at all by targeting the highest possible yield.

Contact us to discuss the benefits of manufacturing in Australia.

This is the 3rd article in a four part series highlighting the benefits of local manufacturing.

Part 1 – The commercial case for manufacturing locally
Part 2 – Operational agility requires local collaboration
Part 3 – The environmental imperative for local manufacture – this post.
Part 4 – Local manufacture will build your brand

Australian manufacturers generally compete on the basis of the value delivered by highly innovative products that are quickly brought to market before copycat competitors attack older models. In this context, operational excellence is more about agility than operational efficiency, although efficiency remains essential. Following are the key operational reasons it makes sense to manufacture in Australia and choose a local contractor to supply your electronic PCB assemblies.

1. Enhanced Communication

Proximity to your manufacturing partner enables direct and timely communication. Face-to-face meetings and on-site discussions allow for immediate clarification of requirements and issues.

Misunderstandings due to language and cultural differences are also dramatically reduced. A key cultural problem is the tendency of Asian manufacturers to only tell you what they think you want to hear and to be respectful to the point of not being helpful. They will be reluctant to say “no”, leading them to say yes to unrealistic deadlines or manufacturing tolerances. They may also be reluctant to proactively suggest improvements to your manufacturing processes. At worst, they can make errors and be reluctant to admit or correct them for fear of losing face. These cultural issues are far less prevalent in Australia.

At Circuitwise, we believe we are far more responsive and collaborative. By contrast, Asian manufacturers are renowned for doing everything they can to win a contract, after which the responsiveness steadily declines. Customers often come to us for quotes after not hearing from their Asian manufacturers for weeks. Of course, some foreign manufacturers are better than others, but it takes a considerable investment in time and many expensive foreign trips to build a trusted relationship.

2. Superior Quality Control

Local manufacturing allows for regular on-site audits, real-time troubleshooting and refinement of production processes. While quality control is mandatory for most manufacturing organisations, regardless of country, not all quality systems are equal. For example, Circuitwise has invested heavily in computer systems with a level of sophistication that is hard to match.

It’s also much easier to work with local manufacturers to define what you need in terms of traceability systems and maintenance of records, in the knowledge they can be relied upon. To gain that level of reliability in Asia requires strict auditing and a lot of overseas flights to keep off-shore manufacturers accountable. While these problems can be overcome by big-volume consumer electronics brands from Western countries, they come at a cost that is not affordable for medium-sized businesses. 

A final factor is all the intangible factors, such as conscientiousness. These factors are hard to prove but nonetheless real. For example, an often-undervalued metric is the stability of our workforce. At Circuitwise our staff have an average employment of over 10 years. By contrast, Asian manufacturers have a high churn rate in their workforces, particularly after the Lunar New Year holidays, with a corresponding dip in quality as newcomers are onboarded. Our loyal workforce leads to pride in work, active contribution to continuous improvement, and a level of conscientiousness that translates to reliability and quality in your Australian-made product.

3. Smoother New Product Introduction

Proximity to local manufacturers facilitates rapid prototyping, allowing for quick iterations and refinements of designs. This agility accelerates the development cycle, enabling faster identification and resolution of potential issues before full-scale production. The ability to prototype and test new designs quickly is a key advantage of local PCB manufacturing, supporting innovation and reducing time to market.

Introducing new designs into production is a complex process where early collaboration with your manufacturer pays enormous dividends. Local manufacturing partners can provide design-for-manufacture (DFM) advice that can make or break the per-unit profitability of your product.

For example, putting all heavy components on one side of a PCB may be best to facilitate easier passage through the reflow oven. This design choice needs to be made early, and DFM collaboration with your manufacturer is key to that.

Beyond DFM, there is a lot of “devil in the detail” at the heart of a smooth new product introduction. For example, rigour in controlling revisions and ensuring the final production version is fully documented is critical. Building a close relationship with a local manufacturer will ensure the volume production process is robust and wholly owned by both your own team and your contract manufacturing partner.

4. Faster time to market

Manufacturing locally significantly cuts down on shipping times and logistical complexities. For companies that value speed of delivery, manufacturing in-country brings obvious benefits. In-country shipments are not subject to strict custom rules and regulations that not only add cost but can introduce delays. A simple mistake with incorrectly completed forms can see parts and shipments stopped or returned. 

Another overlooked benefit of retaining all elements of your supply chain in-country is that the major holiday periods across your supply chain are aligned. Manufacturing in Asia requires a balancing act when their major holiday periods clash with your peak production schedules.

Faster turnaround times are a vital advantage in competitive markets, enabling businesses to maintain production timelines and respond to market demands efficiently.

5. Flexibility in Production Scaling

Local manufacturers can more readily accommodate changes in production volume, whether scaling up for a large order or scaling down during slower periods. This flexibility ensures that your manufacturing capabilities align closely with market demands, optimising resource utilisation and reducing unnecessary costs. The scalability of automated production lines allows businesses to adapt quickly to fluctuating demand, maximising resource utilisation and enhancing overall operational agility.

For example, a Circuitwise customer Adapt Ideations recently introduced a complementary mass charging product to support its flagship asset tracking and monitoring device. The mass chargers were low volume, and they did not want to go through the hassle of dealing with an Asian manufacturer.

Adapt Ideations’ Co-Founder and Director Anirban Gupta said he had wanted to “diversify our supply base to deliver supply chain security and improve the sustainability of our operations as we move forward. We are looking to do more manufacturing in Australia and look forward to working more with Circuitwise in the future.

Choosing to manufacture your PCBAs locally in Australia offers substantial operational benefits as outlined above. These advantages not only improve operational performance but also provide a competitive edge.

Contact us to discuss the benefits of manufacturing in Australia.

This is the 2nd article in a four part series highlighting the benefits of local manufacturing:
Part 1 – The commercial case for manufacturing locally
Part 2 – Operational agility requires local collaboration – this post
Part 3 – The environmental imperative for local manufacture
Part 4 – Local manufacture will build your brand

Four years after the onset of the COVID-19 pandemic, the impacts on Australia’s manufacturing ecosystem continue to reverberate, and there is a slow but steady trend towards increased manufacturing in Australia.

Earlier this month, the Australian government passed its $22.7 billion Future Made in Australia legislation, and it is timely to revisit the core rationales for manufacturing locally in the context of that significant milestone. Following is the first of a four-part series examining the benefits of local manufacturing. The four parts cover commercial, operational, environmental and brand reasons for manufacturing locally in Australia or New Zealand.

While many manufacturers are motivated by operational, environmental, and brand reasons, the bottom line for most companies will always be commercial. Many perceive that manufacturing in Asia is cheaper and the smart thing to do. However, there is a growing sentiment that the smart move is to manufacture locally. Following are six commercial reasons to manufacture locally.

• Better IP protection: Australia has a robust legal framework protecting intellectual property rights. Keeping your manufacturing local significantly reduces the risk of intellectual property theft or infringement, which can be difficult and costly to enforce in international courts. This legal security safeguards your innovations and gives you peace of mind.
• Faster time to market: Being geographically closer to your manufacturing facility allows for quicker production cycles and easier communication. Proximity means you can respond to changing market demands and trends faster, giving you a competitive edge and potentially increasing your market share.
• Access to grants: The Australian government offers various grants and incentives to support local manufacturing and innovation. These programs can fund research and development, capital expenditure, and skills training, making local manufacturing a more financially attractive option.
• Reduced uncertainty: Manufacturing locally helps you avoid disruptions caused by international trade disputes, geopolitical tensions, sanctions, or sudden policy changes in other countries. Local manufacturing ensures more stable operations and reliable supply chains, allowing more assured business continuity.
• Lower tariffs and duties: When manufacturing in Australia, you eliminate many tariffs and customs duties that can significantly inflate costs when importing goods manufactured abroad. Lower tariffs and duties can result in substantial cost savings and improve your profit margins.
• No compliance surprises: Australian manufacturers are already familiar with and operate under Australian standards and regulations, including those related to electromagnetic compatibility and product safety. Local expertise reduces the risk of non-compliance penalties, production delays, and potential damage to your brand reputation.

Talk to us at the Circuitwise group of companies about savings that can be gained by manufacturing locally in Australia or New Zealand.

This is the 2nd article in a four part series highlighting the benefits of local manufacturing:
Part 1 – The commercial case for manufacturing locally – this post
Part 2 – Operational agility requires local collaboration
Part 3 – The environmental imperative for local manufacture
Part 4 – Local manufacture will build your brand

Not all Quality Management Systems (QMS) are created equal. While compliance with quality management standards ensures the foundational requirements for quality, there is a broad spectrum of rigour in how companies implement their QMS. The difference is mainly in how seriously companies commit to continual improvement.

Most companies do the minimum. For example, under the AS 9100D certification for aerospace and defence manufacturing, companies must complete a Process Effectiveness Assessment Report (PEAR) for every process. However, at Circuitwise we are embracing the concept of maturity models and we want to support our customers to do the same.

Maturity models help organizations strive for the highest level of optimization and operational excellence, moving toward perfection in quality. If you’re an original equipment manufacturer (OEM) or product developer, understanding and applying maturity models can significantly enhance product quality, efficiency, reliability, and customer satisfaction.

This article explains the concept of maturity models and how they apply in manufacturing electronics products.

What are quality maturity models?

Maturity models provide a structured framework to evaluate the current state of processes and systems, offering clear pathways for improvement. While there are many QMS maturity models available, they typically assess organizations across several levels of sophistication:

1. Initial/Reactive: Processes are unstructured and inconsistent.
2. Managed: Basic processes are established but not fully optimized.
3. Defined: Standardized processes align with quality standards like ISO 9001 or AS9100.
4. Quantitatively Managed: Performance metrics and data analysis drive decision-making.
5. Optimized: Continuous improvement and innovation are embedded in the organizational culture.

Many famous maturity models, such as the Baldridge Performance Excellence Model, are broadly applicable across any industry. However, many industries develop their own models, and Circuitwise is exploring options relating to its core industries, including medical devices and aerospace. We look at one specific example below.

A maturity model for aerospace

The Aerospace Improvement Maturity Model (AIMM), developed by the International Aerospace Quality Group (IAQG), is specifically designed to help aerospace organizations move beyond compliance with the AS9100 family of standards. AIMM encourages organizations to:

• Conduct self-assessments to evaluate the maturity of their QMS.
• Focus on areas of improvement tailored to their business needs.
• Set measurable targets to enhance process effectiveness and customer outcomes.

AIMM is organized into 26 modules spanning general management subjects such as leadership and communication, through to very specific subjects such as prevention of counterfeit parts. Each module addresses specific clauses of ISO 9001/AS9100. For example, Module 4 (shown below) focuses on understanding the Context of the Organization, helping businesses align their QMS with internal and external factors.

Each module uses a structured assessment to evaluate two critical dimensions:

1. Process Presence: Is the process clearly defined, documented, and implemented?
2. Process Effectiveness: Does the process deliver the intended results?

This dual approach mirrors the Process Effectiveness Assessment Report (PEAR), which is a cornerstone of AS9100 certification. Poor ratings in these areas indicate opportunities for targeted improvements.

Circuitwise’s approach to QMS maturity

At Circuitwise, we informally use AIMM principles as a baseline to optimize our QMS. By integrating these practices into our PDCA (Plan-Do-Check-Act) improvement cycle, we continuously refine our processes to meet and exceed industry expectations. This proactive approach differentiates us from competitors by:

• Ensuring every process is not just compliant but effective and aligned with customer needs.
• Driving continuous improvement through structured assessments.
• Leveraging insights to minimize risks and maximize efficiency.

Start your quality maturity journey today

Whether you’re new to quality systems and exploring ISO 9001/AS9100 certification or looking to enhance your existing QMS, maturity models like AIMM can provide the clarity and direction you need to succeed. At Circuitwise, we’re here to guide and support your journey toward excellence in product quality. This commitment to refining our QMS to its fullest potential sets Circuitwise apart, ensuring we consistently deliver exceptional value to our OEM and product development partners.

If your project involves developing electronics for aviation, space or defence applications, you must comply with the AS 9100D quality management standard. The easiest way is to use suppliers that are already certified to that standard, as Circuitwise is for electronics manufacturing.

To understand your regulatory obligations, it is best to take a step back and examine quality management systems in general, as set out by the ISO 9001 standard.

Most people understand that quality management systems are about identifying and managing the processes used to deliver a product or service. These processes include planning actions, monitoring them, checking the results, and then continually improving the system.

ISO 9001 is broadly applicable in any industry and aims to deliver consistent quality. AS 9100D narrows this applicability to the needs of the aerospace industry.

For example, while both standards require risk management processes to address risks, AS 9100D has some more specific requirements relating to safety, performance, and airworthiness. A greater emphasis on human factors heightens the focus on training, competence, and situational awareness for all team members.

Similarly, AS 9100D emphasises the role of materials, processes and traceability of parts in delivering safety and requires much stricter controls over these. For electronic devices, this relates to the components and manufacturing processes.

In particular, aerospace applications demand that all parts used in a product be genuine, with processes to verify their authenticity. So, the standard requires stringent controls to prevent counterfeit parts from being used.

Similarly, the risk management process for aerospace applications places a much greater emphasis on any “special requirements” aerospace manufacturers may have, as they are usually very demanding and challenging to meet.

Particular attention must be paid to critical items that have a significant effect on the provision and use of the product, including the safety and performance of the device. Such critical items can include factors that affect the item’s service life or the risk of fracture leading to failure of the item. 

When products are being developed, there are usually several different iterations and prototypes before the product is finalised. For example, components may change from one version to the next, even after the product has been launched to the market. AS 9100D requires explicit configuration management controls to be in place, which the more general ISO 9001 does not.

Like its close cousin, the ISO 13485 quality management standard for medical devices, AS 9100D has very prescriptive requirements for documentation of all processes and retention of records. This can be as detailed as measurement data from suppliers (on parts) to operator witness marks on every single screw.

AS9100D rules out any reliance on trust or belief that something was done; it must be proven to have been done. This documentation will be scrutinised during audits and, in the worst case, investigations into a failure.

This is just a brief overview of what is a very detailed standard. For more information, view our Aerospace page or contact Circuitwise to understand how our quality management systems can help you comply with your AS 9100D obligations.

Product developers should take note of a warning on rampant commercial espionage by China, issued by the “Five Eyes” group of national intelligence chiefs. At an unusual public meeting in the US, the group warned of the “most sustained, sophisticated and scaled theft of intellectual property (IP) and expertise in human history” making it the number one threat to innovation today, with cyber-attacks aimed at stealing IP occurring about every 12 hours.

What drew Circuitwise’s attention was the example given by Australia’s ASIO director-general Mike Burgess that described the theft of hardware designs and firmware for an electronic product “similar to a motion detector” that is very typical of the kind of products we manufacture on behalf our clients.

According to an article published on ABC News and other media outlets, an Australian company with a globally successful product suddenly found their sales plummet when an identical but cheaper and inferior quality replica started being sold out of China. The IP theft was traced to a person offering to share information at an international who persuaded a company employee to place a USB stick in a company laptop. When connected back to the corporate network, malware was used to steal the products designs.

According to Burgess the IP was taken by Chinese intelligence services who passed the information to a state-owned enterprise that mass produced the goods and sold them on the market”.

During product development, cybersecurity efforts are traditionally focused on making information gathered by products secure, particularly around compliance with government regulations on privacy. This is a complicated exercise in its own right with multiple standard that could be applicable, such as UL 2900-1 on Software Cybersecurity for Network-Connectable Products.

However, product developers should also pay close attention to ensure that malicious actors are not able to secure access to the IP that underpins their business. IP does not just mean patents, which are ultimately published. IP also cover circuit schematics, PCB layout, firmware code, mechanical designs and more.

Circuitwise recently undertook a cybersecurity audit of its working environment, engaging an external consultant to undertake an independent assessment of our security measures, including penetration testing and identification/remediation of vulnerabilities. However, the most IT secure systems in the world will not work if staff are not aware of social techniques like the example given above. Staff education and training are key.

We would encourage all product developers in Australia to include a budget for ensuring “external” cybersecurity of their business. This should include the company’s own cybersecurity measures as well as an audit of any suppliers that hold critical IP on their behalf. Guidance is available from the Australian Cyber Security Centre run by the Australian Government.