Reliability Matters is a podcast on the subject of reliability of circuit assemblies. Reliability "best practices" and success stories are discussed. This podcast features interviews with experts in the electronic assembly industry. All electronic production segments which effect product reliability are on the table. This includes contamination, coating, cleanliness assessment, inspection, building for harsh environments, reflow, printing, failure analysis, board fabrication, and much more. ...
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SMTAI 2025 Conference & Event Preview - Special Episode
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1:02:30This 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…
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The Chemistry of Reliability: Choosing the Right Solder and Flux: A Conversation with Chris Ward
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44:25In 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 t…
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Humidity: Small Cause, Huge Reliability Risk with Viktoria Rawinski - Episode 177
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48:23On 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 fail…
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War Stories from the Line: Phil Zarrow & Jim Hall Talk Reliability - Episode 175
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58:15Today, 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…
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AI in PCB Design - It's Already Here! With David Wiens & Stephen Chavez, Siemens EDA. Episode 174
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1:03:09In 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. Joinin…
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Improving the Reliability of Public EV Chargers with ChargerHelp! Co-Founder & CEO, Kamale Terry
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47:50As 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…
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Episode 172: From Chaos to Control: Steering ERP Projects Back on Track with Chintan Sutaria
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46:41Today 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 bus…
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Pick & Place Machine Selection and Optimization with Hanwha Semitech Americas CEO, Tim Kang - Episode #171
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52:38Today 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—T…
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Episode 170: Reliability, Safety, and Human Impact: The DMR Approach with Dheeraj Narang
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40:45Today 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 wi…
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Reliability Matters on the Road in Anaheim California at the IPC APEX Expo - Episode 169
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29:33On 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 …
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Reliability Matters on the Road in Anaheim California at the IPC APEX Expo - Episode 168
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35:12On 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 g…
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Episode 167: Meet the Press: A Conversation with Journalist and PCEA President, Mike Buetow
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56:19Today, 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 …
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Electronics: Down Memory Lane and a Vision for the Future - Episode 166
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39:39This 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 provi…
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Stencil Design and Manufacturing Best Practices with Elias Malfavon Jr.
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59:45Today, 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 begi…
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AI Integrated Supply Chain Management Software with Sebastian Schaal
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57:37Today, 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 cu…
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Battery Selection and Safety Best Practices with Alex Norman
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1:02:09Today 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 requir…
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Electronics Testing Best Practices with Robert Boguski- Episode 162
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1:09:36On 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 beco…
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AI-Based Inspection Technologies with Priyansha Bagaria - Episode 161
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1:03:46Today, 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 …
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Opportunities and Challenges within the EV Industry - Episode 160
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1:10:50Today, 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 ro…
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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 ju…
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Episode 158: The New Kids in Town - The Cast of the D-Code Podcast
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1:03:05Today, 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 podcast…
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Episode 157: What's On Your Workbench? Critical Steps to Avoid Contamination of PCA's During the Rework Process
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1:05:42On 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 mat…
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Episode 156: An Introduction to Flexible Circuits with Joseph Fjelstad
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1:04:36On 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 ad…
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Episode 155: Ultra HDI Panel Discussion - Recorded Live at SMTAI
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42:29Today, 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 solution…
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Episode 154: Thermal Profiling Best Practices
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1:00:39One 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 e…
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Episode 153: Contract Manufacturing Best Practices with Adrian Leal
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52:02If 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 elec…
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Episode 152: High-Reliability Solder Paste Selection Best Practices
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47:50As 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 expe…
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Episode 151: Optical Inspection System Best Practices
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58:28Two 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 prec…
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Episode 150: The Truth Behind Statistics
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1:00:17Statistics, 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 indispensabl…
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Episode 149: AOI and X-Ray Best Practices
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1:14:48In 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, manuf…
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Special episode: Surface Mount Technology International - 2024
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40:48Just 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 attendan…
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Episode 148: IPC Apex Special
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31:16Recorded 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 AkrometrixMike Konrad által
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Episode 147: IPC Apex Special
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35:10Recorded 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.Mike Konrad által
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Episode 146: IPC Apex Special (part 1 of 3)
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29:36Recorded 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 ViscomMike Konrad által
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Episode 145: Designing Electronics to be Reliable in Harsh Environments
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1:05:58The 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 ope…
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Episode 144: A Conversation with Indium's Rick Short about Education-Based Marketing
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59:41We’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 w…
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Episode 143: A Candid Conversation with Industry Icon Doug Pauls
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1:16:29We’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 th…
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Episode 142: Live from SMTA's Pan Pacific Strategic Electronics Symposium (PanPac)
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38:26This 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 un…
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Episode 141: Component Tape Splicing Best Practices with Larry (The Professor) Welk
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57:05Optimization 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 feede…
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Episode 140: Circuit Board Design and Acquisition Best Practices
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1:10:28This episode is a little different from our usual episodes. First of all, it’s a dual-branded episode. It’s both a Reliability Matters Podcast and an Ecosystem podcast episode. The Ecosystem podcast host Judy Warner will join me for an unusual topic, at least for The Reliability Matters Podcast. Most of my audience are assemblers of circuit assembl…
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Episode 139: Environmentally Responsible Alternatives to Traditional PCB Fabrication
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55:12Today, we delve into an increasingly critical aspect of technology and electronics manufacturing - the pursuit of environmentally responsible electronics manufacturing. Our industry has witnessed many environmental revolutions. The elimination of popular cleaning solvents brought on by the Montreal protocol in 1989, soon followed by strict VOC re…
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Episode 138: Hand Soldering and Rework Best Practices with Debbie Wade
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1:11:03Today we're diving deep into the world of precision and craftsmanship—two crucial elements in the realm of hand soldering and rework of circuit assemblies. Whether you're a seasoned electronics enthusiast, a hobbyist, or just someone with a curious mind, this episode promises to demystify the art and science behind hand soldering and rework. We'll …
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Episode 137: Building a Sustainable Career with a Sustainable Impact
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1:15:40Today, we delve into the crucial aspects of maintaining well-being on this journey—how to sidestep the notorious burnout, and perhaps more importantly, how to fuel and maintain your motivation. Because, let's face it, the road to creating a meaningful impact can be demanding, and it's essential to navigate it with resilience and purpose. Join me fo…
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Episode 136: Environmentally Responsible/Sustainable Conformal Coating with Dr. Cassandra Zentner
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1:04:07We covered the topic of ultrathin conformal coatings back in November. We covered various conformal coating materials from traditional acrylics and silicones to ultrathin parylene coatings. What other coating materials are available? Where do these types of coatings fit within specific applications? Where do health and safety, environmental concern…
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Episode 135: A Conversation with Dr. Zach Peterson about Board Design Best Practices
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1:13:54In today's increasingly connected and digital world, PCBs are the unsung heroes that power our devices, from smartphones to spacecraft. Yet, the art and science of designing these crucial components often go unnoticed. That’s where this episode comes in. Today, I hope to shine a spotlight on the critical role PCBs play in modern technology and ex…
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On this episode, I have no guests as this is the final episode of the Reliability Matters Podcast for the 2023 season. Instead, let's review what happened on the podcast this year. A special thanks to my guests and listeners/viewers for making this podcast so successful.Mike Konrad által
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Episode 133: Novel Wireless / Wearable ESD Monitoring
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1:05:55We are all aware of the damage electrostatic discharge can wreak on components and electronic products. We mitigate ESD damage through various forms of monitoring. We wear wrist and heel straps, stand on ESD-safe flooring, utilize ESD work stations, and more. We even have ESD testing locations that will test a human standing on a specialized testin…
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Episode 132: A Conversation about Ultra-Thin Conformal Coating with HZO's Lisa Rizzo
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1:00:42Today we’ll dive deep into the world of conformal coating. More and more assemblies are being subjected to conformal coating to protect the assembly from harsh environments. What’s leading the drive to conformal coat electronic assemblies? What types of conformal coating options are available? What are the advantages and disadvantages of each type?…
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Episode 131: A Conversation with Industry Icon Bob Willis
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1:09:24We are all aware of the supply chain issues our industry has faced. Beginning with electronic components, it has spread to so many other types of parts are industry relies on. Fortunately, it looks like we are beginning to come out the other end of the supply chain shortage. But the supply chain problems have further spread to the labor market. If …
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Episode 130: Human-Centered Approaches to Innovation with Dr. Alexis Abramson
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1:03:25Some of you may recall episode 121 where I spoke with Dr. John Mitchell, president and CEO of IPC about his new book “fire your hiring habits”. During that episode, we talked about best practices for hiring the best people. I’d like to travel a little bit up the river to talk about where potential candidates for hiring come from. While most of the …
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