The power management systems had a transformer soldered to the PCB that was showing to be too weak in some situations when prolonged max loads were applied. As a result, there were failures in the field. Their engineers identified that a transformer on the PCB board needed upgrading. During this upgrade, a resistor and a capacitor also required replacing.
During the process, old components required desoldering, and the connection points on the PCB board were cleaned. Afterward, new components were resoldered to the PCB board. Once new components were resoldered, software updates and power tests were performed to ensure the new components were affixed to the board correctly and could perform under max loads.
Before new components were soldered to the PCB board, they were to tested to ensure they were within stated manufacture tolerances and that there wouldn’t be a repeat of the same issue again.
Each completed unit needed serial numbers recorded, repackaged into new packing, and updated labeling applied to the box. This process was estimated to take 90 minutes per unit, and 650 units needed reworking.
The time commitment to the rework was a massive undertaking. Turnaround time needed to be within 60 days, and on top of that, a skilled workforce was required.
Each that failed was a direct revenue loss of more than $2000 with more than 1,300,000 on the line.