FM Transmitter Circuit Production Chart - BBG
BBG FM (NBFM
) - VHF Spy Circuit
Controlled 1/2 WattTransmitter - Circuit Board
The Links to discover More
Secrets behind the Original
Engineering of the BBG
To save the
Production Chart image on your Computer, pull your mouse over the image and then do a right
click on your mouse. Then save the image as - somewhere in your files.
Original Circuit Board Production Chart that I used to mass produce the BBG transmitter circuit is shown
below. Although this particular chart
only displays 6 boards, and was my original master template, I upgraded it to 12 boards on an
8x10 template after a couple of years since I was selling more and more of these units, as
many as 12 to 16 a month - anywhere from $350.00 to $900.00 per unit. The 6 boards below
represent anywhere from over $2,000 to over $5,000 a month worth of product. On an assembly
chart of 12 boards, around $11,000 worth of product.
This Is How I Made
My Production Charts. I would pull up my single circuit board
image on a 1:1 Scale, save it and then pull up Microsoft Paint ( Every Computer Has This
basic Program - since Windows 3.1 ) - then I would click on ( In Microsoft Paint ) edit, -
paste from, and then paste the board next to each other., such as the 6 boards you see
below. This Master was created with the basic Microsoft paint program on your computer.
Never underestimate the power of that free program on your computer.
From There I Would
Printout The Circuit Board Master Below, and then with a Press and Peel
backing run it thru my Laser Printer to make the Master Press and Peel Template. From there
it went to an iron on and then I etched the Master, producing 6 boards at one time. If you
are not familiar with the press and peel method of making circuit boards, there are tons of
tutorials on the net. All you need is the material, a decent printer, a flat iron, copper
board and some etchant. I have perfected it to a point where there are no flaws in my
boards, and factory quality. You can to if you work at it.
I Would Always Build
( Assemble ) A Minimum of 6 of the BBG transmitter circuits at any
single time using special design jigs and then, with a bandsaw, saw them out from the
Master below. On the average it took me around 4 hours to assemble, test, align and then
put the final approval on 6 units before going to assembly in their enclosures. After they
were assembled into their final enclosures, I would always do a "BURN IN" - or put the
battery in and actually run them thru 5 batteries to verify that no flukes or any
components were faulty, and if any were - determine what the problem was, repair as
necessary and then that particular unit would go thru another burn in. The rest went into
That is Basically
The Same Procedure I Would Follow on all of the electronic products I have
produced over the past 50 years.
If you are
curious as to how long it took me to fully assemble the 6 boards above
it takes about 3
hours. All of my homemade jigs were custom made from experience gained over the years, and
much experience gained when I was the Plant Manager of Infax Corporation near Atlanta back in
1985, that manufactured custom Video Equiptment, Custom Boards, Video Monitors and related
One of the major
innovations that I created in my factorywas the Assembly Chart. 30
girls on my solder line, soldering full motherboards from scratch, 30 at a time per girl
was a major headache. That was solved with a custom made assembly chart that you will find
in one of the links below.
I Took The circuit
board to a copy machine, blew it up to an 11X14 board on paper and then drew in the
partsas you will see in the BBG
Assembly Chart in the link below. From there I used different colored highlighters and
colored in certain components on some board charts and other colors on other board charts,
split the line into 8 groups where one group would assemble certain components from their
colored charts and then the boards would pass to the next line and they would assemble the
components on their colored charts. It increased production over 400%. The Assembly Charts
were placed directly in front of them.
The Next Thing I
Did was to build a set of jigs that
was placed between them, the board under assembly and their production chart. The
components were laid in these jigs, exactly from left to right identical to the assembly
chart. I also placed a wooden dowel on a stand next to their trays to place their solder
spools so it would roll when pulled rather than reaching for it, etc.
What It Boils Down To Is That I Created A System. I was asked onetime, John - how
can you go on the road for two weeks, come back with 20 to 30 orders, produce them by
yourself and then deliver all of them 3 weeks later? Now you know how I did it! I had the
above system for each product, out of hundreds that I engineered over the years. It Works,
and it worked with Me, Myself, and I - No Employees.
Below Is A Photo Of
My Production Jig. Enjoy, John