FM Transmitter Circuit BBG Production Chart

FM Transmitter Circuit Production Chart - BBG

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Crystal Controlled 1/2 WattTransmitter Circuit - Circuit Board Production Chart
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Scale 1:1
Note: 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.
The Original Circuit Board Production Chart that I used to mass produce the BBG unit 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 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 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 units 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 my stock.

That is Basically The Same Procedure I Would Follow on all of the products I have produced over the past 50 years.
FM Transmitter Circuit Production Circuit Board
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 computer equiptment.

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
FM Transmitter Circuit Assemble Jig
FM Transmitter Circuit Production Jig - BBG