What Is a Sub Assembly?
A sub assembly is a self-contained, assembled unit that is designed to be incorporated with other units in a larger assembly. Unlike raw materials, sub assemblies are created separately before being integrated into the final product, and each sub assembly generally has a distinct function within the end product, like a circuit board or control panel.
Sub assemblies are used in a variety of industries and products, from cars to computers to airplanes. Manufacturers use sub assemblies — either manufactured in-house or outsourced — to improve efficiency, reduce complexity, and ensure quality control.
Why Use Sub Assemblies?
There are several reasons why manufacturers use sub assemblies:
Improve efficiency
Sub assemblies can be manufactured in batches and then stored as inventory until they are needed. This can help reduce production time and costs.
Reduce complexity
Sub assemblies can make it easier to design and manufacture products because they break down complex products into smaller, more manageable components.
Improve quality
Sub assemblies can be tested and inspected before they are used in the final product. This can help ensure a reliable and high-quality end product.
Facilitate repairs and maintenance
If a sub assembly fails, it can be easily replaced without having to disassemble the entire product.
Reduce time to market
Sub assemblies can help to reduce the time it takes to bring a product to market because they can be manufactured in parallel with the final product.
Types of Sub Assemblies
There are many different types of sub assemblies, but some of the most common include:
Mechanical sub assemblies, which are made up of mechanical parts, such as gears, shafts, and bearings.
Electrical sub assemblies, which are made up of electrical components, such as wires, resistors, and capacitors.
Electronic sub assemblies, which are made up of electronic components, such as integrated circuits and microprocessors.
The Challenges of Designing and Manufacturing Sub Assemblies
There are also some challenges associated with designing and manufacturing sub assemblies:
Interface design: Manufacturing tolerances can vary, making it difficult to guarantee a perfect fit between sub assemblies. Even slight variations can affect performance and reliability. Designing reliable and easy-to-manufacture interfaces between sub assemblies requires careful consideration of factors including compatibility, tolerance, alignment, load transfer, manufacturing feasibility, and environmental conditions.
Weight and size: Sub assemblies can add weight and size to a product. This can have significant implications, particularly in industries where weight or size is a critical factor, like aerospace and automotive.
Cost: Sub assemblies can be expensive to design and manufacture, incurring costs for design, development, tooling, material, labor, inventory, and quality control.
Outsourcing Sub Assemblies
Manufacturers may outsource sub assemblies for several reasons:
Specialized expertise: Outside contractors may have specialized skills or equipment that the manufacturer lacks.
Flexibility: Outsourcing can provide flexibility in production capacity, allowing manufacturers to scale up or down as needed.
Focus on core competencies: Manufacturers can focus on their core business while outsourcing non-core functions.