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June, 2016 Sunstone Kicks Into Gear for Vance & Hines By The Staff of Sunstone Circuits T
he Fuelpak FP3 is a capable and cost-effec- tive fuel management solution, which is cur- rently available for Delphi-equipped Harley-
Davidson motorcycles. “This modification can im- pact fuel economy and performance as it alters the air/fuel ratio, causing the bike to run much lean- er,” says Larry Hinds, manufacturing manager at Vance & Hines. “Our classic Fuelpak devices solved those issues. With the new FP3, we added functionality like increased horsepower, quicker throttle response and increased fuel efficiency.” As the current generation of fuel manage-
ment systems neared the end of product life, de- mand grew for a solution with updated features. The company had the idea to link the FP3 with a user’s smartphone by Bluetooth to provide a more dynamic interface. “The smartphone integration gave us the ability to not only fix performance is- sues, but also to enhance the rider’s experience,” says Hinds. “That meant the FP3 would use Blue- tooth technology and more complex PCBs.” Vance & Hines has been a successful produc-
er of aftermarket motorcycle parts and accessories since 1979. Founded by legendary quarter-mile
For Sunstone Circuits,
high-performance boards in small form factors are nothing new.
racers Terry Vance and Byron Hines, the company is recognized for being at the leading-edge of the market. While most bike enthusiasts came to know Vance & Hines for its distinctive exhaust systems, the community is growing to trust the company for accessories that contain the latest technology. In order to deliver technologically advanced motorcy- cle accessories, the company partners with Sun- stone Circuits for its PCB assembly. For Sunstone Circuits, high-performance
boards in small form factors are nothing new. With smartphone integration, the FP3 demands a lot from a PCB, and from its manufacturer. “The Ap- ple chip was necessary for iPhone integration and it presented a design challenge,” says Hinds. “Sun- stone helped us by using an extended pad link,
can easily deliver within six weeks.” Responsiveness is clearly critical for Vance &
Hines’ production strategy. In addition to collabo- rative prototype services and capacity for high-vol- ume PCB production, Sunstone keeps communica- tion lines open at all time. “We don’t feel like we’re sending our orders into a black hole,” says Hinds. “There’s someone on the other end who cares.” Despite being an organization that produces
thousands of boards every week, Sunstone retains its ground-level customer focus. “What impresses me is that they are a thinking, caring, human or- ganization,” says Hinds. “They are very person- able. There is a human touch to what they do.” Not content to process orders blindly, Sunstone’s pro- duction team scrutinizes every production order, even if it is a PCB that they have manufactured many times before.
PCBs in production for the FP3 at Sunstone Circuits.
which made it easier to verify that the chip had been soldered in properly.” Recognizing potential issues prior to manu-
facture reduces the potential for rework, ensures functionality, and improves cost-effectiveness. But, collaboration does not end with design for manufacturability. Sunstone partners with Vance & Hines from prototype to production.
High-Volume and Just-in-Time Even though the FP3 is a fairly high-volume
product, the company uses a just-in-time (JIT) style of manufacturing. This production method, called Kanban or “blank card”, requires the supplier to commit to a predictable production turnaround. “We set aside six weeks of board inventory and put a card on it,” says Hinds. “When we crack open that box, it signals us to place a PCB order that Sunstone
Going the Extra Mile “Instead of robotically manufacturing boards,
Sunstone has a thought process behind its work,” says Hinds. That process, in its simplest form, is taking every measure necessary to ensure quality before production begins. Anything that can interfere with quality or
performance raises a red flag and the company is- sues a proactive call to Vance & Hines. One time, a new employee accidentally sent over specifica- tions that called for a tin-lead finish, rather than the silver RoHS finish the product requires. The anomaly raised the alarm at Sunstone, and the company’s rep contacted Hinds to confirm the un- usual order. It had been made in error and that email saved an entire production run. “A lot of our products are sold overseas in
countries with zero tolerance for lead-based prod- ucts, so we have to use the silver RoHS finish,” says Hinds. “I didn’t have to tell anyone at Sun-
Continued on page 34
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