Merlin PCB Group · Merlin PCB Group Merlin PCB Group Values • Honesty & Transparency Be open,...

Merlin PCB Group Your Complete PCB Supply

www.merlinpcbgroup.com

Merlin PCB Group


Vision

To be the UK’s preferred Printed Circuit Board

supplier to the global electronics industry

Mission Statement

We will strive to be the leading UK PCB supplier to

the global electronics industry, deploying leadership, lean

methodologies, investment & strategic partnerships in

order to achieve TOTAL customer satisfaction


• FinanceCreate a sustainable positive financial environment for ongoing investment in people & processes.

• TechnologyCreate robust & reliable production processes to achieve our business objectives.

• EnvironmentalMinimise our local & global environmental impact.

• ‘Lean’ ManufacturingDeploy Lean tools & techniques to achieve process improvements & improve efficiencies.

• PeopleInvest in people through continuous training and development.

Merlin PCB GroupPhilosophies

Merlin PCB GroupMerlin PCB Group Values


• Honesty & TransparencyBe open, honest & transparent in everything we do.

• Clarity & CommitmentBe clear about what we seek to achieve and then do what we say we will do.

• Consistency & DisciplineStandardise our approach & adhere to systems & procedures.

• RespectTreat others as we wish to be treated. Treat property as if it was our own.

• Energy & EnthusiasmApproach everything we do with a positive attitude.

• PrideBe proud of the Merlin Group, our products and our service.

• Celebrate SuccessRecognise and reward individual and team achievement.

Merlin PCB GroupGroup Structure

✓ Strong Growth • £20M annual sales• 164 employees

✓ Proactive • Design for manufacture specialist• Enhanced technical Support

✓ Technology Mix • Complete service provided by Merlin Group• R&D support

✓ Lead-time & Logistic Solutions • Fast-track programme support• Managed programme schedules


Merlin Circuit Technology

UK High Tech Rigid

£5M Sales

76 Employees

Kestrel International Circuits

Offshore Specialist

£10M Sales

25 Employees

Elite Circuits

Prototype Rigid

£0.5M Sales

7 Employees

Merlin PCB Group

Merlin Flex

UK Flex & Flex Rigid

£4.5M Sales

56 Employees

Worldwide Merlin PCB Group Locations

ASIA

Kestrel International Circuits LtdLancing, South of England

Merlin Circuit TechnologyDeeside, North Wales

Merlin FlexHartlepool, Northern England

Elite Circuits LtdCranbrook, South of England

Kestrel Hong Kong LtdHong Kong

Kestrel Shenzhen LtdShenzhen, China

UK

OFFSHORE PCB

SUPPLY

UK RIGID

MANUFACTURE

UK FLEX

MANUFACTURE

Merlin PCB Group


Merlin PCB Group UK Merlin PCB Group Locations

Kestrel International Circuits West Sussex, Lancing

Merlin Circuit TechnologyFlintshire, Deeside

Merlin FlexCounty Durham, Hartlepool

Elite CircuitsKent, Cranbrook

Merlin PCB Group Merlin Circuit Technology – Company Overview


• Founded in 1992

• 45000 SqFt

• QTA for Prototype and NPI

• High Technology PCB – HDI, for prototype and NPI up to 32 layers

• MCT is a recognised supplier to the defence and aerospace sector

• MCT have AS9100 approval and are an SC21 company.

• MCT offer 3 day and 5 day turn

• Consultative approach through quote to engineering stages

• Low to medium volume

• 76 employees


• UL Approval for various materials including Multiple Bonds

• Experience with FR4, Polyimide, Rogers, High Speed Hybrid Constructions

• Sequential builds - 3+N+3

• Polar SI8000 Impedance Calculator

• Flat Glass products available

• Halogen Free material Approved

Merlin PCB GroupMerlin Circuit Technology – Materials Used


• Plating Aspect Ratio – 8.5:1

• Blind Via - 1.2:1 (Mech / Laser)

• High Copper Weights

• Filled Blind Vias – Cu +Resin / Cap

• Flat Finishes – ENIG, Ag, OSP

• HASL – Sn/Pb & Pb Free

• Electrolytic Finishes – ‘Hard’ Ni/Au

Merlin PCB GroupMerlin Circuit Technology – Metalisation & Finishes


• Layer Count – 32 Layers

• Board Thickness – 5mm (Max)

• Core Thickness – 75um (Min)

• Track / Gap – 75 / 75um (Min)

• Annular Ring – 100um (Min)

• Solder Mask Clearance - 50um (Min)

• Solder Mask Web – 75um (Min)

• Automated FAIR Generation

• Full Release to IPC6012 Class 3

Merlin PCB GroupMerlin Circuit Technology – General Feature Geometry


• Drill Size – 0.2mm – 6.5mm

• Blind Via – 0.12mm min (1.2:1)

• Back Drilling

• Half Plated Holes (Castellated)

• Rout Tolerance - 100um

• Z-Axis Tolerance – 100um

• Jump Scoring

Merlin PCB GroupMerlin Circuit Technology – Mechanical / Tolerances

Merlin PCB Group Merlin Circuit Technology – Layer Analysis


• Copper Percentage - Panel• Resin content / Fill ratio• Process thickness• Impedance• Material Movement, in

combination with XACT

Merlin PCB Group Merlin Circuit Technology – List of UL Approved Materials


• High Tg FR4 – Isola PCL370HR, Isola IS410*, Ventec VT47,EMC 827i, Nelco N4000- X etc

• Halogen Free – Isola DE104, EMC 370D, Panasonic 1566R

• High Speed – Isola FR408/HR/HRIS, Giga Sync, I Speed, I Tera MT40 Nelco N4000/12/13/SI

• Microwave/RF – Rogers 4000 series, Rogers 3000 series, I Tera MT40, Nelco NH/NX 9000 series

• Hybrids - Rogers/High Tg FR4, High Tg/IS410 (via filling)

Merlin PCB Group Merlin Circuit Technology – Polar/Controlled Impedance

• MCT works closely with Polar Instruments to achieve industry best controlled impedance tolerances.

• These specialist PCBs we supply to Polar meet +/- 2% ohms (industry standard is +/- 10%).

• Range from 28 ohms (Rambus Memory) to 100 ohm differential pairs.

• Working processes to achieve the above created and refined by MCT Quality Director Dennis Price.

Merlin PCB GroupMerlin Circuit Technology - Capacity Planning


• Reviewed at Quote & Contract Review

• Reviewed at the daily Production meeting

• Monitored continuously by production management

• Accurate system created by ongoing Time/ Motion studies

• Paradox System used, allowing Merlin to continuously improve the outputs

Technology 2018 2020 2022

GENERALBoard thickness – 5mm

Min Core Thickness – 75umLayer Count – 32 Layer

Board thickness – 6mmMin Core Thickness – 50umLayer Count – >32 Layer

Board thickness – 6mmMin Core Thickness – < 50um

Layer Count – 38 Layer

FEATURE GEOMETRY

Track & Gap - 75um / 75umAnnular Ring - 100umSM Clearance – 50um


Track & Gap - 50um / 50umAnnular Ring - 50um

SM Clearance – > 25um

MECHANICALRout Tolerance – 100umZ-Axis Rout Tol. – 100um

Min Drill Ø – 0.2mm

Rout Tolerance – 75umZ-Axis Rout Tol. – 50umMin Drill Ø – 0.15mm

Rout Tolerance – >50umZ-Axis Rout Tol.– >50um

Min Drill Ø - >0.1mm

METALISATIONVia Aspect Ratio – 8.5:1

Copper Fill via size – 120umVia Aspect Ratio – 10:1

Copper Fill via size – 150um

Via Aspect Ratio – 12:1Copper Fill via size – >200um

(Including through via)

MATERIALSFR4, Polyimide materials,

PTFE, Halogen Free, Low DK

Low Loss , High Reliability / Speed Materials up to 75GHZPTFE Replacement Materials

>75GHZ High Speed materials.3D Materials

MISCVia Fill (Ink) Technology

Controlled Impedance 10%Conductive Ink Filling (Epoxy)

Controlled Impedance 5%3D Circuit Fabrication /

Metallisation

Merlin PCB GroupMerlin Circuit Technology - Technology Roadmap


Merlin PCB Group Elite Circuits Ltd – Company Overview

• 1-6 layers – Ultra quick turn from 24 hours

• Reverse engineering options available

• ISO9001 approved FM 39259

• Established 1989

• Low volume batch specialists

• Can be used in support capacity to MCT & KIC orders

Merlin PCB Group Elite Circuits Ltd – Capabilities

• 0.3mm to 3.2mm thickness

• 0.5oz to 4oz copper weight

• Low and high TG FR4

• EM-827i, Rogers 4350B & Itera-MT40

• RoHS compliant

• 5 resist colours

• ENIG & LF HASL finishes available

• All the above available on ultra quick turn (1 day+) service

Merlin PCB Group


Merlin Flex - Company Overview

• Established 2010 (Merlin Flexible Circuits + Flex–Ability)

• 56 employees

• The largest dedicated flexible circuit facility in the UK

• 30,000 SqFt

• 50 years Flex PCB experience (MBM Technology – started 1965)

• Specialist ‘In House’ flex assembly


• Approx. 4,500 Sq.Ft. expansion of manufacturing area

• One continuous internal manufacturing process

• Central reception with new meeting rooms & offices

Merlin PCB GroupMerlin Flex – 2018/19 Expansion

£-

£1,000,000.00

£2,000,000.00

£3,000,000.00

£4,000,000.00

£5,000,000.00

£6,000,000.00

£7,000,000.00

2010~11 2011~12 2012~13 2013~14 2014~15 2015~16 2016~17 2017~18 2018~19

Merlin Flex Turnover

• £4.5M turnover (year 2016/17)

• £3.7M order book (firm orders to 2021)

Merlin PCB GroupMerlin Flex – Financial Information

Merlin PCB Group Merlin Flex – Flexible Circuit Capability


• Single-sided & Double-sided Flex

• Multilayer Flex (up to 6 layers)

• Flex/Rigid Multilayer (up to 24 layers)

• Sculptured Flex

• EMC Silver Film Shielding

• Controlled Impedance

• Aluminium Backed Flex

• Long Flex to 1.2M (depending on design and construction)

Merlin PCB GroupMerlin Flex – Specialist Flex Assembly


• Specialist Flex Assembly Since 1987

• Fully Automated SMT Placement (down to 0402)

• IPC J-Std Manual Solder Assemblers

• Conformal Coating

• Connector Back Potting

• DuFlex Crimp Connector Systems

• 100% Functional Testing

• Full RoHS Compliance

• IPC Class 3

Technology 2018 2020 2022

GENERAL CAPABILITY

Long Flex – 1.2M (2 layer PTH)

Long Flex – 1.5M (Flex Multilayer)

Long Flex – 2.0M(Flex/Rigid Multilayer)

FEATURE GEOMETRY

Track & Gap - 100um / 100um

Annular Ring - 125umSM Clearance – 75um



MECHANICAL Mechanical Drill – 0.2mm Mechanical Drill – 0.15mm Mechanical Drill – 0.1mm

METALISATIONVia Aspect Ratio – 8:1

Copper Fill via - DevelopmentResin Fill via - Development

Via Aspect Ratio – 10:1Copper Fill via – ProductionResin Fill via - Production

Via Aspect Ratio – 12:1Copper Fill via – ProductionResin Fill via - Production

MISC Controlled Impedance 10% Controlled Impedance 8% Controlled Impedance 7%

Merlin PCB GroupMerlin Flex – Technology Roadmap

Merlin PCB GroupKestrel International Circuits – Company Overview

• Established in 1995

• Based in Lancing, West Sussex

• Long history of offshore logistical experience

• Single sided, PTH, Multilayer, Flex and Flex-Rigid

• 27500 SqFt facility

• Offshore volume supply specialists


• Value adding Global logistical and lead-time solutions

• Logistic options including Kanban & Consignment stock

• Air Freight and Sea Freight Options

• Tailored logistics solutions

• Managed prototype and NPI transfer to offshore volume

• UK Service and Technical and Centre

• Kestrel technical and logistics in China and Hong Kong

• Latest bar coding and stock control systems implemented

Merlin PCB Group Kestrel International Circuits – Adding Value


Kestrel International Circuits ISO 9001:2015 Quality Management System is designed and implemented to fulfil the requirements of all our PCB customers. It goes beyond the quality levels you would expect to see in the industry with our partners exceeding the same standards.

• Kestrel have a proactive presence in China, combined with Kestrel International Shenzhen, which ensures we have full control with Quality personnel along with Engineers, Supplier liaison and Progress controllers present locally to the manufacturing sites. All our Far East partners are continuously monitored and audited for performance.

• Every batch is quality inspected and reports can be verified by our full in-house verification lab. This allows for best-fit solutions for lead-time, quality, service, technology, risk and price.

• Approvals at China facilities include: ISO 9001, AS9100, ISO14001, UL,TS16949, IECQ, ISO13485, OHSA18001

Merlin PCB Group Kestrel International Circuits – Quality System

Merlin PCB GroupKestrel International Circuits – Offshore Auditing


Kestrel will audit / review all of their offshore

suppliers at least once a year and where

possible every six months. This audit on the

supplier will verify that they can meet the

standards and are capable of producing Printed

Circuit Boards to our customer’s exacting

requirements. From material origins through to

process control to product qualification are

examined by Kestrel trained staff, who have

many years of experience in the Industry.

Certificated Qualified Auditors

Ian Lorimer – Quality DirectorAndy Dalby – Quality Manager

Michael Cheng – China Development Manager


• Our full UK team offers technical service and logistical management; our UK staff include quality, service, engineers, inspectors and dispatchers. Customers only ever deal with our UK based staff.

• Kestrel International Hong Kong logistics centre ensures we have dedicated staff to help consolidate freight from multiple suppliers, shipping either by Air or by Sea to our main central warehouse in the UK. This allows for best-fit solutions for lead-time, quality, service, technology, risk and price.

• Our China staff ensure prompt and reliable progress reports.

Merlin PCB Group Kestrel International Circuits – Logistics


• Kestrel International Circuits has relationships with Far East partners established over many years, this enables a good working relationship and clear communications.

• Kestrel’s significant PCB spend means our suppliers cannot ignore our requests for special terms on price and delivery.

• Kestrel spend and buying power enables us to secure terms that would not be available to other companies attempting to work directly with China suppliers.

Merlin PCB Group Kestrel International Circuits – Buying Power

Merlin PCB Group Kestrel International Circuits

• Kestrel strategic partner since 2000

• Founded 1995

• 4 plants, total 200,000 SqMt facility area

• 2M SqMt PCB produced last year

• $327M sales revenue

• 2-50 layers, HDI, flex & flex rigid

Merlin PCB GroupQuality Record


Group JUL AUG SEP OCT NOV DEC Overall*

OTIF 96.53% 97.45% 93.70% 96.06% 95.30% 94.40% 96.96%

Ext. Quality 99.7% 99.06% 99.70% 99.36% 99.60% 97.39% 99.45%

* – Rolling 12 month figures

MCT JUL AUG SEP OCT NOV DEC Overall*

OTIF 98.27% 98.68% 95.37% 95.83% 94.88% 95.38% 95.89%

Ext. Quality 99.98% 99.90% 99.84% 98.18% 99.19% 99.79% 99.50%

Flex JUL AUG SEP OCT NOV DEC Overall*

OTIF 92.00% 94.00% 87.00% 95.00% 92.00% 91.00% 98.08%

Ext. Quality 99.14% 97.30% 99.26% 99.91% 99.68% 92.43% 98.72%

Kestrel JUL AUG SEP OCT NOV DEC Overall*

OTIF 99.33% 99.69% 98.74% 97.36% 99.03% 96.82% 98.55%

Ext. Quality 99.98% 99.99% 100% 100% 99.94% 99.95% 99.94%

Merlin PCB Group Delivery & Quality Methodology - SC21 & KIC System


• MCT & Merlin Flex use SC21 system to measure quality and delivery performance.

• Kestrel (offshore) use in-house system matching the standards used in SC21 to ensure consistency within the Group.

• In the example on the right we can see in 2016 Kestrel shipped 12,211,972 PCBs with a quality record of 99.97% and a delivery record of 99.19%


✓ EN9100:2016 (AS9100D / JISQ 9100:2016 and ISO9001:2015)

✓ SC21 Bronze Award ✓ UL Approval

✓ IPC-600 Certified Trainers & IPC-600 Certified Specialists (Inspection & Lab)


✓ SC21 Bronze Award (SILVER expected 2019) ✓ ISO14000 (expected 2019)

✓ AS9100 Rev D Trained Internal Auditors ✓ IPC-J-STD Class 3 (Assembly Staff)

✓ IPC-600 Certified Inspection Specialists (Inspection Staff)

✓ IPC-610 Certified Inspection Specialists(Assembly and Inspection Staff)


✓ UL Approval & NADCAP ✓ ISO 14001

✓ ISO TS16949 ✓ IECQ (BSEN 123000)

✓ ISO13485 ✓ OHSA 18001

Merlin Circuit Technology

Merlin Flex

Kestrel International Circuits – Audited Suppliers

Merlin PCB Group Approvals / Accreditations

Merlin PCB Group


Compliance Management

Conflict MineralsDSEARCOSHH RoHS

REACH Controlled DrugsPoisons & Explosives

Merlin PCB GroupMarket Sectors


33%

25%

19%

9%

5%

4%

2% 2%

1%

0%

0%0%

Instrumentation & Controls

Defence & Aerospace

Other EMS Etc.

Transportation

Broadcast & Audio

Fire & Safety

Communication, Data & Storage

Medical

Design

LED / Lighting

Gas & Oil

Green Energy

Merlin PCB GroupA Trusted Supplier


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Merlin PCB GroupA History of Growth


Over 600 Group Customers

Organic Growth

Acquisition Growth

£20M Annual Saleso £10M Offshore Supplyo £5.5M UK Rigid Manufactureo £4.5M UK Flex Manufacture

Range of Sectors Served

STRONG SALES GROWTH

2016 Sales £20M

2009 Sales £9M


Merlin PCB GroupAcquisition History

Mercury Circuits Ltd (Brighton) 1992

Centre Circuits Ltd (Camberley) 1994

Adflex Ltd (IBM Havant) Machinery assets only 1996

Coastline Circuits Ltd (Worthing) 1997

Lantrax Circuits Ltd (Waterlooville) 1998

Robert Smith and Company Ltd (London) 2000

Kemitron Ltd (Chester) 2001

Circuit Express Ltd (Worthing) 2003

Signum Circuits Ltd (Selkirk) 2004

Electropac Ltd (Wigan) 2005

Flex Circuit Division of MBM Technology Ltd (Brighton) 2007

Elite Circuits Ltd (Kent) 2008

Flex-Ability Ltd (Hartlepool) 2010

Artetch Ltd (Littlehampton) 2010

Merlin PCB GroupInvesting in Technology – Recent Investments


•HITACHI XRF Coating Thickness Gauge•Lenz Route machine •SAGE Line 1000•ITC THP 35 Hole Plugging Machine•MOV650-Q2 Universal Robot •PAL OSST Pattern Plate Control System V5.32 •EAS Effluent treatment system•Oxford system CUCL Controller (Inner Layer etch)•Orbotech Inkjet Printer•ECOSPRAY Solder Mask Spray•JUKI Pick and Place machine•Schmoll LIN 2-125 Routing Machine•CTECH Mec Process line •Dual Output Reverse Pulse Rectifier for Pattern Plate •Schmoll Laser Cutter /Drill•Schmoll DDI •XACT PCB Predictive scaling oftware•Frontline InCAM® Front-end software•Schmoll MDI •Fischer XRF (purchased to meet latest specification for ENIG IPC-4552A)

MCT MFMFMCTMCTMCTMCTMCTMFMCTMFMCTMFMCTMFMCTMCTMCTMCTMCT

20142014201420142015201520152015201520152015201620162016201620172017201720182018

£20K£80K£50K£123K£17K£22k£60K£18K£115K£40K£120K£90k£60K£120K£200K£300K£50K£60k£300k50k

Merlin PCB GroupInvesting in Technology – Future Investments


Manufacturing Equipment Asset Value: MCT £9M MF £7M

Future Investments / CAPEX is identified via:-• CSIP• Technology Roadmap (in conjunction with Tier 1 Customers)• Management meeting• Technology Upgrading

Current Items on CAPEX list • Pin-less registration system • AOI Inspection• Direct Metalisation Line• DES Line• LDI Imaging – MF (Ordered - delivery April 18 300k)• Pattern Plate Line - MF

Merlin PCB GroupWorking relationships & Customer support


• Five sales account managers holding regular customer meetings.

• Five technical sales staff available to visit customers to advise on all circuit types.

• 3 customer support centres (1 per division).

• Working relationships reinforced with regular customer visits & customer visits/audits to Merlin manufacturing sites.

Merlin PCB GroupTechnical Assistance


• Merlin has extensive knowledge in all disciplines of PCB manufactureand a high degree of knowledge in both design and assembly.

• Work with customers from initial design stage, development, pre production to assist in:-• Reduction of cost• Improved yield and reliability• Reduction of design iterations, improved time to market• Increased level of manufacturability

• Well placed to advise on scaling up of projects from small / medium volume (UK) to large volume (offshore)• Selecting suitable panelisation• Material selection, to ensure continued functionality / performance• Production methods

Merlin PCB GroupAcademia and Research


• Merlin also work closely with UK and European industry bodies (ICT, EIPC), Academia (Heriot Watt, Leicester University) and research establishments (NPL) on many R & D projects• This gives us access to a much greater technical resource• Access to the latest Test and Analytical machines• Technical library

Aspect Project

Merlin PCB GroupPublished 12 Month Account Results of the Top 10 UK PCB Suppliers


NOTE – Results 4 most recent 12 month accounts. Spirit data pro rata from 18 month period.

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

13 14 15 16

Amphenol

InvotecMerlin PCB

Graphic PLC

Exception PCBFineline VAR

NCAB UK EurotechGroup

Spirit Circuits

GSPK Circuits

Teledyne Labtech

StevenageCircuits

Merlin PCB Group


Why Merlin PCB Group ?

Merlin PCB Group is uniquely placed to offer the best combination of UK manufacture supporting offshore procurement in the United Kingdom.

With 25 years of manufacturing experience and over 20 years of importing expertise, coupled with sound financial strength Merlin PCB Group supplies a high quality service and product to its customers.

Supplying our customers with tomorrow’s requirements today.

Thank you for your time and attention.

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