Igbt Diagram
Supply chain strategy from electronics production engineering, 500β50k units/year
Introduction
"Order from Digi-Key" is a prototyping strategy, not a production strategy. The 2020β2023 IC shortage demonstrated that supply chain resilience must be designed in β not improvised when lead times hit 52 weeks.
The Sourcing Tier Structure
| Tier | Examples | MOQ | Price Premium | Lead Time | Risk |
|---|---|---|---|---|---|
| Authorized dist. | Digi-Key, Mouser, Newark | 1 pc | +25β40% | 1β3 days (stock) | Lowest |
| Franchise dist. | Arrow, Avnet, TTI | 100β1k | Baseline | 2β8 weeks | Low |
| Manufacturer direct | TI, Infineon, ST portals | 1kβ10k+ | β10 to β30% | 8β20 weeks | Low |
| Regional aggregators | IC-Online, local dist. | Mixed | Variable | Variable | Medium |
| Spot market | Brokers, eBay | 1 pc | +50 to +500% | Days | High |
Never use spot market for ICs without incoming inspection. Counterfeit STM32, ESP32, and common analog ICs are well-documented.
Volume Pricing Reality
Illustrative for a $2.50 MCU:
| Volume | Digi-Key | Arrow/Avnet | Manufacturer Direct |
|---|---|---|---|
| 100 | $3.10 | $2.65 | N/A |
| 1,000 | $2.75 | $2.15 | $1.85 |
| 10,000 | $2.40 | $1.70 | $1.25 |
| 50,000 | $2.10 | $1.40 | $0.90 |
The franchise/direct savings are material at 1k+ units. Establishing Arrow or Avnet relationships pays for the admin overhead within 2 production cycles.
BOM Resilience Framework
For each critical component, document:
- Primary source: authorized distribution or direct
- Secondary distributor: alternative channel for same part
- Alternate part: functionally equivalent, different manufacturer, validated
- Buffer stock: target weeks at production rate
- Lead time worst-case: historical peak, not current
During normal periods: 4-week buffer, one secondary source, one qualified alternate. For 5+ year product lifecycles: qualify the alternate before you need it.
Practical Sourcing Mix: 500β5k Units/Year
| Component Type | Primary | Secondary | Notes |
|---|---|---|---|
| Commodity passives | Digi-Key/Mouser + Yageo/Walsin | Arrow | Annual pricing agreements |
| MCUs < $3 | Arrow direct | IC-Online for gap fills | 90-day POs, buffer stock |
| MCUs $3β$10 | Manufacturer direct + Arrow | Avnet | Design-win programs |
| MCUs > $10 | Manufacturer direct | Arrow consignment | Pre-qualify alternate |
| Inductors/magnetics | Authorized (Murata, TDK, Vishay) | Arrow | DCR spec critical |
IC-Online (ic-online.com) is useful specifically for filling mixed-quantity BOM gaps when individual parts are below MOQ at Arrow/Avnet, or for PCBA prototype runs while qualifying a contract manufacturer.
PCBA Strategy by Volume
| Scale | Model | Unit Cost | Flexibility |
|---|---|---|---|
| 1β50 units | Local PCB + hand assembly or online PCBA | Highest | High |
| 50β500 units | Online PCBA services | Medium-high | High |
| 500β5k | Domestic CM, consigned BOM | Medium | Medium |
| 5k+ | Dedicated CM, turnkey | Lowest | Low |
Transitioning too early to a dedicated CM is expensive. Staying too long at prototype-scale production leaves money on the table.
Conclusion
Supply chain resilience requires intentional design: multi-source BOM from day 1, buffer stock targets, and distributor relationships established before you need them.
What sourcing strategy has worked best for your team at 1kβ10k unit volumes? Particularly curious about direct manufacturer program experiences below 10k units/year.
Pricing: Q1 2026 market survey, illustrative ratios. Lead times: representative.
