Building an AS6081-Aligned Receiving Workflow for Electronics Manufacturing Services

EMS companies face a dilemma when it comes to counterfeit components. Parts arrive from a broker, should they be accepted? You want to help, but you also cannot become the one who certifies authenticity and takes on that liability.

An AS6081-aligned receiving workflow gives you a way to handle that tension without guessing. It defines what to check, what to document, and when to escalate so the customer can make the decision.

Counterfeit and suspect components show up often enough that you cannot treat them as rare exceptions. Government assessments have found a significant percentage of organizations encountering counterfeit electronics, especially during shortages and lifecycle constraints.

When authorized supply disappears, OEMs turn to brokers and independent distributors. That is when risk increases, and receiving is the first place where that risk becomes visible.

Your role is narrower than people think. You are not the final authority on authenticity. You are the operator of a controlled process; your job is simply to put the right part in the right spot in the right way.

The trick with counterfeit mitigation is to provide expert guidance without crossing the line into assuming liability for counterfeit detection.

Put simply, an EMS should never make counterfeit component decisions, but should always provide expert guidance to an OEM making those decisions. Your value shows in how you flag exceptions and clearly present actionable evidence to the OEM.

Not guesses or vague concerns. Evidence.

AS6081 is not just an inspection checklist, it is a risk-based framework for preventing counterfeit electronic components by defining how organizations assess sourcing risk, apply appropriate inspection and test methods, control suspect material, and ensure traceability and reporting.

However, the full scope of AS6081 extends well beyond what is practical at the EMS incoming inspection stage, so any implementation at this level should focus on a simplified, risk-aligned subset of these controls rather than attempting to replicate the entire standard.

A key element within this framework is External Visual Inspection (EVI), which scales in rigor from basic, low-magnification checks to more detailed, high-magnification analysis depending on risk. Think of EVI as the gatekeeper; parts that raise questions during EVI need deeper analysis.

What you need is "AS6081 light", an AS6081 aligned workflow that executes EVI and specifies two things:

• Information to collect
• Criteria for acceptance

If those are clear, the rest of the process follows.

Every incoming lot from an unauthorized distributor should be routed to your AS6081 workflow. Ideally, your ERP allows you to create this flag by vendor. All parts from brokers should start in a controlled state and enter this flow. No exceptions.

At the dock, you verify standard incoming inspection:

• Part number, quantity, and PO match
• Packaging condition and seals
• Basic labeling

Now the parts should be routed to a controlled area with appropriate supplies and equipment, not your standard MRB cage (Material Review Board).

Level 1: Basic Inspection

Level 1 is intended to confirm the order is correct and consistent with documentation.

• Focus: part number, manufacturer, quantity, date code, packaging, labeling.

Goal: catch administrative or obvious handling errors early.

Missing or inconsistent documentation is a meaningful risk signal. Standards require retaining traceability evidence and inspection records for long periods because those records support authenticity decisions later.

Level 2: Enhanced Visual & Packaging Inspection

This level is intended to identify visible inconsistencies or handling issues that could indicate risk

• Focus: label accuracy, marking consistency, packaging integrity, ESD/MBB compliance, general physical condition
• Goal: detect common quality issues and early counterfeit indicators

Look for resurfacing, relabeling, mixed labels, or conditions that do not match new product. These are common counterfeit indicators.

Capture images and write clear notes using a consistent format so the findings are usable later.

Level 3 is intended to surface stronger counterfeit or quality concerns requiring OEM review or further testing.

• Focus: dimensional checks, detailed visual defects, marking permanency, signs of resurfacing or tampering
• Goal: provide evidence-based justification for escalation (e.g., further testing per AS6081 at an ISO17025 accredited lab.)

Marking permanency tests are a key part of Level 3. We are recommending alcohol and acetone wipe tests because they are simple and reasonably objective.

We are not recommending the mechanical permanency testing, aka the scrape test, because in practice this test is quite subjective and relies on experienced operators not usually present in EMS warehouses.

Read More: X-Ray Inspection for Counterfeits: When You Need It (and When You Don’t)

There are a couple of additional tests you might want to add to your workflow, particularly if you already have the equipment and/or expertise in-house.

Heated Chemical Testing (HCT)

You can reasonably perform this test with a magnetic-stir hot plate and Dynasolve 750 or 1-methyl-2-pyrrolidone (NMP), both commonly available. Otherwise this test is very similar to alcohol or acetone testing.

X-ray Fluorescence (XRF)

Use XRF to check for the presence of lead on a unleaded (ROHS compliant) device. The issue is not lead per se, discrepancy in documentation is what you care about. This test is quick and non-destructive, but unless you already have the equipment it's probably not worth investing $15,000 or more just for this purpose.

Radiographic Inspection (X-ray)

Another non-destructive test that only makes sense if you already have the X-ray and it happens to be suitable for this purpose. Making use of X-ray images for AS6081 requires expertise, but can be very useful if you have known-good parts in stock that you can compare. X-ray images are also an impressive addition to your inspection package presented to an OEM.

At the end of your AS6081 aligned workflow there are two outcomes, acceptance or exception.

Notice "reject" is not an outcome we recommend. It is ultimately up to the OEM to decide what goes into their products and if you assume responsibility for rejection, even in very obvious situations, you risk blurring a line you may regret later. Further, such material is often procured under non-cancelable/non-returnable (NCNR) terms and rejection could trigger a contentious situation with the supplier.

Even "acceptance" crosses the line for many EMS companies. If an incoming lot passes all the inspections with flying colors, should you accept it? Yes, if that is consistent with your OEM relationship and you are not assuming liability for the decision. Liability avoidance is typically grounded in explicit permission or direction to purchase from an unauthorized source, and explicit permission to accept such material if it passes all inspections in your workflow.

Acceptance: Passes all documentation and inspection checks and OEM has agreed to accept passing material without further notice.

Exception: Red flags exist requiring customer review.

Bottom line, the EMS provides the evidence, the OEM decides how to proceed.

When escalation is needed the quality of your escalation package determines how quickly the OEM can act.

A weak escalation is vague and forces the customer to guess what went wrong, ask follow up questions, and likely escalate internally leading to more questions.

A strong escalation package includes:

• Lot identity and supplier
• Documentation reviewed
• Inspection steps performed
• Specific anomalies observed
• Photos and notes
• Recommendation for next action

This aligns with requirements to document inspection methods, results, and supporting evidence.

The spectrum of recommendations you might make is wider than "send them to a lab". Sometimes parts can pass AS6081 but still present problems in manufacturing. Legitimate parts might have been re-taped for a number of reasons, and the tape may not match your programming. Leads may be bent, or surface mount parts not co-planar, both leading to re-work. It's smart to do a solder test on older parts and you may find challenges. The recommendations are your opportunity to present and mitigate these kinds of costs up front.

Broker buys usually happen under schedule pressure.

If your EMS already has a good working relationship with a qualified lab, escalation moves faster. Labs operating under ISO17025 demonstrate consistent testing competence, which matters when decisions carry risk.

Established relationships also reduce friction around test scope, communication, turnaround time, and cost.

There are many accredited labs in the U.S., a couple we have worked with and can recommend are Whitehorse Labs and GD4 Test Services.

A Quick Note on Handling and Storage

Inspection is only part of the job. Handling mistakes can damage good parts.

ESD handling should already be in your DNA. Moisture-sensitive components require more attention to maintain proper storage.

That means:

• Verify moisture barrier packaging
• Track exposure time
• Store or bake parts when required

Skipping this step could create failures that look like counterfeit issues but actually start as handling problems.

An EMS does not need to certify authenticity. It needs a controlled receiving process that identifies risk, captures evidence, and supports customer decisions.

A strong workflow stops questionable material early and gives the OEM clear, documented options for next steps.

And it's a great way to stand out from the crowd in a competitive EMS landscape.

Ready to let Cofactr handle sourcing, negotiations, storage, kitting, and delivery while your team focuses on building products? It’s free to get started with Cofactr today.

What is an AS6081-aligned receiving workflow?

An AS6081-aligned receiving workflow is a risk-based process that guides EMS teams on inspection, documentation, and escalation, helping identify suspect components while preserving traceability and supporting OEM decision-making.

Why does counterfeit component risk increase with broker sourcing?

Risk increases when authorized supply disappears, forcing OEMs to use brokers. Shortages and lifecycle constraints correlate with higher counterfeit incidence across organizations handling electronic components.

How to implement “AS6081 light” at incoming inspection?

Focus on External Visual Inspection and define required data capture and acceptance criteria. This simplified approach aligns with AS6081 while remaining practical for EMS receiving operations.

What is External Visual Inspection (EVI) in this workflow?

EVI is a scalable inspection method that ranges from basic to high-magnification checks. It acts as a gatekeeper, flagging parts that require deeper analysis or escalation.

How does quarantine-first receiving reduce risk?

All broker-sourced parts enter a controlled state before inspection. This prevents premature use, ensures traceability, and enforces consistent evaluation before any acceptance decision is considered.

What happens during Level 2 enhanced inspection?

Inspectors review labeling accuracy, packaging integrity, and physical condition. Common counterfeit indicators include resurfacing, relabeling, and inconsistent markings, supported by documented images and structured notes.

When does Level 3 inspection require escalation?

Escalation occurs when strong risk indicators appear, such as marking inconsistencies or tampering signs. Evidence supports OEM decisions, often leading to advanced testing at ISO 17025 accredited labs.

Can an EMS accept or reject suspect components?

EMS providers typically avoid rejection decisions. They present documented evidence and classify outcomes as acceptance or exception, leaving final decisions to the OEM to avoid liability.

What makes a strong escalation package effective?

A strong package includes lot details, supplier data, inspection steps, anomalies, photos, and recommendations. Clear documentation accelerates OEM decisions and reduces follow-up questions.