Optimizing the Board Assembly Process

135 Pages·2015·2.5 MB·English

by  Nadia Anwar

Optimizing the Board
Assembly Process
Greg Caswell
Senior Member of the Technical Staff
[email protected]
©©© 222000000444 --– 22200001197000 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
DfM Abstract
In the electronics industry. the quality and reliability of any product is highly dependent
o
upon the capability of the manufacturing supplier, regardless of whether it is a
contractor or a captured shop. Manufacturing issues are one of the top reasons that
companies fail to meet warranty expectations, which can result in severe financial pain
and eventual loss of market share. What a surprising number of engineers and
managers fail to realize is that focusing on processes addresses only part of the issue.
Design plays a critical role in the success or failure of manufacturing and assembly.

Designing printed boards today is more difficult than ever before because of the
o
increased lead free process temperature requirements and associated changes
required in manufacturing. Not only has the density of the electronic assembly
increased, but many changes are taking place throughout the entire supply chain
regarding the use of hazardous materials and the requirements for recycling. Much of
the change is due to the European Union (EU) Directives regarding these issues. The
RoHS and REACH directives have caused many suppliers to the industry to rethink
their materials and processes. Thus, everyone designing or producing electronics has
been or will be affected.

This course provides a comprehensive insight into the areas where design plays an
o
important role in the manufacturing process. This workshop addresses the increasingly
sophisticated PCB fabrication technologies and processes.
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Course Outline
MODULE 1: INTRODUCTIONS MODULE 4: DfM - COMPONENT
• Component Robustness
Intro to Design for Manufacturing
o
• Temperature Sensitivity Level
Key Global DfM Guidelines
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• Moisture Sensitivity Level

MODULE 2: INDUSTRY
MODULE 5: PCB ISSUES
STANDARD DESIGN RULES
• Shock/Strain /Flexure Issues
(Reference)
• Pad Cratering
o Quick View of Industry • Cleanliness
Standards
Electro-Chemical Migration (ECM)

MODULE 5: DfM - SOLDER
MODULE 3: OVERVIEW OF DFM
General Soldering
TASKS •
Lead Free Solder Alloy Update
•
Types of Review Processes
o
Hand Soldering
•
Root Cause Problem Solving
o
Copper Dissolution
•
Failure Analysis (Reference)
o Mixed Assembly
•

©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Module 1: Introduction

Introduction to Design for Manufacturing (DfM)
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Design for Manufacturing (DfM)
Definition
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The process of ensuring a design can be consistently
o
manufactured by the designated supply chain with a
minimum number of defects
Requirements
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An understanding of best practices (what fails during
o
manufacturing?)
An understanding of the limitations of the supply chain
o
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
DfM Failures
DfM is often overlooked in the design process for
o
some of the following reasons:
Design team often has poor insight into supply chain
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Original Equipment Manufacturer (OEM) requests no
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feedback on DfM from supply chain
DfM feedback consists of standard rule checks (no
o
insight)
DfM activities at the OEM are not standardized or
o
distributed
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Introduction to Design for Manufacturing
(DfM)
DfM is the process of proactively designing
o
products to:
Optimize all of the manufacturing functions:
o
supplier selection and management,
procurement, receiving, fabrication,
assembly, quality control, operator training,
shipping, delivery, service, and repair.
Assure that critical objectives of cost, quality,
o
reliability, regulatory compliance, safety, time-
to-market, and customer satisfaction are
known, balanced, monitored, and achieved.
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Introduction to Design for Manufacturing
(DfM)
Successful DFM efforts require the
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integration of product design and process
planning
If existing processes are used, new products
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must be designed to the parameters and
limitations of these processes regardless of
whether the product is build internally or
externally.
If new processes are used, then the product
o
and process need to be developed carefully
considering the risks associated with “new”
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Why DfM? (cont.)
Reduce Costs by Improving
Manufacturability Upfront
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Key Design for Manufacturing Guidelines

The foundation of a robust Design for Manufacturing
o
system is a set of design guidelines and tasks to
help the product team improve manufacturability,
increase quality, reduce lifecycle cost and enhance
long term reliability.

These guidelines need to be customized to your
o
company’s culture, products, technologies and
based on a solid understanding of the intended
production system – whether internal or external.

The next module will review global “Top 10” DfM
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guidelines and tasks that are applicable to most
industries and processes.
©© 22000044 -- 2200019700 0 0 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com