May/June, 2012 PCBA Bonepiles Continued from previous page
ence to each project with the purpose of providing customers with the best solution possible. The customer is provided with regular status reports as well as failure disposition data and trend analysis, and also is given the opportunity to review each pro- gram for cost-effectiveness and derived value at regular intervals. Nothing in the process is unique other than the execution and, of course, the results. Using state-of-the-art 100 per-
cent solder joint automatic X-ray inspection machines and engineer- ing’s expertise in X-ray inspection, X- ray image analysis, Datest identified solder joint defects normally hidden or undetected due to design. X-ray is augmented, where necessary, by fly- ing probe, boundary scan, and in-cir- cuit testing.
Case Studies A designer/manufacturer of cus-
tom digital flat-panel displays enlist- ed Datest’s assistance in trouble - shooting 25 high-end video processor
assembly capacity for higher-priority products. Meanwhile, the field service operation has evolved from a cost cen- ter into a profit center. The customer expects to save several hundred thou- sand dollars annually over the life of this initiative, which is expected to last at least two years and possibly as long as four years.
Failed Analytical Instruments A manufacturer of analytical
instruments, working with multiple contract manufacturers over a period of several years, had accumulated a significant bonepile valued conserva- tively at $300K. The majority of this value had already been written off the client’s books. Initially, Datest
www.us-tech.com
was hired to provide X-ray services for a control group of failed PCBAs selected from this bonepile. Using X- ray inspection, Datest was able to identify root causes of failures of the majority of the boards in this control group.
Encouraged by this initial suc-
cess, Datest, in consultation with the client, added more resources — specifically, flying probe, boundary scan and in-circuit testing — to aug- ment X-ray and to attack other por- tions of the client’s bonepile. In an 18-month period, Datest was able to successfully rehabilitate 80 percent of the customer’s failed PCBAs. This was “found money” for a very happy customer. Datest has applied its proven and longstanding expertise in the board testing and inspection
Page 63
realm to establish a systematic solu- tion to this problem, deliver enduring value and contribute to a better envi- ronment. By analyzing the failures and
using its full range of testing solu- tions, platforms, and engineering know-how, Datest can rehabilitate many of the bad boards, restore “lost” revenue and contribute to a greener world. This is an economical and intuitive answer to a perennial issue that delivers significant monetary and environmental benefits in a world where diminished resources have become a fact of life. Contact: Datest, 47810
Westinghouse Dr., Fremont, CA 94539 % 510-490-4600 fax: 510-490- 4111 E-mail:
rboguski@datest.com Web:
www.datest.com r
TAKAYA CORP.
Takaya pioneered Flying Probe Test and became the worldwide standard by providing the performance, reliability, and local support to meet the demanding and varying requirements of electronics manufacturers, especially in a quick-turn environment.
One of many costly PCBs res- cued from the bonepile by com- prehensive testing.
cards. Fully burdened cost of the assembled boards was approximately $2100 per piece. Datest used Agilent 5DX X-ray technology to pinpoint missing components, misplaced com- ponents, solder bridging and insuffi- cient solder conditions. Boards were returned to the customer with defects that the X-ray inspection had identified. The customer performed its own repairs, following instruc- tions provided by Datest, and was able to successfully rehabilitate and return to service 18 of the 25 boards — a restored value of nearly $40K. Cost of X-ray program and inspec- tion: $6K.
Security Systems on the Pile As part of a major green initia-
tive, a leading manufacturer of securi- ty systems hired Datest to assume responsibility for rehabilitating field returns of a major product line. Prior to engaging with Datest, the customer was discarding field failures of this product as scrap and e-waste. Now Datest is taking regular returns from this customer, processing them through flying probe, in-circuit and X- ray test technology. It also identifies failed parts and replaces them, and retests them using the customer’s functional test apparatus. Following passage of all of these
steps, good boards are returned to the customer’s inventory as working units for possible replacement into future field returns. In addition to the obvi- ous green benefits, adoption of this initiative has reduced OEM costs by eliminating the need for a production line to manufacture replacement boards, thereby freeing internal
APT-9411CE
Industry Standard for Most Electronics Manufactures
APT-9411SL Maximum Test Area for Large Board Applications
APT-9611CER
Convertible Single / Dual Sided Probing
2012 IPC APEX EXPO
Visit us at the to see how a
Takaya Flying Probe Test system can help you! San Diego Convention Center February 28 - March 1, 2012 Booth 3403
TEXMAC, Inc. TEXMAC, Inc.
3001 Stafford Drive, Charlotte, NC 28208 704-394-0314
www.texmac.com See us at SMT Hybrid Pkg. Booth 7-421
www.texmac.com
3001 Stafford Drive Charlotte, NC. 28208 704-394-0314
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