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tech.com
July, 2015
Ensuring Success in PCB Manufacturing and Assembly, Part 1
By Michael Ford, Senior Marketing Development Manager, Mentor Graphics Corp.
the design of the next great technolog- ical device and the finished product. All critical business metrics, includ- ing cost, quality, and delivery, are directly affected by performance dur- ing production. Today, more than ever, as customer demand becomes more volatile, product performance and productivity depend on PCB manufacturing and assembly, with rapidly increasing pressure on engi- neering and materials infrastruc- tures. Eight steps are required to ensure success in PCB manufacturing and assembly. This first of a two-part article will examine the first four steps, with the last four steps covered in part 2 in a later issue of U.S. Tech.
P
Knowing a PCB product to be manufactured and its
requirements is essential for production success.
The first step involves knowing
the product to be manufactured. The product model is an uncontrolled variable that directly affects manu- facturing. The costs for rerunning the production line for a modified design with corrections or for imple- menting countermeasures for pro- duction issues can exceed the cost of
Extracting maximum values from design data can go a long way toward avoiding unexpected pitfalls later during production.
Production processes must be matched to product requirements in ways that support high quality. Completed designs should be
checked against manufacturing stan- dards before manufacturing engi-
for PCB fabrication, as well as assembly, can be performed with clear feedback for layout improve- ments, without a PCB layout design engineer requiring manufacturing expertise.
rinted-circuit-board (PCB) man - u facturing and assembly repre- sents a crucial stage between
the earliest rectification by several orders of magnitude. In addition, the delay for a new product introduction (NPI) can cause significant lost fol- low-on business opportunities as new products fail to reach customers on time.
Design for Manufacturing Knowing a PCB product to be
manufactured and its requirements is essential for production success.
neering processes have started. Design- for-manufacturing
(DFM) tools for PCB manufacturing can help mitigate risk and promote product quality. The most advanced DFM capabilities are based on rules derived from actual process capabili- ty and configuration. Such tools can analyze designs in seconds to reveal opportunities for improvements in the cost of manufacture, yield, quali- ty, and testability. Hundreds of tests
Advanced DFM tools employ the
ODB++ file format to communicate the complete and accurate manufac- turing product models. This ensures that manufacturing receives all infor- mation needed to produce a product as the designer intended, without the need for data reconstruction. The second step is to do what
needs to be done, when it is needed. Traditionally, the first action taken when introducing a new product into assembly manufacturing is to pre- pare data for a specified set of manu- facturing processes. But preparation and use of several production config- urations is really needed from the start to meet any special customer requirements. Planning on the pro- duction floor must determine produc- tion times, rates, and quantities for each item, with a choice of suitable production processes to meet deliv- ery requirements. As the number of discrete products to be manufactured increases, and tolerance for finished goods stock decreases, lot sizes must become smaller with a much higher degree of production interleave.
Enterprise Resource Planning Enterprise resource planning
(ERP), manufacturing execution sys- tems, or generic shop-floor optimiza- tion software are not effective tools in finding efficient ways to perform such
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