Manas Bajaj, Georgia Tech - Slide 1 Towards Next-Generation Design-for-Manufacturability Frameworks...

Manas Bajaj, Georgia Tech - Slide 1

Towards Next-Generation Design-for-Manufacturability Frameworks for

Electronics Product RealizationPhase 1: Rule-based Manufacturability Verification of Circuit Board Designs

Manas Bajaj, Dr. Russell Peak, Miyako Wilson, Injoong Kim

Thomas Thurman, M.C.Jothishankar, Mike Benda

Dr. Placid Ferreira, Dr. James Stori

Semicon West 2003SEMI Technology Symposium: International Electronics Manufacturing Technology

Session 210: Factory Simulation, Automation and IntegrationSEMI and IEEE/CPMT San Jose, CA

July 18th, 2003

Recipient of the “Best Paper Award” in Session 210, IEMT, Semicon West 2003

Updated web version: http://www.eislab.gatech.edu/pubs/conferences/2003-ieee-iemt-bajaj/


Contents

• Introduction -- Simulation for Flexible Manufacturing• Design-for-Manufacturability (DFM) Framework

– Motivation

– Core Ingredients

– Functional Foundation

– Building the SDF (SFM DFM Framework)

– Future Architecture

• Conclusion• Acknowledgements• Questions?


Contents


– Motivation







• Enable a collaborative environment for engineers (design, manufacturing, producibility, test etc.) to work together and negotiate for a robust product model

Simulation for Flexible Manufacturing (SFM)

Project Vision

System Engineer

Device Supplier

PDM / Library

EE/ME Product Designer

Analysis Model Supplier

Fabrication Vendor

Assembly Vendor

Known Good Data

Package Data Supplier



Project Timeline Teams• Teams

– Rockwell Collins (RCI)• Thomas Thurman, M.C.Jothishankar, Mike Benda

– Georgia Tech (GIT)• Dr. Russell Peak, Manas Bajaj, Miyako Wilson, Injoong Kim

– University of Illinois at Urbana Champaign (UIUC)• Dr. Placid Ferreria, Dr. James Stori, Dong Tang,

Deepkishore Mukhopadhyay

• SFM Project Timeline– Initiated in August 2002– Completed Phase 1.1 in December 2002– Completed Phase 1.2 in April 2003– Developed Framework used for production at RCI in

May 2003


• Develop a DFM Framework – Enable designers, manufacturers, assembly and test

engineers to work collaboratively

• Domain of Interest– Printed Circuit Assembly design process

• Motto of the DFM Framework– Develop a generic and modular architecture

– Core components customizable for specific enterprises


Project Phase 1


Contents


– Motivation







Motivation for building a DFM framework

Simulation-based Design General Overview

• “Systems Approach” to product realization -- organizing the “smorgasbord”– Capturing mutual interaction amongst design, manufacturing,

assembly, testing, packaging etc. related activities

– Building product and associated process models

– Creating smart configurations – adaptable to changing technology and business needs

• Reduce cycle time and possibilities of redesign– Capturing activity specific knowledge and utilize it for

enhancing related activities and tasks

– Learning from today’s experience to improve performance tomorrow – Intelligent Systems


• Simulate Printed Circuit Design process

• Emulate expertise of manufacturers, test and producibility engineers for robust designs

Motivation for building a DFM frameworkSimulating Process Emulating Knowledge

Environmental

Placement

Fabricate Test/Inspect

Part Symbol& Footprint

Assemble

Doc/Proc/RegGuidelines

Corrections

Release

Learn todayUtilize tomorrow

Functional

Layout

Req

uir

emen

ts

Routing Review

Des

ign

Build


Contents


– Motivation







Core Ingredients of a DFM Framework1. Electronics Product Design Model

• Need of an Integrated Design Model– Ability to support different dimensions of product design

• Functional Model• Part - Assembly Structure• Configuration Management • Requirements Specification

– Formal data specification for higher fidelity across engineering domains

– Semantically rich in content and coverage – ability to expand to the ever rising complication in product and process data structure


Core Ingredients of a DFM FrameworkChallenges towards an Integrated Design Model

Existing Tools

Tool A1 Tool An...

“dumb” information capture(only human-sensible,I.e., not computer-sensible)

LegendContent

Coverage Gaps

ContentSemantic Gaps

Smart Product ModelBuilding Blocks • Models & meta-models

• International standards• Industry specs• Corporate standards• Local customizations

• Modeling technologies:• Express, UML, XML, COBs, …

Example “dumb” figures


• Need to capture the expertise of manufacturers– To be able to gather manufacturing knowledge

– To be able to represent this genre of knowledge

– To be able to use these knowledge sets to guide design decisions

– To be able to share this knowledge across enterprise specific manufacturing facilities

Core Ingredients of a DFM Framework2. Manufacturing Expertise


Core Ingredients of a DFM Framework Challenges towards capturing manufacturing knowledge

Design Parameters

• geometrical dimensions

-- gd_1

-- gd_2

-- ….

• material properties

-- mp_1

-- mp_2

-- …

• ……

Manufacturability

high

low

1

• >10

• <9

• “strong”

Manufacturability

Knowledge

2

• “weak”

• >”tensile”

• > 10 MPa

• Fuzzy nature of manufacturability knowledge


Contents


– Motivation







Functional Foundation of DFM Framework1. Answering integrated design model challenge

• Use of STEP AP210 standard specifications to build the semantically richer and higher fidelity integrated design model


Product Enclosure

External Interfaces

Printed Circuit Assemblies(PCAs/PWAs)

Die/Chip Package

Packaged Part

InterconnectAssembly

Printed Circuit Substrate (PCBs/PWBs)

Die/Chip

STEP AP 210 (ISO 10303-210) Domain: Electronics Design

(ap210.org)

~800 standardized concepts (many applicable to other domains)Development investment: O(100 man-years) over ~10 years


Functional Foundation of DFM Framework2. Answering knowledge capture challenge

• Use of Expert Systems Technology– Expert Systems are computer programs to emulate human

expertise and take decisions to the best of current knowledge.

– Used for problems / scenarios that are complex (abstract, deeply branched decision tree etc.) enough to require human expertise.

– Facility to add knowledge– Explanation facility to track the chain of logic – serves as a

conformance test


Core Advantages of Expert Systems

• Separation of knowledge from control– Better foundational architecture

– Ease of maintenance

– Ability to add new knowledge and refine functionality

• Ability to handle abstraction– Support decision making in the design process in the

absence of knowledge – to the best use of as-available information

• Trace the tree of design decisions– Ability to track the logical steps in process

– Serves as an explanation facility

– Used for conformance testing


Contents


– Motivation







Conceptualizing the DFM ArchitectureFundamental Framework: “Pulling it all together”

Enterprise DatabaseAuxiliary design information

ECAD tool

Design Integrator

STEP AP210design model i

End User View

Manufacturability Feedback ij of a given design i

Rule-based Expert System

Results Manager

Design Manufacturability Report ij

Design View j Generator

Design view ij

Manufacturability Knowledge-base


Building the SDF (SFM DFM Framework)

SFM Results Viewer

UIUC

SFM Design Integrator

LKSoft

SFM Rule based Expert System

Boeing + GIT

SFM Design View Generator

GIT

PCA parts library database

RCI

ECAD tool (Zuken, Mentor etc.)

ECAD tool

RCI

Auxiliary Product Information

STEP AP-210

AP210 part 21 fileKappa design

Design view

DFM violation results

Step - 1

Step - 2

Step - 3

Step - 4

End user view


Integrated Design Model: STEP AP210Example view in STEP Book – AP210 Browser (LKSoft)


DFM document j (human sensible) Rule Description Facility (RDF)

Rule Execution Facility (REF)

rules in RDF (computer sensible)

Manufacturability Knowledge Base j

Results ij

Design View ij

SDF Rule-based Expert SystemRule authoring tool Rule checking tool


Results Log(from SFM Rule-based

Expert System)

Results Viewer(highlighted featureshave DFM violations)

SDF Results ManagerViewing DFM violations in the Results Browser


Contents


– Motivation







Future Architecture Standards-based Framework

Simulation forFlexible Manufacturing

LK

So

ft

Fit-Check

Product Definition Dataset

Computer IntegratedManufacturing

AP 2033D Viewer

Exc

epti

on

s

RulesRepository

AP 210

AP 2103D Viewer

RulesEngine

CIMPackageLibrary

AP 203

Converter

VisulaPackageLibrary

ECADDesign

MCADAssembly

Design

MCADPart

Design

CAMApplication

MachineSimulator

InspectionApplication

PDF2D Viewer


Future ArchitectureExpanding the scope of the current architecture

• Enhancing the scope of the DFM Framework to a generic DFX Framework– DFX: Design for X

• where X: Manufacturing, Testing, Assembly etc.

• Expanding the downstream application of the 210 design model– Rule-based Manufacturability analysis

– Finite Element based PWB Warpage analysis

– Engineering economy based analysis (Design-to-Cost)


Contents


– Motivation







Conclusion

• Achievements of the SDF: SFM DFM Framework– Demonstrated the ability to build an integrated design model

to support manufacturability constraint check

– Use of STEP AP210 standard • to support product life cycle related tasks• foundation for building semantically richer and higher fidelity

product models

– Demonstrated the ability to capture and utilize manufacturing expertise

– Integrating core functionalities for developing a collaborative environment for designers and manufacturers


Contents


– Motivation







Acknowledgements• Rockwell Collins

– Kevin Fischer, Floyd Fischer, Wayne Foss, Dick Postma, Jennifer Waskow, Ian Wicke, Jim Lorenz, Jack Harris

• LKSoft (lksoft.com & intercax.com)

– Lothar Klein, Viktoras Kovaliovas, Giedrius Liutkus, Kasparas Rudokas

• PDES Inc. Electromechanical Team (pdesinc.aticorp.org)

– Greg Smith (Boeing), Mike Keenan (Boeing), Craig Lanning (Northrop Grumman)

• Arizona State University– Prof. Teresa Wu

• Georgia Tech– Prof. Robert Fulton, Prof. Nelson Baker


Contents


– Motivation







Questions?

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