SURVIVAL TECHNIQUESStreamline AOI/AXI process with software innovations

Presented by

Bruce Isbell

Agilent Users GroupJan 16, 2008

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AGENDA “Survival”

Presentation (30 min)

-SMT/NPI Conditions“Severe weather ahead”

-Valor software innovations“Survival kit”

Lean data modelAuto-generationVirtual Sticky tapeJob portabilityECN implementationImport SMT programsRe-Optimization

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HIGH LEVEL Manufacturing PressuresLack of performance visibility

High Scrap Level

Poor OEE

RoHS compliance, product declarations

Unpredictable customer demand

Shrinking profits

Traceability Audit

Higher mix / Higher complexity

Inventory turnover slowing

Long changeover times

“Pull” demand from customers

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LOW LEVEL data issues pile on

Multiple CAD types

Incorrect shape data

Gerber as only source

Centroids are wrong

CAD to Gerber mismatches

CAD to BOM mismatches

Variable Solder Paste apertures

Multiple machine libraries

Multiple BOMs per PCB

Multiple Zero Rotation values

Multiple ECNs

SMT / AOI Programming Environment

Low Level issues

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High Level issues

-Bad data-Incomplete data-Tooling errors-Library conflicts

-Unpredictable demand-Frequent Changes (ECNs)-Higher complexities-Regulations for Traceability & RoHS

COMPOUNDING events

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URGENT pressures collide…

Valor software solutions Valor software solutions were designed to bring were designed to bring order out of chaosorder out of chaos

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How?

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STREAMLINED EFFICIENCY REQUIRES LEAN/LINKED DATA MODEL

Technology “Survival Kit” for AOI/AXI process

vPlan Database Engine

Product ModelBOMCAD/Gerber

Resource ModelLinesFactory DefinitionMachine Parameters

MPD (Manufacturing Process Definition)Process ModelDocumentationNC Programs

LibrariesParts (IPN, MPN, vShape)Manufacturing Process RulesPreferences

Lean/Linked Data Model Define once & Use for Many Products / MPDs

Lean Data Model -

Enables Automatic Change Management

Parts RulesResources

Projects

MPDs

Fast.Accurate.Easy ECN Implementation

Original MPD and Master Library:All data is synchronized

Fast.Accurate.Easy ECN Implementation

Synchronize MPD dataBy clicking on MPD elements:- Process Model- Documentation- NC Programs

Fix Rotation Problems

Fix X/Y Problems

Fix X/Y Problems

IncorrectPlacement

Information updated in MPD and Master Library

Fix Wrong Shape

Fix Wrong Shape

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Building a STREAMLINED FLOW. Quickly

• Flow1: Handling Gerber with NO Centroid list• Flow2: Handling Gerber with Centroid list• Flow3: Creating accurate component data with VPL• Flow4: Importing data from SMT programs/libraries

• Handling CAD variations with automation• Handling ECN process variations with automation• Rotation neutralization• Centroid Correction

Flow1: Handling Gerber with NO centroid list

Gerber reverse engineering tools• Layer stack-up• Cleanup• Using Component extraction

• Create Centroids• Component packages are neutralized

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Flow2: Handling Gerber with centroid list

Gerber reverse engineering tools• Layer stack-up• Cleanup• Using footprint extraction

• Create Footprints• Correct Centroids• Neutralize rotations (to be discussed later)

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Handling CAD variations with automation

• Customer or design center libraries• Maintains all CAD preferences for each design center• Maintains all fiducial aliases for each design center

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Need for rotation neutralization - examples

• Designer1: Zero degree rotation:

• Designer2: Zero degree rotation:

Rotation fixes are needed in the AOI preparations!!!

Valor Neutralizes all rotations to a Valor Standard

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Need for Centroid Correction - Examples

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Placement fixes are needed in the AOI preparations!!!

Valor Corrects Centroids to Valor standards

Flow3: Creating accurate component data with VPL

• VPL library merge• Accurate Package representation• Accurate Centroids• Package type classification• VPL Package and Part attributes

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25 © 2006, Valor. All trademarks are the property of their respective owners.

DFMVST Data Preparation

Line Balancing Optimization

Putting it all together

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CAD /BOM and AVL Merge

Gerber Reverse Engineering

Product model Validation

Import SMT program data

DFMVST Data Preparation

Line Balancing Optimization

Putting it all together

CAPTURE, VALIDATE, NUETRALIZE

PCACreated

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DFMVST Data Preparation

Line Balancing

Verify that PCA can be efficiently manufactured using more than 700 pre-defined checks.

Make instantaneous reports to communicate results

Putting it all together

ANALYZE & REPORT

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DFMVST Data Preparation

Line Balancing Optimization

Virtual Assembly

Line Creation

MPN

vSupply-Form

vShapes

Machine Parts Auto Generation

Optimized SMT Placement

Line Balancing and Grouping

Stencil Design

AOI/AXI outputs

PTH Machine output

Manual Assembly Planning

Documentation, drawings, instructions

Putting it all together

Manufacturing Process Definition (MPD) creation

MPDCreated

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DFMVST Data Preparation

Offline Placement Simulation

XY Corrections

Placement Correction

Rotation Correction

Line Balancing

Putting it all together

Off-line process simulation and correction

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Complete solutions for dynamic assembly

Feeder VerificationInventory

consumptionWIP

TrackingWIP

TrackingQuality Data

SPCMSD controlLead FreePerformance MonitorDFMMachine

ProgrammingLine BalanceLibrary auto-generation

Assembly instructions

Front-to-Back solutions

Thank you for your interest in Valor !

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