THE SOLUTION THE BENEFITSmedia.virbcdn.com/files/55/FileItem-280886-casestudies...TruView 105 ust...
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“‘I was first introduced to Creative Electron by a mutual DoD customer. Creative Electron provided us with crucial education to setup a counterfeit detection lab. Their value goes well beyond their TruView equipment. They are vested in our success. We still call them to tap into their expertise.” VP of Eng. R E L I A B L E • S C A L A B L E • A F F O R D A B L E T r u V i e w I n s p e c t i o n T We met with the company to assess their con- cerns and to determine the level of inspec- tion needed to meet their requirements. This analysis led to a series of recommendations, which included changes to the company’s qual- ity documents and the purchase of laboratory inspection equipment. The first equipment the company acquired was a TruView 180 radiog- raphy system, capable of 100% inspection of components on tape, tubes, and trays. We also trained them in how to identify counterfeit parts. The latest production run at a large aerospace company was compromised by the infiltration of counterfeit electronic components. Their comprehensive quality assurance and control system was not properly designed to deal with counterfeit components. They came to us look- ing for help on how to ramp up their counterfeit detection capabilities within the context of their established quality control system. TruView was deployed in the receiving de- partment of the company. TruView’s non- destructive inspection allowed company to check all inbound parts before delivery to manufacturing. The fully automated solu- tion enabled the company to perform 100% component inspection of parts in tubes, reels, and trays. The scalable TruView sys- tem allows for future upgrades that might be needed as electronics miniaturize and more detailed inspection is needed. A single counterfeit detection of Samsung parts saved the company $96k. This amount does not account for other potential costs as- sociated with boards failing in the field. CASE STUDY AEROSPACE COMPANY FIGHTS COUNTERFEIT COMPONENTS THE CHALLENGE THE SOLUTION THE BENEFITS THE RESULTS Made in USA TruView 180 Creative Electron, Inc. 253 Pawnee St. San Marcos, CA 92078 Phone: 760.752.1192 [email protected] www.creativeelectron.com Visual inspection did not show anomalies in the lot X-ray images overlaid onto photo of reel showing suspect
Transcript of THE SOLUTION THE BENEFITSmedia.virbcdn.com/files/55/FileItem-280886-casestudies...TruView 105 ust...
“‘I was first introduced to Creative Electron by a mutual DoD customer. Creative Electron provided us with crucial education to setup a counterfeit detection lab. Their value goes well beyond their TruView equipment. They are vested in our success. We still call them to tap into their expertise.” VP of Eng.
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TruView InspectionT
We met with the company to assess their con-cerns and to determine the level of inspec-tion needed to meet their requirements. This analysis led to a series of recommendations, which included changes to the company’s qual-ity documents and the purchase of laboratory inspection equipment. The first equipment the company acquired was a TruView 180 radiog-raphy system, capable of 100% inspection of components on tape, tubes, and trays. We also trained them in how to identify counterfeit parts.
The latest production run at a large aerospace company was compromised by the infiltration of counterfeit electronic components. Their comprehensive quality assurance and control system was not properly designed to deal with counterfeit components. They came to us look-ing for help on how to ramp up their counterfeit detection capabilities within the context of their established quality control system.
TruView was deployed in the receiving de-partment of the company. TruView’s non-destructive inspection allowed company to check all inbound parts before delivery to manufacturing. The fully automated solu-tion enabled the company to perform 100% component inspection of parts in tubes, reels, and trays. The scalable TruView sys-tem allows for future upgrades that might be needed as electronics miniaturize and more detailed inspection is needed.
A single counterfeit detection of Samsung parts saved the company $96k. This amount does not account for other potential costs as-sociated with boards failing in the field.
CASE STUDYAEROSPACE COMPANY FIGHTS
COUNTERFEIT COMPONENTSTHE CHALLENGE
THE SOLUTION THE BENEFITS
THE RESULTS
Made in USA
TruView 180
X-Ray of Components in Tape
Creative Electron, Inc.253 Pawnee St.San Marcos, CA 92078
Phone: [email protected]
Visual inspection did not show anomalies in the lot
X-ray images overlaid onto photo of reel showing suspect
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TruView InspectionT
The company acquired a TruView 100 for their NDE quality assurance. The cost of inspecting 100% of their parts was minimized by the fully automated platform and software. Our team also designed a custom jig so multiple parts could be inspected with minimal human inter-vention. TruView’s automated anomaly com-parison software was critical determining good/bad parts. Data collection enabled manufactur-ing process to run root cause analysis and to fully document the results.
A medium size medical device company re-cently experienced a sudden decrease in their finish-product yield in one of their man-ufacturing lines. Their customers required an explanation. The company decided to implement a 100% non-destructive evalu-ation (NDE) of parts before shipping until problems were solved. Initial studies showed that 100% inspection was cost prohibitive.
The TruView platform enables NDE, which saves time and money in quality assurance because the product is not destroyed. Tru-View’s automated sample manipulation also enables cost-effective 100% inspection. Tru-View helped this customer not only to identify “what” was wrong, but also “why” was it going wrong. Scalability of the system allowed com-pany to buy entry level. As their devices get smaller, they have the option to upgrade to a higher resolution system when needed.
Problem with shorted thermistors was traced down to a defective soldering probe. Once probe was replaced, yield went back to normal.
CASE STUDYMEDICAL DEVICE COMPANY PLAGUED
BY MANUFACTUING DEFECTS THE CHALLENGE
THE SOLUTION THE BENEFITS
THE RESULTS
Made in USA
TruView 100
Creative Electron, Inc.253 Pawnee St.San Marcos, CA 92078
Phone: [email protected]
Good Thermistor Failed Thermistor with shorted terminals
“‘In the medical field quality isn’t everything, it’s the only thing. A big customer was going to walk away if we didn’t reduce fails. We found TruView to be the best in class for our quality assurance team. We have been able to diagnose problems that saved us hundreds of thousands of dollars.” Quality Manager
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The company acquired a TruView 200, for its ability to easily penetrate the shielded areas in the PCB. The x-ray camera of the TruView 200 can be set up with a long exposure time, which is ideal for inspections of dense materials. The 200’s automated custom path inspection was easily configured to inspect different parts on the board, thus producing consistent and reli-able inspection of the areas of interest. The TruView system’s portability was ideal to move it between manufacturing lines.
A large contract manufacturer was hav-ing trouble with the assembly of a complex smartphone PCB. The multiple shields on the board made it difficult to inspect parts under these metal lids. This post-production quality problem led to delivery delays and revenue loss. The company needed a diagnostics tool capable of finding the root cause of the issue.
TruView is a powerful radiography system that allowed this contract manufacturer to deploy the tool in the production line - at the point of defect. The unique portability of the system and its superior image quality, made the Tru-View 200 the perfect solution in this case. The contract manufacturer was able to determine the root cause of the problem faster than they would have done with other x-ray systems. De-tailed documentation of manufacturing issues enabled process analysis and optimization.
A recent yield issue was traced to a PCB short. The problem was determined to be a failure in a stencil. Savings in the thousands of dollars.
CASE STUDYCONTRACT MANUFACTURER’S
PROCESS OUT OF CONTROL THE CHALLENGE
THE SOLUTION THE BENEFITS
THE RESULTS
Made in USACreative Electron, Inc.253 Pawnee St.San Marcos, CA 92078
Phone: [email protected]
Short circuit found in PCB as-sembly of smartphone
Detail of short circuit found in PCB of smartphone
TruView 200
“‘TruView was the perfect solution that allowed us to diagnose and solve critical manufacturing problems that saved us hundreds of thousands of dollars. The perfect blend of image quality and portability let us bring the solution to the problem in the production line.” Head of Quality Control
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TruView InspectionT CASE STUDY
CABLE MANUFACTURER LOOSES CONNECTION TO QUALITY
Made in USACreative Electron, Inc.253 Pawnee St.San Marcos, CA 92078
Phone: [email protected]
A detailed analysis of their manufacturing pro-cess led to the purchase of a TruView 105. The basic system with a large 4” camera was ideal to inspect their products. A set of custom jigs was designed to expedite the automated inspection of cable assemblies. Main initial goal was to qualify production line to “zero defects”. During this stage 100% inspection was conducted. Once yield was high, compa-ny started a sampling program based on qual-ity standards for the automotive market.
A small cable/connector assembly company decided to expand their business and enter the lucrative automotive market. However, an audit of their quality assurance systems revealed a gap in their inspection tolerance. The level of er-rors accepted by their current commercial cus-tomers would not be accepted by their prospec-tive automotive customers. They needed to ramp up quality in a fast and cost effective way.
TruView allowed the company to execute a complete root cause analysis of their manu-facturing problems. TruView’s inspection docu-mentation tools enabled easy and cost effec-tive preparation for customers’ quality audits. The scalability of the TruView platform is key to the company’s growth. The success in the automotive market will fuel investment in the medical devices market. At that point, they plan to invest in a microfocus source to inspect the smaller cables and connectors for that market.
THE CHALLENGE
THE SOLUTION THE BENEFITS
TruView 105
“‘Just recently TruView helped us keep a major account. That’s why I see it as an insurance policy we bought for our quality department. Thanks to TruView and the guys at Creative Electron we not only fig-ured out what was going on, but also found a way to solve the problem at its root.” CEO and President
Problem was traced down to a defective crimp-er. Thousands of dollars were saved in material, inventory, scrap, and further testing.
THE RESULTS
Connector assembly, good sample
Connector assembly: failed sample with broken wire
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The original TruView 105 was upgraded to a TruView 285. Our engineers visited the labo-ratory to install the new microfocus source and reel-to-reel system. The whole installa-tion was done in 3 hours, and it was done after hours, thus without any operational interruptions to the company. The new sys-tem was ready for training on the following morning. Since the software architecture is the same within the TruView platform, train-ing requirements were minimal.
A test laboratory acquired a TruView 105 main-ly for PCB assembly inspections. Their busi-ness prospered, and as a result the test lab decided to expand their service offerings. They contacted us looking for an upgrade to their TruView system. The upgrade required a mi-crofocus x-ray source for failure analysis cus-tomers. They were also interested in entering the component counterfeit detection market.
The TruView solution platform allowed this test lab to acquire the radiography system that they needed when they needed. The lab did not have to pay for the extra features they didn’t need a the time. Then, when these upgrades became necessary, the lab was able to easily upgrade their TruView system to meet the new requirements. The sophisticated software platform is a key en-abler that minimized the need to retrain their staff on the new system.
The company estimates savings of over $200k thanks to their investment in the up-gradable TruView solution platform.
CASE STUDYTEST LABORATORY OUTGROWS ITS
RADIOGRAPHY SYSTEM THE CHALLENGE
THE SOLUTION THE BENEFITS
THE RESULTS
Made in USA
TruView 285
Creative Electron, Inc.253 Pawnee St.San Marcos, CA 92078
Phone: [email protected]
PCB assembly image with TruView 105
PCB assembly image with TruView 285
“‘We first invested in a TruView system about a year ago. At the time the system was perfect for what we needed and within our budget. As our business expanded we needed more. I’m glad we didn’t have to buy a whole new system and retrain our team. Upgrading our TruView machine was way easier.” CEO
