The SMART Group PPM Monitoring Launch Seminar. Bob Willis SMART Group Technical Director

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2 The SMART Group PPM Monitoring Launch Seminar Bob Willis SMART Group Technical Director

3 SMART Group Meeting Agenda History of The SMART Group s Involvement in PPM Monitoring Reason for DTI Process PPM Monitoring Support Proposed Methods of Collecting Data Criteria for inspection Establish Product Technology Level

4 SMART Group Meeting Agenda Lunch at 12.30pm Confidentiality of the Data Presentation of the Results PPM Defect Report Availability Agreement on Project Methodology Open and Final Discussion on the Project Afternoon tea at 3.00pm

5 History of The SMART Group s Involvement in PPM Monitoring 1994 Surface Mount Club/SMART Group Project SMART Group Workshops Chelmsford and Manchester 1999 SMART Group PPM Club /Web Site Based Collection

6 SMART Group s Involvement in PPM Monitoring

7 SMART Group s Involvement in PPM Monitoring

8 Total Defects X 1,000,000 = PPM Baseline 10 X 1,000,000 = 2000PPM 5000

9 SMART Group s Involvement in PPM Monitoring

10 SMART Group s Involvement in PPM Monitoring Process Sample Size Machine Checking Frequency Operator Board Reference

11 SMART Group s Involvement in PPM Monitoring Date Time Board/Sample Number Defect Classification Total Defects Baseline Parts Per Million

12 SMART Group s Involvement in PPM Monitoring Log Number Defect Date Time Initial Corrective Action

13 SMART Group s Involvement in PPM Monitoring Organise an initial meeting Audit production lines Illustrate the monitoring procedures Produce ppm-monitoring.com monitoring.com web page Initial results from company audits Second level for contributing companies Causes of most common yield variations Produce a project report & main web site

14 SMART Group s Involvement in PPM Monitoring How would your company benefit from having an industry average Parts Per Million (PPM) defect level for each manufacturing process on a monthly basis

15 SMART Group s Involvement in PPM Monitoring Benchmarking our processes has been something we have considered for a while now but we have so far been unable to locate data (common) to benchmark against. This would be very interesting to us. Since we are currently looking at re-starting our quality forum the PPM data would give us ideal stake in the ground aims. Ongoing we would be able to get an impression of our company s standing overall.

16 SMART Group s Involvement in PPM Monitoring We presently measure various process parameters (in PPM) but can only determine adverse or positive deviations we do not know how good we are. To meet ISO 9000 requirements we need to continually improve As we are embarking on a continuous improvement project the information received would allow our progress to be benchmarked with other organisations We would use it to verify (or not) our belief that we have a high yield, high quality process. If not, then we can measure improvements and benchmark our success.

17 SMART Group s Involvement in PPM Monitoring We operate a system of continuous improvement. Without this sort of data we operate in a shell we do not know how good, or poor, we are. We are currently implementing a project whereby we are attempting to measure our process stability using PPM (as per IPC recommendations) and would therefore be extremely interested in knowing whether the PPM we are reporting are actually of any order that is comparable to other companies.

18 SMART Group s Involvement in PPM Monitoring I would be prepared to make our site available for a SMART SMT audit. While there is always the issue of confidentiality and the threat of our competitors gaining knowledge of our processes, with careful management this could be minimised - we would need to work closely with you on this. I would also be prepared to contribute monthly un-named named yield data.

19 SMART Group s Involvement in PPM Monitoring Basic feedback has been very good Meeting with IPC January 2002

20 Reason for DTI Process PPM Monitoring Support Increase companies competitiveness in the UK Support for established trade group Reference for other Manufacturing Projects

21 Proposed Methods of Collecting Data 49

22 Proposed Methods of Collecting Data IPC 7912 July 2000 Calculating of DPMO and Manufacturing Indices for Printed Board Assemblies IPC-9261 March 2002 In-Process DPMO and Estimating Yields for PWAs

23 Criteria for Inspection

24 Criteria for Inspection

25 Criteria for Inspection

26 Criteria for Inspection

27 Establish Product Technology Level

28 Establish Product Technology Level

29 Confidentiality of the Data Company Representative SMART Group Project organiser Web Page Developer

30 Presentation of the Results Web Site monitoring.com Access to average yields for each process Access to the procedures for PPM Monitoring Access to process defect guides Benefits on contributing to the project PPM Monitoring News Letter

31 Contributors Presentation of the Results Web Site monitoring.com Access to all of the results Small Medium Large Volume Access to process technology levels Access to basic process information Defect types causing PPM shift per month Contributors discussion forum Other information

32 PPM Defect Report Availability Provide Monthly Process Average on Web Sites Quarterly Report for Sale to Fund Web Site Present Results at Seminars and Conferences

33 PPM Parts Per Million Defect Levels PPM January Stencil P rinting Com ponent R eflow Soldering W ave Soldering Placem ent

34 PPM Parts Per Million Defect Levels PPM September Stencil Printing Com ponent Placem ent Reflow Soldering W ave S oldering

35 Agreement on Project Methodology Train a group of staff in the data collection process used for PPM Monitoring and establishing process yield Confirm criteria for: Solder paste printing Component placement Reflow soldering Wave soldering

36 Agreement on Project Methodology Monitor a sample of boards from a batch currently in the assembly processes to obtain the data to provide the initial average PPM levels Define the basic process used for assembly for future reference Define the technology level of the products inspected to allow companies to better understand the yield data

37 Basic Process used for Assembly Screen Printing Stencil Type Laser Cut, Electroform, Etched Stencil Thickness 0.005, Squeegee Blade Metal, Rubber, Sealed Head Inspection 3D or 2D Paste Type No Clean, Water Wash PCB finish - Copper - Tin/lead - Gold - Silver

38 Basic Process used for Assembly Placement PCB finish - Copper - Tin/lead - Gold - Silver

39 Basic Process used for Assembly Reflow Soldering Number of zone Length of oven PCB finish - Copper - Tin/lead - Gold - Silver Convected Air - Nitrogen

40 Basic Process used for Assembly Wave Soldering Flux type - No Clean - VOC - Water Soluble Selective soldering One or two waves Solder tin/lead or lead free PCB finish - Copper - Tin/lead - Gold - Silver Air or Nitrogen

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42 Agreement on Project Methodology Train a group of staff in the data collection process used for PPM Monitoring and establishing process yield Confirm criteria for: Solder paste printing Component placement Reflow soldering Wave soldering

43 Agreement on Project Methodology Printing Number of apertures printed Placement Number of components placed Reflow Number of joints soldered Wave Number of joints soldered

44 Agreement on Project Methodology Monitor a sample of boards from a batch currently in the assembly processes to obtain the data to provide the initial average PPM levels Define the basic process used for assembly for future reference Define the technology level of the products inspected to allow companies to better understand the yield data

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