Automating the In-Circuit Test in Your Factory

Measurement Test Division

Keysight Technologies

July 23, 2015

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Page Agenda

– Overview of Inline ICT automation - Introduction to Keysight & In Circuit Test - Test automation and ICT automation - Keysight engagements in ICT automation

– Considerations that impact the decision to automate in-circuit test - Products - is your product suitable for automation? - Manufacturing and test processes - Organization - who will be involved?

– Benefits of automation - Improved product quality - Lower costs - Other automation considerations

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A Brief History of Keysight

1939–1998: Hewlett-Packard years A company founded on electronic measurement innovation

1999–2013: Agilent Technologies years

Spun off from HP, Agilent became the World’s Premier

Measurement Company. In September 2013, it

announced the spinoff of its electronic measurement

business

2014: Keysight begins operations

November 1, Keysight is an independent

company focused 100% on the electronic

measurement industry

We believe in “Firsts” Bill Hewlett and Dave Packard’s original vision launched

Silicon Valley and shaped our passion for “firsts” 75 years

ago. Today we are committed to provide a new generation

of “firsts” – software-oriented solutions – that create value

for our investors and valued insights for our customers.

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Keysight in Electronic Measurement The industry leader

FY13 $2.9 billion revenue | 18.9% operating margin | 31% ROIC | best in class financial profile

Communications Industrial, computer,

semiconductor

Aerospace/defense

(1) Presented on a non-GAAP basis; reconciliations to closet GAAP equivalent provided. See reconciliations for definition of ROIC.

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World-class applied research driving tomorrow’s

innovations

Ph.D. researchers including multiple IEEE Fellows creating

new measurement IP to address emerging customer needs

ASIC design center and proprietary fabrication facility

Technology centers for MMICs, optical components, and

microelectronic packaging

Aligned to product divisions to accelerate customer

solutions

Keysight Technologies Measurement Research Instrumental to our customers’ success in a rapidly changing world

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Consistent ICT Market Leader *

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1985 - 3060 1994 - 3070 SII 1998 - 3070 S3 2007 - i3070

2009 – i3070 Series 5 2012 – i3070 HNC 2013 – i3070 E9901EL 2013/4 – i3070 S5i

Continuous product evolution & upgradability for greater ROIC.

* Market Leader as per Prime Research

• #1 Market Share * with 7000

systems deployed globally

• Pioneer in maintaining high test

coverage with limited access

• Key OEM, CEM, ODM

customers globally

• $70K ~ $400K range of products

to suit all needs and budgets

2010-i1000D i1000 Inline

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Keysight Automation History

1970s 1980s 1990s 2000s 2010s

3070

EFS-

Express

Fixturing

System

inline

3070 JOT

Handler

Partnership with major inline automation companies such as JOT, IPTE, CRS, etc.

> 1100 automated ict systems (including robotic arms)

3070 inline

HP 3060

HP 3065 i1000 inline

HP 3070

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Page In-Circuit Automation Configurations

– Externally Integrated Handlers

– Automation with Robots

– Fully Integrated handlers

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External integrated handlers can be categorized in two groups: • Bridge type handlers

• Go across the system with a long board travel distance

• In-feed needed to reduce handling time.

• 19 inch handlers • Functional + ICT

• Customized fixture interface and solution

These handlers are using motorized or pneumatic press. • Vacuum based fixtures need modification

Pros

• Flexible configuration and customization to needs

• Potentially works with existing systems and fixtures

Cons

• Multiple suppliers to complete the automation

• Restricted fixture options such as fixture suppliers

External Integrated Handlers ICT

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Automation with Robots

Robots purely replace operators and handle boards in the same way.

• Requires different types of grippers such as suction, craw, etc. to lift the board.

• Number of moving axis in the robots affects the effectiveness of handling against cost.

Pros

• Potentially lower cost if factory robot expertise is leveraged

• Works with existing systems and existing fixtures can be re-used

• Dual well fixtures possible to further reduce handling time.

Cons

• Large production area needs to be fenced

• Robot arm programming and configuration time Optimizing axis movement for handling time and accuracy

Gripper change – shape, weight/center of weight, and type of grip

• Potentially slower handling time (except for dual well)

• Follow up support cost of the robot and engineering

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Fully Integrated Inline ICT

Fully Automated Inline ICT provides best support model with balanced cost.

• Uses the same conveyor transport like the bridge handlers

• Normally come in press-down style.

Pros

• Single contact window for support needs

• Easy maintenance

• Zero foot print

• Upgradable from existing systems

Cons

• Limited node count and configuration

• May not be compatible with existing fixtures

• Difficulty in customization

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Page Considerations for Going to Automation

Efficiency is the foundation – testers and handlers needs to run without interruption.

High number of false fails and handling problems can make automation a

nightmare.

Two areas should be considered.

– Board Characteristics

– Manufacturing and Test Process

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Board Design Considerations

Automation Friendliness from Physical Board Design

• Size/dimension

• Max board size and the dimension limits of the handler.

• Weight balancing affects effectiveness of robot arms gripping as well as conveyor transport

• Warpage can be significant on thin PCB as well as large boards that affects auto alignment

• Size of test points and PCB tolerance

• PCB tolerance affects the position of test points.

• Normally test access size needs to be greater than 20mil

• Odd shape boards might not work perfectly with board stoppers

• Board carriers needs to be implemented.

• Requires 3mm straight board edge for transport

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Board Design Considerations

Number of test access and node count

• Normally handlers are good with 2,000~2,500 nodes and first pass yield drops

significantly for 3,000 nodes or above.

• For 10ppm risk of off-target

- Contribute 1% false call at 1,000 nodes

- 2% at 2,000 nodes

• If 50ppm risk

- 5% false call at 1,000 nodes

- 10% false call at 2,000 nodes

Additional efforts to handle the fall outs from

the inline station

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Board Design Considerations

– Single side vs. double side

• Topside and bottom side probing alignment makes testing double side boards more difficult.

– Panelization

• Panelized board normally increase the efficiency

• Some parallel testing can be performed to further improve output.

– Component height - especially tall components on both sides of the DUT.

• Topside is normally not an issue – as high as 100mm

• Bottom side normally is 25mm as IPC standard.

• Flow direction considerations

C R 40mm

60mm?

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SMT and Test Process Considerations

Semi automated

– Manual insertion and wave soldering

– Test after depanelization/routing

– Manual placement/removal of carriers

Full Automated

Semi Automated

Full Automated

– Automated through hole insertion

– Reflow oven with pin-in-paste

ICT Automation is easier for a fully

automated line

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SMT and Test Process Considerations

Wave soldering vs. Reflow Oven

• Wave soldering requires carriers and may not be suitable for ICT (test access

blocked)

• Loading DUT to carriers is manual – not automatic

Depanelization and Routing

• Routing/depanel can remove the board edges.

• Routing before ICT will need design with sufficient board edge

Carriers – non rectangular boards, panels, lack of board edges

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Testing

SMT and Test Process Considerations

Island strategy vs. in-line strategy

– Moving within the same strategy will be more straight forward.

• Change in strategy increases complexity

- # of testers, tester leverage level, etc.

– Island strategy usually runs more models and requires more considerations such fixture exchange time.

Production

Production Line

ICT

ICT

in-line manual strategy Island strategy

Inline

Automatic

Island

Automatic

Inline

Manual

Island

Manual

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SMT and Test Process Considerations

Extra equipment needed:

• Cooling for capacitors testing

• Buffer conveyors

• Barcode, auto barcode readers and MES shopfloor

• Paperless repair station

It will be Product Models going automation. Not single product model.

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Page Benefits from Automation

– Quality Improvements

– Production Management

– Cost Reduction

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Benefits from Automation

Reduce Human Interaction with Your Product

Human interaction is a quality concern

- Boards can get damaged during handling

• ESD protection and board damage?

• Too many fixture engagements caused damage?

- Un-tested boards can flow to customers

• Testing only one board and pass all the other boards?

• Unauthorized test program and fixture changes?

- Process improvement opportunities bypassed by operators

People touching

the board!

Quality Improvements

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Benefits from Automation

Unified process between lines and factories

• It is common for the same product to be produced in different countries.

• It is even more common for one model to run on multiple lines in the same factory

With automation, you can achieve one test program runs on multiple lines in different

countries.

Quality Improvements

Brazil

US

China

Hungary

Same configuration Same configuration

1

2

3

4

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Benefits from Automation

Quality improvements link to corrective actions and activities are traceable

• Quality changes can be reflected in ICT yield almost immediately.

• Environmental factors (such as human interventions) affecting quality can be

greatly reduced

Quality Improvements

Probe change

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Benefits from Automation

• Output Volume – stable and predictable shipments

- No more baskets of un-tested boards

• Remove labor variations – cost and experience

- Temporary operators, shift changes

• More output per line – better efficiency

Production Management

Two shifts Two shifts

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Benefits of Automation Production Efficiency and Handling Time

Test Time Handling time Manual handling

Test Time

Improved efficiency

Automated inline

Improved handling efficiency - 10~15% depending on actual test time.

Will automation inject line down time and eats up the benefits from handling time?

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Benefits of Automation Down Time is Crucial to Production Efficiency

Production Time Line down time

Line down time

• New product introduction (NPI) debugging

• Production test program fine tuning

• Maintenance

• System break down

NPI Debugging – Occupies time from production line

Production Fine Tuning – making first pass yield improvements

System Maintenance and Repair

After implementing automation, you don’t expect a higher down time.

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Cost of Automation

– Reduction: operator cost

– Addition:

• Board handler and accessories

• Additional equipment costs

• Fixture conversion investment

• Annual maintenance cost

• Engineering expertise on automation

– Intangible Benefits:

• Better quality products

• Improved brand image and value

Does it really save money?

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Benefits of Automation

– Operator cost : $25K per year per person

– Automation hardware cost : $90K

– Fixture conversion cost : $30K

– Annual maintenance cost : $5K

Cost of automation pays back in the 6th year.

Example of Automation Savings

Actual savings in dollar amount may not be

obvious in the initial years.

But improvements in quality, brand image

and value will be significant.

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Benefits of Automation

– ICT automation involves many departments and manufacturing processes. The right

product characteristics and optimized process produce the best results.

– Benefits from ICT automation includes

• Quality improvements

• Production management

• Cost reduction

– Keysight has a long history and experience in ICT automation. We can help you with

deeper insight to meet various ICT automation needs, from robotic arms, bridge

handlers to fully integrated solutions.

Summary

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Questions?

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What’s Coming Up Next?

– Keysight Automated Inline ICT Series

• Automated Inline ICT – Powertrain and Hybrid August 19 at 10 a.m. PT

• Automated Inline ICT – Body Electronics, Safety and Driver Assistance September 24 at 10 a.m. PT

• Automated Inline ICT – Infotainment and Communication October 29 at 10 a.m. PT

• Automated Inline ICT – Industrial and Home Appliances November 19 at 10 a.m. PT

• Automated Inline ICT and Functional Test December 10 at 10 a.m. PT

– Next session will focus on the “Powertrain and Hybrid” test application

– Please visit the event page to register now

– For more information about Keysight Automated ICT products, please visit our product page at http://www.keysight.com/find/ict

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