“Process Control Tools for the PCB Industry”

What’s New..!!!

Process Control SURPRISE..!

Agenda

INTRODUCTION▪ ScanCAD International, Inc.▪ Today’s PCB Assembly Environment

PROCESS CONTROL TOOLS▪ PRE PRODUCTION

▪ New Product Introduction (NPI)▪ Product Changeover

▪ PRODUCTION▪ Traceability▪ Real Time /Closed Loop▪ Direct Feedback

SUMMARY

Introduction – ScanCAD Int’l

▪ Over 1000 Companies in 47 Countries

- First Systems Installed in 1987

▪ Company Founded in 1990

- Global Sales & Support Network

- OEM Partners

▪ Vision Systems

- PC- Based

- Low Cost, Easy to Use,

- Multi purpose

▪ Strategic Partnership – ECT - Dover Corporation

- 3000+ Software Licenses in Asia/Europe/Americas

PCB Assembly:

Today’s Environment – Challenging?▪ DESIGN: Manufacture products that are designed by somebody else out of your

control with little regard as to whether they can really be built

▪ SOURCES: With raw materials coming for a variety of sources (bare boards,

components, lead free solder, fixtures, stencils, screens, etc.

▪ EQUIPMENT: On a wide variety of machines, feeders, printers, ovens, conveyors,

packaging, testing, routing, depaneling, burn in, etc,

▪ PROCESSES: That have many processes that including molten liquids, pastes, glues,

epoxy, squeegees, hot, cold, press fit, manual, automatic, testing, carriers,

tape, feeders, carriers, etc, etc.

▪ LOCATIONS: Across multiple locations, possibly even globally

▪ PEOPLE: Supporting a large variety of people skills, languages and experience

▪ COMPONENT SIZE: Everything is getting smaller & smaller… 0101, micro bga, etc.

▪ CHANGE OVER: Production runs are getting shorter and shorter

▪ NEW PRODUCT: Product life cycles are shorter – from years to months or less

▪ COMPLIANCE: All done in a clean, secure, safe environment

▪ NO DOWN TIME: 24/7

▪ TRACEABILITY: Medical, Safety, ISO, CE, UL, FAA, etc.

▪ AND….. Do it with….

▪ ZERO DEFECT: With zero defects and no rework…!

In a word…. You are Magicians..!

Pre-Production - Existing Tools

▪ A Variety of Skill Level People Using:

- CMM (Granite based)

- Optical Comparitor

- Calipers, Microscopes, Gauge Blocks/Pins

- Word Processor Based Work Instructions

- etc.

▪ Push back to suppliers

No significant changes in 30 years…!!!!

▪ Catch problems BEFORE production floor – PRE-Production▪ Design (holes, slots, real estate, manufacturability…)

▪ Components (multi vendor, shape , color, size….)

▪ Boards (multi vendor, variables…)

▪ Stencils/screens (stretch, wear, missing, blocked or damaged apts.)

▪ Work instructions (clear, current, precise, multi-language…)

▪ Catch problems REAL TIME - Production▪ Close the loop

▪ Direct Feedback

▪ Watch the process

▪ Detect trends BEFORE they reach failure

▪ In-line or Off-line SPC

▪ Traceability at all steps of production, including manual operations

Process Control Philosophy

NO SURPRISES…!!!

Inspection vs. Measurement

ScanCAD Inspection Systems

▪ Check 100% of Part – Ensure no bad parts ship

▪ Output is Pass/Fail vs User Defined Tolerance

▪ Low Cost

▪ Overlay CAD and Image - Very Easy to Program

▪ Fast - Inspect parts with millions of features in minutes

▪ Multi-Purpose - Inspect multiple part types and create data

▪ Can also provide some measurement capability

▪ Complimentary to measurement systems - many customers have both. (Measurement systems not able to inspect 100% of part)

Defects Found by Inspection

Wafer Bump Stencil

Over 350,000 Apertures – 100 um diameter

1 mil blockage

Pre-Production – New Tools

Pre-Production – New Tools

▪ Simulate Production and create work instructions using actual parts…!

▪ Overlay all variables in a virtual environment

▪ Perform “tweaking” BEFORE production

▪ Change or create data that “matches” material

▪ Don’t move to production until 100% confident

How…?

Use Low Cost Vision Technology

▪ Use Existing Vision Platform▪ Camera, lighting, motion control “all” in one unit▪ Worldwide availability and support▪ Excellent price/performance ratio▪ Low risk – not proprietary hardware

▪ Very High Resolution ▪ 200 – 12,800 dpi, Color or B&W▪ A3 size scan area – inspect up to 800 X 800 mm

▪ Accurate▪ Calibrated system with NIST glass plate

▪ Software performs self diagnostic test

▪ Robust Hardware▪ Small footprint▪ High MTBF

“…a very smart package”

True Optical Mpixels Total

Year Scanner Resolution(DPI) per sq. in. MPixels

1990 Model F1 400 x 400 0.16 31

1998 Model E8 800 x 1600 1.28 247

2001 Model E16 1600 x 3200 5.12 988

2004 Model E24 2400 x 4800 11.50 2224

2006 Model E32 (A4) 3200 x 6400 20.50 2002

2009 Model E48 (A4) 4800 x 9600 23.00 2224

2013 Model E24x 2400 x 4800 11.50 2224

Scanner Evolution (1990 – Present)

1 Model E24x Scanner equal to

440 5Mpixel Cameras!

(2.2 GigaPixel)

Pre-Production Process Control

▪ Scanner Faces Up

▪ Part Faces Down▪ Dry parts or

▪ 3D & wet parts with standoff

▪ Lighting▪ Top or bottom

▪ Calibrated System▪NIST Glass plate

Pre-Production Process Control PCB Assembly

ScanINSPECT VPIVirtual Product Inspection

With a single system check:

▪ Design - holes, slots, real estate, manufacturability…

▪ Components - multi vendor, shape, color, size…

▪ Bare Boards - FR4, Ceramic, Flex (multi vendor, variables…)

▪ Wet Boards - paste, adhesive, coatings, etc.

▪ Loaded Boards - SMT, Through hole, Connectors, etc.

▪ Stencils/screens - stretch, wear, missing, blocked or damaged apertures

▪ All variables come together in VIRTUAL system before Production

And in addition, same system can:

▪ Create stencil Gerber data from scanned image of PCB, artwork, etc.

▪ Create assembly programs from CAD, Gerber data or scanned images

▪ Create component vision files for SMT placement machines

Pre-Production Process Control PCB Assembly

Bare PCB’s

Stencils Components

PCB’s with Paste or

Adhesives

Loaded PCB’s

Flex Circuits

ScanINSPECT VPI

SMT Magazine Article

▪ GOOD NEWS: ScanINSPECT VPI ROI ARTICLE:

▪ “Using Stencil Design to Reduce SMT Defects” - SMT Magazine, April 2006

▪ http://www.ems007.com/pages/zone.cgi?a=62964&artpg=1

▪ Case Study of benefits of making a STENCIL that matches the PCB

▪ 125,000 units over three weeks to obtain the data

▪ Board measurements made using CMM at 6 reference points

▪ Modify Gerber data to match board

▪ Stencil made to PCB instead of Gerber

▪ 43% solder paste defect reduction…..!!!

Click Here

SMT Magazine Article - continued

Figure 5. Pad positional deviation

measurements (mils) between a

stencil and PCB prior to scaling.

Relative to the original Gerber

data, some pads were off by as

much as 0.005”-0.006”.

Figure 6. The same X, Y pad aperture

deviation after scaling the stencil to

the PCB.

Pre-Production Process Control Hybrid Microcircuits

ScanINSPECT VPIVirtual Product Inspection

With a single system check:

▪ Design - holes, slots, real estate, manufacturability…

▪ Artwork – Mylar, diazo, glass, chrome, etc.

▪ Wet Substrates – conductor, dielectric,resistor, etc.

▪ Loaded Substrates – Components, connectors, leads, etc.

▪ Stencils/screens - stretch, wear, missing, blocked or damaged apertures

▪ All variables come together in VIRTUAL system before Production

And in addition, same system can:

▪ Create stencil Gerber data from scanned image of PCB, artwork, etc.

▪ Create programs from CAD, Gerber data or scanned images

▪ Create vision files for SMT placement machines

▪ Create Work Instructions (WIS)

Pre-Production Process Control Hybrid Microcircuits

LTCC or Thick Film

Print

ScreensArtwork

Substrates with Paste

or Adhesives

Loaded Substrates

Holes in

Substrates

ScanINSPECT VPI

Pre-Production Process Control Tools

▪ Promote consistent, repeatable processes

▪ Compliment your current processes with the new tool..!

▪ ROI possible with one production run

“VIRTUAL problems are much

cheaper than REAL problems…!!!”

Production Process Control

Real-time, closed-loop systems

including manual operationsPaperless

Deployment

Paper Deployment

Instruction TerminalsEquipment Interface

Data CollectionElectronic Forms

Generate pdf FilesPrint Work Instruction

Process Management

Server

Production - Existing Environment

▪ A variety of skill level people using:

- Microscopes, calipers, gauge blocks/pin

- Inspection Stations

- Sampling

- Word Processor Based Work Instructions

▪ Single function, expensive automated systems

- AOI, SPI, X-Ray and Electrical Test

- Only used on select lines and/or products (High Margin)

- Does not address manual processes

▪ Difficult & Slow Post Production Analysis

- Insufficient history, process control, traceability, etc

- Missing real time feedback for manual processes

Production – New Tools

Off-line & In-line

▪ Low Cost

▪ Multi Purpose

▪ Easy to Use

▪ PC Based

▪ Direct Feedback

▪ Real Time Job Status

▪ Full Traceability

Electronic Work Instructions

Paperless Work

Instructions

Electronic Work Instructions

It’s Not Just Work Instructions!

It Disseminates and Collects Manufacturing Intelligence

ScanCAD products

combine a dynamic blend of

process management, work

instruction and Manufacturing

Execution Software (MES) that

allows for the dissemination and

collection of Manufacturing

Intelligence (MI) on the shop floor.

Paperless Deployment

Paper Deployment

Instruction TerminalsEquipment Interface

Data CollectionElectronic Forms

Generate pdf FilesPrint Work Instruction

Process Management

Server

Process Management

Process Monitoring

Data Collection

Reporting

Electronic Work Instructions

Display: Pictures, Video, Drawings

Simple and Efficient Editing

Revision Control

Fully Scalable

Link to Other Business Systems

Multiple Language Support

Integrated Crystal Report Generation

Traceability

Interface External Applications

CAR / PAR Support

Standardized Training Tools

Replicate & Synchronize Processes Across Regions

Electronic Work Instructions

Higher Quality -Process is performed the same way every time

Not people dependent

All QA checks performed to the same standard

100% Traceability for compliance

Improved Efficiency -

Fewer mistakes

New users trained by software, not another user

Lower skilled workers perform higher level tasks

Knowledge is in the software

Increased Productivity -Issues solved quickly

Automated repetitive functions

Users are guided through entire process

Process Portability -

Entire process with support documentation can

easily be exported to other facilities

Benefits

▪ Missing or miss-placed bonds are automatically

detected

▪ Golden board programming

▪ Flexible and quick to program

▪ Improve yields and minimize rework

ScanINSPECT WBI provides 100% verification of absence / presence

of wire bonds before adding further value to the package.

ScanINSPECT-WBI™

Wire Bond Inspection

0.7 mil

wires

▪ Automatic Inspection of:

• Bridging

• Paste on Pads

• Total Area of Paste

▪ Golden board programming

▪ Flexible and quick to program

▪ Improve yields and minimize rework

ScanINSPECT SPI provides 100% verification of printed solder paste

before adding further value to the PCB.

ScanINSPECT-SPI™

Solder Paste Inspection

▪ Bridging

▪ Over printed paste

▪ Under printed paste and shifted paste

ScanINSPECT-SPI™

Solder Paste Inspection

▪ Missing or undersized material is automatically detected

▪ Golden board programming

▪ Inline or offline

▪ Flexible and quick to program

▪ Improve yields and minimize rework

100% inspection (AOI) of adhesive, epoxy or paste placement

(absence / presence) on PCBs after dispensing or printing.

ScanINSPECT-ADI™

Automatic Dispense/Print Inspection

▪ First article or production inspection

▪ Utilize Gerber for 100% verification of print images to

detect missing or excess material

▪ All errors automatically flagged and viewed

100% inspection (AOI) of excess and voids of screened / printed

conductive and thick film materials on green tape and ceramic substrates.

ScanINSPECT-API™Automatic Print Inspection

Sample error images

ScanINSPECT-API™Automatic Print Inspection

100% Automatic inspection of ball or bump placement,

pre and / or post reflow

ScanINSPECT-BPI™Ball Placement Inspection

▪ Confirm ball or bump absence / presence

▪ Detect errors before reflow permitting easy rework

ScanINSPECT-BPI™Ball Placement Inspection

Missing Error

0.3 mm balls

Summary

▪ Catch problems BEFORE production floor – “Virtual problem”

▪ Catch problems REAL TIME – before failure – “Close the loop”

▪ Eliminate REWORK

▪ Full TRACEABILITY, including manual operations

▪ Environmentally friendly

▪ Maximize existing capital investment

▪ Reduce operator, engineer & management stress

ScanCAD™ Process Control Tools

Eliminate SURPRISES…!!!

▪ Proven - 1000+ Systems Installed in 47 Countries

▪ Economical - Low Cost Systems - Quick ROI

▪ Easy to use - User Friendly, PC Based

▪ Off-line - Small Footprint Desk or Desktop

▪ In-line - Small Footprint Conveyor

▪ Accurate - Calibrated System

▪ Flexible - Many Inputs / Outputs

▪ Multi-purpose - All Software on Same Platform

▪ Powerful - 50 micron (2mil) Features

▪ Upgradeable - Annual Releases Since 1990

▪ Environment - Minimize Scrap and Rework

Scanner Based Systems

▪ Proven - 3000+ Licenses in Asia/Europe/Americas

▪ Economical - Low Cost Systems - Quick ROI

▪ Easy to use - User Friendly, PC Based

▪ Standalone - Entry Level System

▪ Scalable - Network Based System

▪ Quality - Consistent Processes

▪ Flexible - Many Inputs / Outputs

▪ Portable - Processes Shared Across Facilities

▪ Efficient - Reduce Training and Setup Times

▪ Traceable - Bring to Manual Operations

▪ Global - Multi-Language

Work Instruction Systems

12779 West Belleview Avenue

Littleton, CO USA 80127

Phone: +1 303.697.8888

Fax: +1 303.697.8580

info@scancad.com

www.scancad.com