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SURVIVAL TECHNIQUESStreamline AOI/AXI process with software innovations
Presented by
Bruce Isbell
Agilent Users GroupJan 16, 2008
© 2006, Valor. All trademarks are the property of their respective owners. 2
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
© 2006, Valor. All trademarks are the property of their respective owners. 3
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
© 2006, Valor. All trademarks are the property of their respective owners. 4
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
© 2006, Valor. All trademarks are the property of their respective owners. 5
High Level issues
-Bad data-Incomplete data-Tooling errors-Library conflicts
-Unpredictable demand-Frequent Changes (ECNs)-Higher complexities-Regulations for Traceability & RoHS
COMPOUNDING events
© 2006, Valor. All trademarks are the property of their respective owners. 6
URGENT pressures collide…
Valor software solutions Valor software solutions were designed to bring were designed to bring order out of chaosorder out of chaos
© 2006, Valor. All trademarks are the property of their respective owners. 7
How?
© 2006, Valor. All trademarks are the property of their respective owners. 8
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
© 2006, Valor. All trademarks are the property of their respective owners. 18
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
© 2006, Valor. All trademarks are the property of their respective owners. 19
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)
© 2006, Valor. All trademarks are the property of their respective owners. 20
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
© 2006, Valor. All trademarks are the property of their respective owners. 21
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
© 2006, Valor. All trademarks are the property of their respective owners. 22
Need for Centroid Correction - Examples
© 2006, Valor. All trademarks are the property of their respective owners. 23
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
© 2006, Valor. All trademarks are the property of their respective owners. 24
25 © 2006, Valor. All trademarks are the property of their respective owners.
DFMVST Data Preparation
Line Balancing Optimization
Putting it all together
26 © 2006, Valor. All trademarks are the property of their respective owners.
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
27 © 2006, Valor. All trademarks are the property of their respective owners.
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
28 © 2006, Valor. All trademarks are the property of their respective owners.
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
29 © 2006, Valor. All trademarks are the property of their respective owners.
DFMVST Data Preparation
Offline Placement Simulation
XY Corrections
Placement Correction
Rotation Correction
Line Balancing
Putting it all together
Off-line process simulation and correction
© 2006, Valor. All trademarks are the property of their respective owners.
30
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 !
© 2006, Valor. All trademarks are the property of their respective owners. 31
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