CERN

Betty Magnin TS-DEM

TS-DEMTS-DEM

Betty Magnin

CERN

Introduction of Quality Procedures in the Electronics Design Office

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Betty Magnin TS-DEM

TS/DEM missionTS/DEM mission

• From schematics to mounted PCBs

• 1 to 200 pieces/project, largest 2000 pieces

• Project cost: CHF 150.- to CHF 20’000.-

• Around 800 projects / year– (500 new designs, 150 modifications, 150 production only)

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Betty Magnin TS-DEM

Introduction

Introduction

• 2002: two Design Offices from EST and PS merged.Both had their own tools and methods

• 2003: we provided additional services with smallseries production of electronics

• 2004: FSU contract requires change of methods

• 2004: volume of projects drastically increased

Design office

DEM-BE

Circuit manufacturing

DEM-PMT

Assembly

DEM-WS

Sub-contracting

Large quantitiesmember states

Planning office(DEM-BE)

‘commercial’ contact

Ordering

Tracking

Invoicing

Circuit or moduleRequest

TS-DEM TS-DEM

Sub-contracting

(overflow of CERN capacity)

Prototypes, fast turn-aroundlocal industry

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Betty Magnin TS-DEM

Process Chart

Process Chart

Plan and follow-up the project

Design librairies

Order PCB’s

Order mechanical parts

Order components from stores

Order Assembly

Design layout

Deliver and

Invoice

Receive order

Advise for DFM

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Betty Magnin TS-DEM

Why quality procedures ?Why quality

procedures ?

• Understand and satisfy the customer’s needs

• Standardise working methods

• Design layout suited for manufacturing and assembly

• Have a reliable management of the activity, inhouse and subcontracted

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Betty Magnin TS-DEM

The sources of non-quality

The sources of non-quality

Policies

PlantPeople

Procedures

Design Office

Can be determined through Ishikawa Diagram (4P’s)

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Betty Magnin TS-DEM

People

People

• Determination of designers’ versatility

• Training through visits to assembly site

• Technical training to increase versatility and competencies (Cadence, High-Speed Design,…)

• Regrouping of the two design offices in one building

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Betty Magnin TS-DEM

Plant

Plant

• 5S ProcessThe five S stand for the five first letters of Japanese words meaning: Sorting out (Seiri), Systematic arrangement (Seiton), Spic and span (Seiso), Standardizing (Seiketsu), Self-discipline (Shitsuke)

• Eliminate what is useless

• Organise archiving of paper document and files

• Organise storing of components and documents for orders

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Betty Magnin TS-DEM

Procedures

Procedures

• Specify input data (together with DUG)

• Promote Design Review (together with DUG)

• Elaborate input data verification check-list

• Define a common procedure to produce documentation of mechanics drawn with Autocad

• Review generic PCB layout (panelisation, fiducials,…)

• Specify format of board and assembly part-lists

• Elaborate output data validation check-list

• EDMS archiving

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Document management via EDMS Document management via EDMS

• Schematics

• Specification

• PCB Layout

• Manufacturing

• Assembly

• Mechanics

• Pictures

• Supplier info

We send only the EDA number to subcontractors!

Items: EDA-xxxxx

Items: EDA-xxxxx

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Betty Magnin TS-DEM

Policies

Policies

• Standardise design rules

• Standardise librairies

• Review available standards: JEDEC, NF, IPC, …

• Define IPC as the standard: covers all aspects from design to manufacturing, assembly and repair

IPC: Institute for Printed Circuits

              

               

 

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Betty Magnin TS-DEM

Planification

Planification

Prototype electronics productionmulti-layer PCB, standard priority

• Control of the turn-around time means:- tight planning and follow-up- companies you can rely on

Queue

2-3 weeks

Layout

1-2 weeks

Layout (and queue)

4 weeks

PCB fabrication

3 weeks

Assembly

2 weeks

Margin

1 week

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Betty Magnin TS-DEM

Planification

Planification

• Until 2004, several tools– one Filemaker database, 3 Excel files

• JMT2 project for DEM– released for invoicing of multisection jobs

Under test for the invoicing of specific PMT and WS jobsIn work for the planning aspects

• The Design Office needs a single centralised activity management tool until the JMT2 project of TS/CSE is fully released

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Betty Magnin TS-DEM

Activity management tool

Activity management tool

• Centralised entry of all needs

• Simultaneously accessible by all section members

• Issues queries of orders to be launched by a supplier (internal or external)

• Issues queries of ongoing or late orders

• Issues the global invoice, for a one time entry in JMT2 when the job is delivered

• Simple MS-Access Data Base requiring no special knowledge to be maintained

Outil de gestion-planification

Outil de gestion-planification

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Betty Magnin TS-DEM

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Betty Magnin TS-DEM

Next stepsNext steps

• Continue with the planned actions

• Training (visits of PMT and WS workshop, EMC, …)

• Document in EDMS the procedures defined in 2004

• Finalise the input and output controls for designs

• Finalise the implementation of JMT2

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Betty Magnin TS-DEM

ConclusionsConclusions

• Quality is important

• There is a lot to improve– will give cheaper and better producible electronics

– will give higher quality designs (more reliable, less noise...)

• I have the ideas on how to improve– using standards, technical training, improving procedures

• We have started the process, but it is not easy– long history

– high workload for LHC

– no resources for a “bureau de méthodes”