Tecnomatix for electronicsComprehensive NPI software solutionsfor PCB assembly and test

Siemens PLM Software provides PCB assemblers with the mostcomprehensive software solution set for planning, optimizingand testing new product introductions for PCB assembly.

www.siemens.com/plmSiemens PLM Software

The Tecnomatix® PCB Assemblyand Test software solutionprovides PCB assemblers withthe most comprehensivesoftware solution set for planning,optimizing and testing newproduct introductions for PCBassembly by seamlessly convertingdigital product development intomanufacturing programs fromupfront assembly and testabilitychecks to fully commissioned SMT,hand insert and tester machineprograms. Using the PCBAssembly and Test solutionmanufacturers can optimize theirSMT machines cycle time, balancethe SMT lines and minimizechangeovers by optimizing thesequence of the jobs usingclustering technology.

Coping with NPI complexityand facilitating flexiblemanufacturing

Short product lifecycles, seasonaldemand fluctuations, intensecompetition and increased enduser customization allow littletime for developing optimalmanufacturing processes.This complexity is furthercompounded by the fact thatmany manufacturers need tocope with multiple live productsat any given time. Designing andvalidating the NPI process offlineallows full use of manufacturingresources whether for high-mix orhigh-volume scenarios resulting inmaximum uptime and achievinghighest throughput from time ofproduction launch. Flexibility is

inherent in the process as usersare able to select specific linesor manufacturing sites based onsimulation results in the processplan.This flexibility also enablesmanufacturers to cope withsevere volatility in the form offluctuations in job orders, suddenschedule changes and increasedproduction mix.

Covering the entire NPI processfor PCB assembly, the TecnomatixPCB Assembly and Test solutionprovides electronics manufac-turers a complete and integratedplatform for designing andoptimizing the entire NPI processfor high-mix and high-volumemanufacturing addressing specificbusiness scenarios. Elements ofthis include:

• Merging CAD and BOM whilechecking for discrepancies earlyin the process

• Design for assembly by checkingboard layout against more than300 manufacturing rules toassure error-free NPI

• Managing part, shape andmachine library including aliasingand new part annotation forbetter library management andfaster new part updates

• Designing for test beforeproduction start to make certaintest coverage is sufficient or tomake changes in design toexpand test coverage

• Offline process design andallocation among SMT, THT, handinsert and test processes

• Programming single and mixedvendor SMT lines

• Optimizing cycle time for thesingle machine

• Balancing the SMT line foroptimal throughput

• Minimizing changeover time byclustering jobs based on productcomponent commonality

• Machine programming for morethan 150 different assembly andtest equipment platforms

• Automatically generatingmanufacturing documents andhand insert instructions

• Engineering change introductionsautomatically updating theentire process

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New product introduction solutions for PCB assembly and test

Optimizing manufacturing process design andproduction performanceBetter process management results in shorter NPI durations bycompressing the NPI cycle from days and weeks to just hoursresulting in faster production ramp up. Cycle time optimizationincreases manufacturing throughput, with gains of up to 20 percent.Manufacturing uptime is dramatically improved with process designcapabilities that allow for several jobs to be clustered on a singlemanufacturing setup. Many Siemens’ customers have enjoyed uptimeimprovements of 50 percent or more by seeking part commonalityacross their live jobs allowing universal setup. Every gain inmanufacturing performance improves top-line revenues for electronicsmanufacturing through faster ramp up, increased throughput and theability to accept more jobs without having to make expensive capitalequipment investments. Tecnomatix PCB Assembly and Test solutionsenable optimal manufacturing performance.

Continuously improving the complex NPI processContinuous process improvement can be a key business enabler foran industry that experiences irregular cycles and limited forecastvisibility. Through continuous improvement initiatives, manufacturerscan shorten NPI durations with the result of faster and error-free

production launch. Furthermore, such initiatives allow better resourceutilization, enabling increased flexibility in schedule changes and suddenorder picks. With the Tecnomatix PCB Assembly and Test solution,manufacturers can establish a clear NPI workflow standard configurableto their needs residing on a single database containing job, part andresource libraries.

Key benefits of Tecnomatix for PCBAssemblyand Test solutions

• Optimize your SMT line performance by increasing throughputand uptime through best-in-class optimization technologies

• Get the NPI process right the first time

• Continuously improve your NPI processes by defining and enforcinga step-wise standard way of designing the NPI process

• Perform all your NPI tasks, from CAD import to production launch,on a single, integrated platform

Data preparation• CAD/BOM import• Manufacturability andtestability analysis

• Part library management

Process definition• Assign componentsand processes

• Configure lines andoperations

• Define workflow

Process optimization• Eliminate process bottlenecks• Optimize for increased line throughput• Optimize for production setup

Validation and output• Fine tuning• Machine recipes• Hand insert instructions• Manufacturing documentation

Launch• Mass production• Integration with MESfor Electronics

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Data preparation

Import and merge CADand BOMCapture board layout from nativeCAD including parts, shapes,drills, pads, nets and traces.Support more than 65 CADplatforms with frequent readerupdates. Upfront CAD-to-BOMdiscrepancy checks preventincorrect loading of job versions.

Design for assemblyPrevents manufacturing defectsby checking board layout againstmore that 300 manufacturingrules using the IPC-SM-782Afootprint verification.

Design for testDFT reports are generated withinminutes of job import to verify testcoverage and to highlight areaswhere a test may be compromisedby missing nets, components,clearance and absent or incorrectlylocated test points.

Data preparation is a critical first step in the NPI process. TecnomatixPCB Assembly and Test solutions provide the means to recover digitaldesign data and perform upfront manufacturability and testabilitychecks. By validating the manufacturability and testability of the design,manufacturers shorten NPI durations, eliminate manufacturingissues associated with marginal design and enable “get it right thefirst time” engineering.

Import CAD from virtually any sourceWith 65 different ECAD systems supported, Siemens is the leadingprovider of CAD readers both in terms of number of native CADplatforms supported and the extent of CAD capture which includeswhole board layout, component shapes and net traces. Once CAD isimported, it is then merged with the bill of materials (BOM) and checkedfor any revision discrepancies with automated alerts. Utilizing CADsubstantially accelerates the NPI process and eliminates ambiguitywhen it comes to placement locations and document generation.

Design for assemblyChecking designs against established sets of manufacturing rules willavoid manufacturing defects downstream. Siemens provides electronicsmanufacturers and design departments the ability to check board layoutagainst more than 300 manufacturing rules to assure that a board may beassembled as designed. Rules may be configured for unique organizationalrequirements. Rule violation reports are generated within seconds andare graphically linked by html so violation locations are identifiedimmediately and corrective action can be taken.

Design for testUpfront design for test (DFT) analysis is an important step during thedata preparation process. DFT assures adequate test coverage beforeproduction launch, eliminating process bottlenecks and false positivesduring actual test. DFT reports are available within minutes of job importoffering immediate coverage feedback. Issues such as accessibility due tocomponent dimension, clearance and wrong placement of test points.The solution allows manufacturers to determine the desired degree oftest coverage taking into account selected nails and probes as well as testmethodologies. Performing upfront DFT will eliminate test bottlenecksassociated with insufficient test coverage.

Key benefits of Tecnomatix solutions for data preparation

• Accelerate NPI and eliminate job preparation errors through fullimport of native CAD

• Get it right the first time by checking for any revision discrepanciesbetween CAD and BOM

• Minimize or eliminate manufacturing defects associated withmarginal design using upfront design for assembly analysis

• Minimize or eliminate test process bottlenecks associated withinsufficient test coverage with upfront design for test checks

• Process new jobs quickly by maintaining a central part library

Data preparation

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Process design

Platform supportModeling and programming supportfor more than 230 different SMT,THT, AOI and ATE equipmentplatforms are available – the mostcomprehensive support in theindustry allowing full virtualmodeling capabilities.

Factory definitionConfigure line definitions includingspecific processes and equipment.Virtual capture of factory definitionsallows users to select and simulatewhich lines are best suited for specificjobs as well as facilitate transfer fromline to line or from site to site.

Flexible user workflowCustomizable user workflowstreamlines the NPI process andfacilitates continuous improvementfor faster time-to-volume whilereducing or even eliminating errors inthe process.

Simulate the factory layout with offline modeling capabilities.Offline process design allows manufacturers to capture entirefactory environments for line setup, processes used during assemblyand machine platforms deployed. In this virtual setting, manufacturerscan simulate different line configurations to select and validate bestmanufacturing strategies.

Virtual factory definitionsProcesses and resources are captured and retained in libraries.Lines are configured by specific processes and available machines.Tecnomatix PCB Assembly and Test solutions support more than230 different equipment platforms – enabling manufacturers toconfigure “best-in-breed” lines from multiple equipment vendors.

Configure unique workflowsConfiguring unique workflows allows manufacturing organizationsto instill a discipline with each step in the NPI process beingfollowed and completed before moving on to the next operation.This eliminates ambiguity in process planning and workflow aswell as captures and retains organizational memory enablingcontinuous improvement initiatives.

Increase manufacturing uptimeWith offline programming, manufacturers can enjoy increased uptimeby keeping their lines dedicated to production and not to validatingprocess setup. Users are able to play virtual “what-if” scenarios bysimulating different line configurations to achieve the best possibleprocess definition within the constraints of their available resources.Even fine-tuning the process is possible as users have the flexibilityto manually edit component assignment and feeder setup.

Key benefits of Tecnomatix solutions for process planning

• Institute engineering discipline with the development of a commonNPI process workflow

• Enjoy greater manufacturing flexibility with offline factory modelingby defining line configurations including machine platforms andinline processes

• Develop and select best manufacturing strategies taking intoaccount business requirements and available resources

• Enable “best in breed” equipment selection with the supportof more than 230 different equipment platforms

Process design

Process optimization

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Machine programming and optimization

Setup optimizationCluster jobs to achieve acommon feeder setup,significantly reducingchangeover and increasingmachine uptime.

Parametric optimizationImprove machine cycle time byoptimizing placement sequencewith parametric optimizers thatsupport the most commonly usedSMT platforms.

Iterative line balancingComponents are swappedbetween assignments factoringmachine, feeder and componentattributes to achieve an optimallybalanced line.

Deploy optimization strategies that meet yourorganization's business requirementsWhether for high volume or high mix, manufacturers can deploydifferent optimization strategies that meet specific businessrequirements. For higher volume production runs, users may optimizefor throughput by targeting faster SMT machine cycle times. Whenmanufacturing is characterized as high mix with frequent productionchangeovers, users will elect to optimize for setup to reduce downtimefor feeder changes. Whatever strategy is required, the Tecnomatixoptimization solutions for PCB assembly and test offer manufacturersthe ability to program and optimize mixed machine lines on a singlesoftware platform.

Eliminate process bottlenecksOffline iterative line balancing across the SMT line will achieve abalanced setup that eliminates bottlenecks by taking into accountmachine and part libraries and factoring attributes and mountingconstraints. With SMT line balancing solutions from Tecnomatix,users can perform thousands of iterations, completely offline,within minutes.

Cycle time optimizationTecnomatix PCB Assembly and Test solutions incorporate parametricoptimizers that are modeled on actual SMT machine kinematics.Taking into account machine class, feeder assignment, available nozzlesand vision system, the parametric optimizers will output a placementsequence that is optimized based on the specific machine and lineconfigurations. Reported gains of 5 to 15 percent in cycle timeimprovement are typical. Furthermore, the parametric optimizersoften outperform machine vendor software, particularly on PCBboards with higher density, due to the software's ability to performmultiple iterations, model setup and provide better parametricmodeling. Simulation validates that the placement path is optimized orindicates if fine tuning is required. If fine tuning is desired, then users areable to virtually edit placement path or to reassign feeders.

Optimizing for setupShorter production runs and high mix with frequent multiple dailychangeovers is becoming the norm for many PCB assemblers. In manyways, optimizing for setup is becoming more important than exclusivelyoptimizing for throughput. Siemens is the only solution provider thatoffers electronics manufacturers the means to cluster multiple jobs byseeking part commonality achieving a common feeder setup. Usershave reported reductions of 50 to 75 percent in changeover timewhich is directly converted to manufacturing uptime, increasingthroughput and improving revenue opportunities.

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Feeder setup editingOffline editing of feeder setupallows users to virtually fine-tune programs for furtheroptimization when required.

Timing reportSimulated timings are used toestimate production throughputenabling manufacturers to betterplan capacity.

Better planning and reaction capabilitiesIncreasing end-user customization means that manufacturers often havelittle visibility, in some cases no more than a few days, to plan theircapacity. There is more volatility than ever with tighter and irregularbusiness cycles. Offline optimization, whether for high-mix or high-volume, will allow manufacturers to better plan and utilize existingcapacity and can offset the need for extensive investments in capitalequipment during periods of increased order loads.

Programming support for single and mixed linesBy supporting more than 230 different equipment platforms, Siemensallows PCB assemblers to select their line configurations based on“best-in-breed” criteria. Manufacturers are able to provide optimizedmanufacturing recipes for mixed vendor line configurations both forhigh mix and high volume scenarios.

Key benefits of Tecnomatix solutions for machineprogramming and optimization

• Achieve optimally balanced lines through iterativebalancing capabilities

• Improve machine cycle time performance by 5 to 15 percentwith optimization based on machine-specific parameters

• Improve machine uptime and reduce production changeover timeby up to 75 percent with common feeder setup

• Accept more business by better planning capacity and improvingexisting resource utilization

• Increase flexibility in machine selection with mixed-line programmingand optimization on a single software platform

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Documentation

Operator line balancingTaking into account specificstation resources, stuffing rules,operator experience and throughputrequirements, work instructionswill be generated that will bebalanced for hand-insert operations.

Drawing and image importUsers can draw, annotate, highlight,blow up or add various drawing andpicture files to documents foradditional clarity.

Placement documentationand hand-insert instructionsBased on the actual NPI job, wholesets of placement documents andwork instructions are createdautomatically.

Viewing and distributionDocuments may be published aspaper hard copies or distributedvia viewer networks, enabling apaperless factory environment.

Documentation

With automatic generation of manufacturing documents, PCBassemblers can reduce process engineering efforts from days tohours and create full sets of work instructions and visual aids basedon NPI job data.

Eliminate the documentation bottleneckDocumenting the process is a last hurdle to production, whichtypically cannot begin until the entire process is defined and validated.In many facilities document creation is still a manual process that cantake days to a week to complete, risking delay of production start.With Tecnomatix PCB Assembly and Test solution, users canautomatically create whole sets of documents based on the NPI jobincluding CAD layout and taking into account parts and processes.When a job revision is introduced, the entire document set isautomatically updated. Documents are output in user-configurabletemplates. Drawing and picture files may be added as well as hyperlinksto external documents giving users another layer of clarity.

Balance hand-insert linesWhen creating hand-insert instructions, users can balance the processtaking into account such factors as component height, polarity andcomponent inspections. An electronic approval process can be used tolock the set of shop floor documentation for release. Documents mayalso be distributed via a viewer network, speeding up publication andeliminating paper.

Key benefits of Tecnomatix solutions for documentation

• Eliminate a major process bottleneck through automateddocument generation

• Avoid ambiguity with a single documentation tool based on theNPI job database, including smart links for automated updates andsignoff to assure correct document versions are deployed onthe shop floor

• Optimize hand insert operations with line balancing based onuser defined parameters

• Create a paperless environment through electronic publicationover viewer networks

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Test engineering solutions for electronics manufacturing

Siemens offers PCB assemblers a better way of doing test withautomated design for test analysis, probe and nail selection andsupport of 75 different tester and inspection machine platforms.Used extensively by both manufacturers and test engineering serviceproviders, the Tecnomatix test solution is the most widely usedsoftware of its kind in the PCB assembly industry.

Increase test accessibilityUpfront design for test (DFT) analysis assures adequate test coveragebefore production launch, eliminating process bottlenecks and falsepositives during actual test. DFT reports are available within minutesof job import, offering immediate feedback to testability issues suchas accessibility issues due to component dimension, clearance issuesand wrong placement of test points. The solution allows manufacturersto determine the desired degree of test coverage, taking into accountselected nails and probes as well as various test methodologies.Performing upfront DFT will eliminate test bottlenecks associatedwith insufficient test coverage.

Accelerate production launch with automated testengineeringICT fixture designs are automatically generated, avoiding the need towait days or weeks for fabricators to assemble fixtures. Fixtures maybe designed universally to be used on job variants, eliminating the timeand cost of developing unique fixtures. Wire optimization will improvethe quality and coverage of the test program. Develop programs formore than 75 different automated test platforms including the leadingin-circuit, automated optical inspection and flying-probe machines.

Shorten repair durationsWith html links between schematic and CAD layout, repair teams usethe Tecnomatix test solution to navigate at the board level to quicklylocate defect locations without having to delve through pages ofschematic drawings. This powerful graphical link enables faster repairturnaround time allowing manufacturers to deliver product earlier.

Key benefits of Tecnomatix solutions for test engineering

• Accelerate NPI with automated test engineering

• Eliminate testability issues with upfront DFT analysis

• Increase test coverage, even on highly dense boards, with automatedprobe and test point selection

• Boost test flexibility by incorporating the development andprogramming of various test methodologies on a single platform

• Launch production faster with automated fixture design andmachine programming

• Shorten repair durations with linked navigation between schematicand board layout

Library editingAdd and modify attributes forindividual or selected electricaldevices, physical outlines and parts.

Variant managerUse the same fixture for manyvariants (or versions) of one board.A universal fixture design will beautomatically generated to testproduct variants for an entireproduct family.

Design for testDFT reports are generated withinminutes of job import to verify testcoverage and to highlight areaswhere test may be compromisedby missing nets, components,clearance and absent or incorrectlylocated test points.

Tester program generationAutomatically generate testerprogram recipes for more than 75different test equipment platformsincluding the most commonly usedICT, flying-probe testers, x-ray andAOI machines.

Test engineering

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Tecnomatix for the electronics industry

Electronic solutions

Electronics manufacturers must bring cost-effective products tomarket faster than ever while meeting a variety of challenges includingthe introduction of a large number of new products in record time;manufacturing a growing mix of complex products; meeting customerand regulatory demands like traceability and lead-free manufacturing;and introducing new technologies, components, software, equipmentor processes.

Beyond these day-to-day manufacturing challenges, global electronicsmanufacturers face the challenge of acquiring new facilities; selecting theright equipment; balancing the workload between factories; managinginventory and quality on a global scale; and managing the outsourcingbusiness process.

Siemens’ Tecnomatix for electronics solutions addresses these criticalissues by providing the most commonly used digital manufacturingsolutions for designing, managing and integrating the NPI process,production execution on the shop floor and the outsourcing businessprocess at the single plant, corporation and extended enterprise levels.

Use this complete, end-to-end manufacturing solution to design, optimizeand execute board- and box-level production processes. Tecnomatixhelps you introduce new products faster by more easily programmingand optimizing the widest variety of assembly machines and testequipment in low- and high-mix scenarios, logging defectsin the repair process and managing all aspects of manufacturingexecution – from material management to machine monitoringto quality management to full product and process traceability.

Tecnomatix enhances your enterprise competitiveness by allowingyou to:

• Get the NPI process right the first time

• Optimize throughput even in high-mix conditions

• Cope effectively with change

• Tighten your grip on shop floor execution

• Minimize size of product recalls and internal reworks

• Analyze production information and get to the root cause of issues inreal time to prevent mistakes from eroding your cost margin

• Meet ever growing customer and regulatory demands

• Streamline the OEM-ODM/EMS/CM outsourcing business process

Global professional services

Maximize the benefits of yourTecnomatix solutionSiemens offers customers much more than depth of expertise.We take great pride in our ability to deliver the highest level ofprofessional services so that you can achieve maximum benefitsfrom our Tecnomatix solutions in the shortest possible time.

Whether you face challenges at home or in a remote part of theworld, Siemens has the flexibility and the people in place to respond.Our professional service experts share vast experience andbusiness knowledge in project implementation, project designand project methodology. They are your experts in TecnomatixMPM technology.

We are ready to help you achieve maximum impact on your businessprocesses by providing end-to-end MPM solutions matched withconsulting, development, implementation support and engineeringservices that fit your environment and objectives.

Prepare, predict, perform better manufacturing processes

The Siemens PLM Software professional services team can help you to:

• Maximize market potential for your products

• Optimize and manage global distributed manufacturing

• Respond quickly to new market opportunities

• Accommodate frequent changes in where and how you produce,as well as what is produced

• Deliver speed and flexibility across the extended enterprise

© 2007 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. Teamcenter, NX, Solid Edge, Tecnomatix,Parasolid, Femap, I-deas, JT, UGS Velocity Series, Geolus and the Signs of Innovation trade dress are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc.or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.

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About Siemens PLM SoftwareSiemens PLM Software, a division ofSiemens Automation and Drives (A&D),is a leading global provider of productlifecycle management (PLM) softwareand services with 4.3 million licensedseats and 47,000 customers worldwide.Headquartered in Plano,Texas, SiemensPLM Software’s open enterprise solutionsenable a world where organizations andtheir partners collaborate through GlobalInnovation Networks to deliver world-classproducts and services. For more informationon Siemens PLM Software products andservices, visit www.siemens.com/plm.

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Siemens PLM Software leads togreater innovationThere is no single road to innovation, but thereare signs you’re headed in the right direction.Leading innovators get to market faster, managecompliance, optimize resources and achieveglobalization. They’re also four times morelikely to use PLM software to plan, define,build and support their products. SiemensPLM Software’s family of PLM solutionshelps businesses establish Global InnovationNetworks that transform their processof innovation. Drive your businessto greater innovation andaccelerate your growth.

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