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This webinar will focus on Re-Engineering Obsolete Printed Circuit Boards. Many OEM's are finding their mature PCB designs are peppered with a dwindling supply of obsolete components and/or they are paying for additional labor to install inefficient thru-hole components. These challenges will often lead to compromised schedules and strained margins. We will review the items required to make the process of redesigning a customer's antiquated or obsolete printed circuit board into a contemporary and cost effective product.
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DELIVERING QUALITY SINCE 1952.
Printed Circuit Boards Webinar
Re-EngineeringObsolete PCB’s
11.22.13
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America's Oldest,A History of Innovation
Privately held company, established in 1952.
Estimated 2013: Sales: US$40 Million
100+ Employees Worldwide (70 – North America, 30 – Asia, 3 – Europe)
Design and manufacture customized, built-to-print, performance-critical products for all sectors of the electronics industry.
Leading provider of printed circuit boards, membrane switches, graphic overlays, silicone rubber products, electronic heaters, fans, motors and custom battery packs.
Integrated supply chain management solutions to handle the complexity of today’s global marketplace while making sure that every order is being manufactured at the “right” factory.
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Agenda
Required Business Information
Required Technical Information
Define the Scope of Work
Define any New Features for Product
Case Studies
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PCB Design Engineering Services
Electrical Engineering
Signal Integrity Analysis
Mechanical Engineering
Library Management
Database Translations
PCB Layout
Re-Engineering
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Re-Engineering Existing Products
Why Re-Engineer?– Cost Reduction
– Obsolete Components
– Obsolete Technology
– Standards Compliance
– Yield Improvement Today’s Desired Outcome:
– Help you to better understand what information is required for quoting the cost of Re-engineering an Existing Product.
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Required Business Information
Requirement– You need a proposal for the re-design of an existing product.
What do you need to do?– Qualify the Return on Investment
• Is there a viable ROI?– You’ll have to invest into this effort to be efficient & successful.– Do you have the time and a budget for this work?
– Does the Product Life Expectancy support the ROI?
• IP Ownership?– Do you actually own the rights to all of the technology you are looking to
re-engineer?
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Qualify the ROI (cont.):
– Does the product data include any “reference designs” from a third party that would gate the effort.
– Does the “reference design” contain “protection” in the programmable devices designed to prevent direct copying?
– Do you have a functional specification available that defines all modes of operation. This includes environmental operational and storage requirements along with agency certifications (UL, FCC, and others).
Required Business Information
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Can you provide the Current Product’s Cost Data?
– The Existing Costed BOM with Manufacture & Manufacturer’s Part Numbers and Unit Prices.
– The Current Actual Unit Cost Including Assembly Labor.
– Target Cost
– Projected Product Volumes
This data will provide the operationalspecifications and cost benchmarksrequired for comparing new andreplacement components.
Required Technical Information
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Required Technical Information
We’ll need the Existing Product’s Schematic in a .pdf format or the original schematic archive format.
– Providing the current design data upfront will help to minimize engineering time.
We will need the Documentation or User Manual that provides the User Interface Information.
We will need existing productsamples to use for verificationof the actual design.
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Define the Scope of Work
It is very important to define the Scope of Work upfront.
– This is best achieved in a written Statement of Work (SOW).
Clearly define the Performance Requirements and Re-Engineering Objectives.
– Cost Reduction?
– Obsolescence Abatement?
– Functional Improvement?
– Consolidation?
– Size/Shape Change?
– Standards Compliance?
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Define the Scope of Work
Scope of Work Options
– Investigate possible new technologies that can be implemented to reduce product cost or improve product performance.
– Verify the desired product life expectancy requirements (Component Obsolesce).
– Review the existing manufacturing processes required to build the PCB (fab) and PCBA (assembly). Research alternatives.
• Layer count reductions, single side assembly, consolidations
– Review unit assembly and final assembly manufacturing processes to identify any potential process improvements.
– Explore logic consolidation opportunities.
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Define the Scope of Work
Define Any New Product Features
– Identify the new product features / enhancements that are desired
– Are there any physical changes required
– Evaluate packaging improvements
Define Who will Validate/Approve Final Design
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Key Takeaways
It’s vitally important to qualify the ROI. Quotingre-engineering projects requires an investment on both the OEM and the supplier.
Try to determine what the budget is. This will help to avoid a mismatch.
Try to determine what the life expectancy of the product is. This will determine if there is a sufficient ROI for there-engineering effort.
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Key Takeaways
It’s important to define the Scope of Work clearly upfront. Providing a written Statement of Work will help to define the requirements and improve the chances for an accurate proposal and lessen the potential for scope creep.
Once we have an SOW and have reviewed the customer supplied data, we would recommend a scheduling conference call to confirm our understanding of the Scope of Work and address any issues.
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Key Takeaways
You need to understand that you will be part of theRe-engineering process. There are key elements of the existing product and re-engineering that only you can answer.
Your support is a key component the projects efficiency, cost-effectiveness and successful.
The quality of the customer supplied data important to providing an accurate cost estimate.
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Case Study #1
16 Port, 2 Gigabit Fiber Channel Switch– 16” x 9”, 16 layer PCB– Intel P3 Processor– 696 pin BGAs– Controlled Impedance– 155 MHZ Differential Pair Buses– 2G Differential Pair signals– Fault tolerant system– Hot Swap power supplies– 1867 Components/2400 Nets
Deliverables– Logic Design– Consolidated 2 PCBAs into 1– PCB Layout– Mechanical Design (sheet metal chassis)– Thermal Analysis– Signal Integrity analysis
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Design Cost Reduction & Logic ConsolidationMultiservice Access Platform (MAP)Customer’s existing product was in needof redesign for cost reduction andcomponent obsolescence.–Engineering team Provided:
• Logic Design
• Converted 5V circuitry to 3.3V
• Converted PTH components to SMT
• FPGA Design and Simulation
• Consolidated logic functions
• Reduced component count
• Design For Supply Chain BOM analysis
–PCB Layout• Physical Layout of the PCBA for DFM/DFT
• Converted from Double to Single sided PCB
–Verification Test• Functionality verification with existing products
• Customer performed product validation
Case Study #2
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Design Cost Reduction and Logic Consolidation
ATE Platform– 14 PCBAs that required PTH to SMT
conversion Logic consolidation intoFPGAs
– Customer acquired existing productfrom another OEM
• Did not have complete documentation
• Did not have engineers with productknowledge
• Require Engineering team to be veryresourceful
Case Study #3
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Case Study #4
Before:– Motherboard with 2 daughter
assemblies– PTH components– 8 I/O channels– 6U Assembly
After:– Single Assembly– SMT components except Backplane
connectors are press fit, FPGA Used for logic consolidation
– 16 I/O channels– Maintained 6U form factor
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Our Products
Battery Packs Flex & Rigid-Flex PCB’s User Interfaces
Fans & Motors Cable Assemblies Printed Circuit Boards
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Design Centers & Technical Support
Battery Pack & Power Management – Denver, CO User Interfaces – Largo, FL Fans & Motors – Wales, UK PCB’s – New Bedford, MA & Shenzhen, China Flex & Rigid Flex – Toronto, Canada Cable Assemblies – New Bedford, MA
Our Engineering and Design teams are ready to help our customers create world class and cost effective product solutions.
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Q&A
Questions?– Enter any questions you may have
in the Control Panel.
– If we don’t have time to get to it, wewill reply via email.
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Thank YouCheck out our previous webinars at www.epectec.com.
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