MILWAUKEE ELECTRONICS NEWS Q2 2017 Tecte Fcility Adds SMT Line IN THIS ISSUE Len Chngeovers 2 New SC Product Mgr. 2 HDI Chllenges Solved 3 About Milwukee Electronics Milwukee Electronics designs nd mnufctures custom circuit bord ssemblies for the medicl, trnsporttion, militry, HVAC nd vriety other industries. The Compny opertes over 135,000 squre feet mnufcturing in Portlnd, Oregon; Milwukee, Wisconsin; nd Tecte, Mexico. In ddition to EMS nd product design nd engineering services, it fers PCB lyout services through its Sn Diego PCB business unit nd quick-turn prototyping through its Screming Circuits business unit. A new Pnsonic NPM SMT line hs been instlled in Milwukee Electronics Tecte fcility to dd cpcity in support two new progrms. The line is identicl to the line instlled lst yer nd utilizes the sme crt system, ltest version PnCIM 10 st- Above, the Tecte fcility s newest SMT line in opertion. wre nd DGS Dchip shooter, Pnsonic NMP-W2 multit Cretion System. It includes n Ekr Serio (Continued on pge 4) 4000 screen printer, Pnsonic NPM-W2 Messge from Mike Growth in new business nd the need to keep pce with dvnced technology products is driving dditionl equipment investment in both our Portlnd nd Tecte fcilities. Our credo hs long been to deliver Perfect Product. One the chllenges every electronics mnufcturing services (EMS) compny tody fces is tht mintining superior qulity in products with incresingly complex ledless components. These components bring unique chllenges, nd we re investing to keep pce with tht. First, we ve dded nother SMT line in Tecte to support their need for dditionl cpcity. We continue to see strong growth in mnufcturing requirements on both sides the border. Our investments in new screen printing technology nd x-ry inspection cpcity help us more quickly set up repetble processes nd verify the results, prticulrly in reltion to the chllenges posed by higher pin count BGAs nd QFNs. They lso provide utomted reporting tht ligns with customer qulity dt reporting requirements. The dt from lst yer s customer stisfction survey ws instrumentl in mny the opertionl improvement investment decisions we ve mde over the lst few months. Our choice the Aegis Fc(Continued on pge 4)
MILWAUKEE ELECTRONICS NEWS Portlnd Fcility Utilizing Len to Optimize Efficiency While much the new equipment tht Milwukee Electronics hs purchsed during the lst yer is inherently more efficient, there is humn fctor s well. Alex Hughes, who joined the Portlnd fcility s Mnufcturing Mnger in December hs been pplying Len mnufcturing principles to ensure the cpbilities the new line re being fully exploited. chngeover. In some cses, the SMT plcement equipment ws chnged over first nd then reflow oven prile ws set. We needed to eliminte vrition in the wy we set up nd estblish process tht ddressed criticl pth issues first. If the reflow oven must cool down for the next job, tht typiclly becomes the gting item on chngeover time. So, the setup tem now sets the oven prile first. Setup tem members hve ssigned duties nd n ssigned sequence tsks, Alex sid. Our SMT line s PnCIM stwre mkes it esy to generte reports on mchine downtime nd cycle times. I ve set up dily, weekly nd monthly reporting. In The SMT line s stwre recommends the best feeder plcement reviewing those reports, length bsed on PCBA lyout. chngeover time stood out. In could ship to us, so the problem ws some cses, it ws running n hour, The ddition the new Ekr Serio 4000 solved without hving to purchse ddialex sid. hs lso contributed to improving tionl feeders, Alex dded. Alex begn his pok-yoke process by chngeover time, s it is much fster to Another re improvement ws the tlking to the SMT opertors nd setup lod to thn previous printer. ctul setup process itself. people. He found feeder constrints With the chnges in plce, chngeover were the biggest issue. Prt the improvement effort ws time now rnges between 10 nd 39 simply setting expecttions. I wnted to While we hd enough feeders to run minutes per job. The line s built-in verifisee our verge chngeover time get our jobs; we didn t lwys hve enough ction process tht ensures components down to 20 minutes. Tht ws chnge feeders to hve the next job step up nd nd feeders re loded correctly, will in mindset for tem tht hd been redy to move onto the mchine s the limit how much more time cn be elimiused to working with fr less efficient lst job ws finishing. In those cses, the nted from the chngeover process. equipment, Alex sid. tem hd to wit for the mchine to However, Alex nd his tem re not finish nd then unlod nd relod the Alex looked t the process for setup in through with improvements yet. The feeders. I checked with Tecte nd the re. The tem hd no specificlly (Continued on pge 4) found they hd extr feeders tht they ssigned tsks or n order process Grttn Nmed Screming Circuits Product Mnger Mrgret Grttn hs joined Screming Circuits s Product Mnger. She ws previously ssocited with Rockwell Collins s Indi Business Reltionship Mnger. During her ninemrgret Grttn yer tenure with Rockwell Collins she lso served s project mnger, subcontrcts engineer nd stwre engineer. help us crete synergies for customers in new nd innovtive wys, sid Jered Stoehr, Milwukee Electronics VP Sles nd Mrketing. Milwukee Electronics hs developed gret res specilty in recent yers Screming Circuits nd Sn Diego PCB being the best exmples. Our opportunity tody is to lign these trgeted services in new wys to dd more vlue to customers. Mrgret brings gret mix technicl, process nd interntionl experience to our tem. She will Mrgret received Bchelor Science degree in Computer Science from the University Knss nd Mster Business Administrtion degree from the University Iow. She is fluent in Spnish. Also Avilble on MilwukeeElectronics.com Pge 2
MILWAUKEE ELECTRONICS NEWS Engineering in Action Sn Diego PCB s Holistic Approch Solves HDI Issues As products continue to shrink, more importnt it becomes to the engineering lyout nd tke holistic pproch tht mnufcturbility chllenges looks t mnufcturbility or grow. The lws physics hvewht we cll DFX long with n t chnged; but the mount electricl integrity nd solvvilble rel estte hs shrunk bility. Industry stndrds prodrmticlly. Imgine moving vide strong foundtion for from 2000 sf house to 200 sf DFX, but there my lso be prtment. You wnt to be ble equipment constrints t the hve individul spces to sleep, mnufcturer tht need to be et nd relx. Tht requires considered, sid Mike. mjor shift in thinking nd The tem t Sn Diego PCB much more efficient use ddresses the DFX chllenge spce. It lso requires good through trining nd holistic This product is n exmple dense solvbility chllenge due to its understnding unintended con16 lyers nd High-Speed (gigbit dt trnsfer) signl requirement. pproch. sequences s tht spce Our designers go through trinshrinks. Your 2000 sf house put The end lyout met signl nd electricl integrity requirements nd ing nd re ultimtely certified outlets fr wy from running ws highly mnufcturble. s IPC CID or CID+ Designers. This gives wter for sfety. The noise dish When n engineer designs product, he them much broder understnding the wsher or wshing mchine ws likely or she is typiclly focused on form, fit nd impct their design decisions. Being prt not noticeble in the bedroom. Your function. The detils how the engineer Milwukee Electronics lso helps. They electricl service ws sized to your ing specifiction trnsltes to PCB lyout hve estblished processes for integrting preferences. However, in the smller re typiclly left to the PCB designer. We DFX nlysis nd recommendtions into prtment, sfety, noise nd electricl cll this process solvbility, becuse it inproduct development. Insted tking lod considertions must be blnced volves figuring out how to plce nd route siloed pproch tht divides engineering, with vilble spce constrints. ll prts, signl trces, voltges nd ground lyout nd mnufcturing into completely within the spce llotted, sid Mike Printed circuit bord (PCB) lyout seprte tems, the groups hve strong Creeden, VP Lyout Services. tems hve the sme chllenges when understnding ech other s constrints designing high density interconnect However, simply designing the PCBA to nd work together to implement cohe(hdi) printed circuit bord ssemblies industry-stndrd guidelines my not be sive solution, sid Mike. (PCBA). Ech lyer the PCBA needs enough. Sn Diego PCB s holistic focus on solvbilto perform s specified in terms sig It is possible to design PCBA tht meets ity, electricl integrity nd DFX reduces nl nd power integrity. However, the electricl integrity specifictions nd the lyout time nd helps ensure tht Rev 1 incresed complexity hving more solvbility chllenge tht is nightmre to works. lyers doing more things in less spce mnufcture. And, tht hppens firly cn crete untended consequences ten when the design tem works in tht degrde signls or cuse the PCBA vcuum. The more complex the PCBA, the to overhet. Screen Printing nd Inspection Cpbilities Enhnced Products cross ll industries re getting smller nd more powerful. Concomitntly, components re lso becoming smller with more complex interconnections to the printed circuit bord (PCB), tht cn t be verified through stndrd visul inspection mens. Tht drives two behviors from mn- ufcturing stndpoint. First, the entire ssembly process must be tightly controlled to minimize the possibility tht defects will occur. Second, utomted inspection technology must be dequte to esily detect ny defects tht do occur. Adding to the complexity is the fct tht cost pressures continue to increse nd the time expecttions from order to fulfillment continue to Also Avilble on MilwukeeElectronics.com decrese. To ddress customer requirements nd these trends, Milwukee Electronics hs recently enhnced its screen printing nd x-ry inspection cpbilities in Portlnd, OR nd Tecte, Mexico. Ask ny mnufcturing engineer nd (Continued on pge 5) Pge 3
MILWAUKEE ELECTRONICS NEWS New Tecte Progrm Mnger Nmed Mnuel Fornes hs joined Milwukee Electronics Tecte fcility s Progrm Mnger. Previously, he ws Progrm Mnger/ Customer Service Mnger Mnuel Fornes Autosplice, Inc. in Tijun. He ws erlier ssocited with The Chmberlin Group nd Motorol Connected Home Solu- Messge from Mike (Continued from pge 1) torylogix s our Mnufcturing Execution System (MES) in prticulr, ws driven by the strong feedbck given reltive the need to increse speed on our mnufcturing floor. When fully implemented, we believe it will reduce documenttion trnsfer nd progrmming time on new Chngeover Time tions in progrm mngement supply chin mngement, engineering nd qulity engineering roles. Mnuel brings nerly two decdes mnufcturing experience in production fcilities with world clss technology nd processes. His expertise enbles him to be both n effective customer dvocte in res where we need to improve our service, nd n effective progrm mnger when it is necessry to better fine tune customer forecsts, explin the benefits our Dfx recommendtions or drive collbortive improvement efforts, sid Pirouz projects by over 50 percent nd provide dditionl efficiencies in other prts our mnufcturing processes. Our next customer stisfction survey will be sent out in the August/September timefrme. If you receive one, I strongly encourge your prticiption. While we see only the ggregte dt, the trends Pourhshemi, Tecte Generl Mnger. Mnuel received his Bchelor in Electricl Engineering degree from the Instituto Tecnológico de Sonor nd his Mster in Business Administrtion degree from the Instituto Tecnológico y de Estudios Superiores de Monterrey. He is Six Sigm Green Belt nd hs lso completed trining in Len mnufcturing nd opertionl excellence. He received Motorol University trining in project mngement. the survey revels relly do help guide our decisions in the investments we mke to better support your requirements. P. Michel Stoehr President & CEO (Continued from pge 2) line s DGS Dt Cretion System utomticlly performs line blncing by recommending optimum feeder positions bsed on component plcement requirements. This determintion best sequence component plcement cn substntilly reduce cycle time, prticulrly when mesured over month production. Compred with our old line, this optimiztion literlly gives us extr dys Tecte Equipment (Continued from pge 1) functionl pick-nd-plce mchine nd 10-zone Vitronics Soltec XPM3m reflow oven. The PnCIM stwre cn show reltime informtion on production cycle cpcity. However, we weren t fully exploiting the cpbility. The new line ws purchsed with set number nozzles for the plcement heds. Now tht we hve better ide the production trends on the line, we ve been purchsing more nozzles to fully utilize the cpcity the heds, Alex sid. The tem is now focusing on its next chllenge, which is optimizing the line s bility to utomticlly do feeder chnges when prts run out vi free feeder progrm- time, mchine performnce, opertion rtio, plcement quntity nd production quntity, or be customized to show ny informtion desired. The mchine verifiction (MV) feture in the PnCIM stwre utomticlly checks the feeders in ech crt to vlidte the right prts re ming option. Improvement should be continuous process. We ve chnged the culture the tem from one we re limited by our equipment to one let s figure out how the best wy to cpitlize on wht our equipment cn do. Tht opens the door to continuously improving cycle times nd is credit to the ingenuity nd dediction our tem, Alex sid. present. The DGS system cn recommend optimum feeder loding sequences nd the best nozzle sizes to minimize plcement time. The fcility hs lso dded Yestech BX utomtic opticl inspection (AOI) system. Also Avilble on MilwukeeElectronics.com Pge 4
MILWAUKEE ELECTRONICS NEWS Screen Printers, X-Ry Inspection (Continued from pge 3) they will tell you tht qulity strts with solder pste deposition. Environmentl fctors such s mount time the solder pste hs been exposed to ir, shpe the screen pertures, height nd slump pste ll impct solder joint qulity. We wnted to select screen printer tht ddressed s mny these fctors utomticlly s possible, sid Dn Yntz, NPI/Engineering Mnger. The Ekr Serio 4000 screen printer fit those requirements nd more. Opertor input is done vi touchscreen nd is menu-driven. Stencil setup is utomted. The printer pulls the stencil in, positions it nd locks it in utomticlly. Tht feture lone hs reduced chngeover time from n verge 5 minutes to 30 seconds. Progrmming is lso simple nd fst. When PCB is loded, the mchine scns it. The opertor touches the fiducil on the bord imge nd the mchine utomticlly sets up the bord. The opertor hits the tech button nd the mchine stores the prmeters for use with every identicl bord. The opertor cn lso crete subroutines tht pply the sme set prmeters to common bord fmilies. The ese setup nd opertion is importnt. It mens we get repetble process nd it is much fster thn our older mchines. And while sving five minutes on stencil setup my not seem significnt, when you multiply it times the seven or eight setups we do per dy, the svings re substntil, dded Dn. From process control stndpoint, the Newsletter Contct printer monitors stndrd set prmeters such s squeegee pressure nd cn lso be progrmmed to mesure userspecified prmeters. The printer contins two 600 grm crtridge dispensers tht cn dispense utomticlly vi pste detection system tht cn be progrmmed to high nd low prmeters, or The new screen printer s touchscreen, menu-driven user interfce reduces setup nd chngeover time drmticlly. be controlled by the user when throughput is better served by mnully progrmming the mount pste dispensed. A built-in 2.5D solder pste inspection (SPI) compres the stencil perture with pd on the PCB nd mesures solder brick height. The opertor simply indictes on the touchscreen, which res the PCB should be inspected. The utomtic stencil clening system is lso enhnced, using vibrtory tool tht clens both X nd Y xes. Sciencescope X-spection 6000 X-ry inspection systems were lso purchsed for Portlnd nd Tecte. The units hve rotting nd tiltble stge enbling opertors to get full 360 degree imge the printed circuit bord ssembly Jered Stoehr, VP Sles nd Mrketing Emil: jstoehr@milwukeeelectronics.com www.milwukeeelectronics.com Sles inquiries: sles@milwukeeelectronics.com Copyright 2017 Milwukee Electronics All Rights Reserved (PCBA). A digitl cmer cptures the imge nd converts it to 3D rendering with no loss clrity. Our customers operte from trust but verify perspective, prticulrly with mission criticl pplictions such s medicl products tht hve QFNs or BGAs. They wnt inspection photos every first rticle to vlidte tht the process is delivering the expected levels solder joint qulity, since x-ry is relly the only non-destructive option for determining tht, Dn sid. The cmer opertes t higher mgnifiction power thn the previous unit, enbling more ccurte inspection. The imges we re getting mke it much esier to identify issues. Plus, the systems include stwre ppliction tht nlyses the imges. It will utomticlly clculte the density the solder brick, pd or bll nd provide the volume nd mount voiding. It lso mesures the rdius ll collpsed blls on BGA, mking it esy for us to identify devitions, sid Dn. Inspection time per bord hs lso been substntilly reduced. For exmple, on one bord with 15-20 QFNs, inspection time hs been reduced from 10 minutes to 1-1.5 minutes, primrily due to the fct tht once progrmmed, the mchine utomticlly rottes the bord to cpture the required imges. Adding the ltest solder pste printing nd x-ry inspection technology hs utomted lot things we did mnully. It sves times, improves ccurcy nd dds fetures tht enble us to better meet customer requirements, Dn sid. 5855 N. Glen Prk Rod Milwukee, WI 53209 Tel: 877.960.2134