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The keys to superior producibility in new product design can be found in the expanded design process. One of those keys is the role of metrics or data-based analysis of planning trade-offs.

+

Expanded Design Process The new expanded design process that incorporates planning, trade-offs, and manufacturing audits is shown in Table 19.1. The process is made up of 12 separate functions that incorporate the planning and trade-offs sections in this book:

TABLE 19.1 The Expanded Electronics Design Process Function Specification Capture of system description Synthesis Trade-off Physical CAD Simulation Design advisor Manufacturability audit Tooling MFG PDM database Purpose User-supplied constraints and ideas formulate executable specifications. Technology trade-off analysis: balance of loss and gain in various domains performance versus cost. Generation of a netlist from the executable specifications. Selection of layout, fabrication, and assembly features versus cost. Conversion of netlists to system and module layouts. Detailed analysis of design structures to support all other design (CAD) activities. Continuous display of design rated by performance rules. Check of design to manufacturing design rules and capabilities. Conversion of module layouts to panel layout. Conversion of module layouts to physical products (fabrication or assembly). Enterprise wide database containing all product information (product data management, or PDM) including design files, libraries, manufacturing information and revisions, etc. Multi-team designs via access over the internet

Georgianna Frenzelas s professional background in training and development spans over thirty years of experience. Her work has involved various levels of associates in sales, leadership, corporate, and eld operations. Contact at jerrygoard@ msn.com.

1. 2.

3. 5.

EASY 1. Minimum Drill Diameter 0.050 " (1.27 mm) 1 10 20 0.022 " (0.559 mm) 30 40 0.018 " (0.457 mm) 50 60 70 0.011" (0.279 mm) 80 90 0.001 " (0.025 mm) 100 -

FIGURE 19.9 Elements of the figure of merit process: (a) brainstorming factors; (b) grouping similar ideas; (c) ranking factors; and (d) assigning values to factors.

paired ranking, as seen in Fig 19.9c. Whatever the method of voting, the values are normalized by dividing by the smallest nonzero value. The resulting voting scores form the coefficients, Cx. Those factors with no votes are zeros and drop out of consideration. 19.3.6.2 Factor Weightings, FWx. Each factor that emerges from the ranking process is calibrated by assigning values from one (1) to one hundred (100), as seen in Fig. 19.9d. The 1 factors are easy to manufacture, and the 100 factors are impossible today but may only be very difficult in a few years. The resulting scoring equation will look like and be used as shown in Eq. 19.1. SCORE = (C1) (FW1) + (C2) (FW2) + (C3) (FW3) + (Cn) (FWn) + .... where Cx = coefficients based on ranking FWx = factor weightings of assigned values (1 100) (19.1)

For example, assume that the producibility of a bare PWB may be scored with the preceding equation if the FOM process established the following factors:

Now assume that the proposed PWB design specifies the following:

Size of the substrate: FW1 = 36 Number of drilled holes: FW2 = 18 Minimum trace width: FW3 = 31 The producibility SCORE would equal: 232 = 54 + 54 + 124 = 1.5 36 + 3.0 18 + 4.0 31

The SCORE can be used if it is calibrated based on the prior history of this type of product. Prior products are scored with the FOM linear equation (Eq. 19.1). Those products that went into production smoothly and presented minimum problems determine the minimum SCORE that should be sought. The SCORE from products that were a problem, had to be reengineered, or presented delays in introduction determines the SCORE that the design should exceed if problems occur and producibility is to be obtained.

Predicting density and selecting design rules are two of the primary planning activities for layout. The actual layout of a PWB is covered in s 13, 14, and 15. The selection of design rules not only affects circuit routing but profoundly affects fabrication, assembly, and testing.

Dianne M. Kipp is an experienced coach, motivational speaker, writer, educator, and seminar leader in the areas of personal achievement, leadership development, and corporate culture transformations and organization design. A visionary leader, she founded Follow Your Heart Journeys and Dianne M. Kipp & Associates, LLC, to support corporations in improving employee ful llment, increasing productivity, and advancing social consciousness in the workplace. She can be contacted at www. diannekipp.com.