Circuits Assembly - September 2008 - (Page 44)

RF Production This helps the design company optimize the product for manufacture. At the same time, while testing should be sufficiently effective to ensure products are compliant, it must also be cost-effective in volume production. In the manufacturing process, robust inspection processes also can be critical because, when products in this application fail, it may be a noticeable compliance failure that draws the attention of not only the end-customer, but also that of the agency regulating the end-customer. Partnering with an EMS Provider While the term product realization is widely used in the EMS industry as a generic description of design-throughdelivery capability, in this case, industry-specialized product realization is truly the service needed. Key benefits the EMS provider should be prepared to deliver include: • A robust product development process, which includes both support of conceptual design issues and the more traditional design for manufacturability/design for testability (DfM/DfT) expertise. • Ability to support needed prototyping for product qualification and the subsequent ability to efficiently transition to volume manufacturing. • Engineering expertise related to RF test strategy and test development. • Component selection recommendations that consider quality, availability and cost. • Ability to place fine-pitch components. • Ability to support software integration and other customization requirements in a variable demand environment. • Ability to provide required testing to ensure continued product regulatory compliance. • Ability to support post-manufacturing requirements such as fulfillment, repair depot and spares support. EMS contributions typically are made incrementally throughout the product development and manufacturing process and over time shorten design cycles, reduce design to production learning curve issues and improve quality. The following example outlines a project outsourced by an OEM wishing to add RF technology into its system solutions for the utility market. Key challenges that needed to be addressed included: • A requirement for a product operational life of 15 or more years. • Hostile operating environments that could include high moisture contact and significant temperature variations. • Different product configurations for different markets. • High engineering change notice (ECN) activity, particularly in relationship to software revisions. • Variable demand driven by utility ordering practices. • A regulated design that could require formal re-qualification if component substitutions were made. 44 Circuits Assembly SEPTEMBER 2008 The EMS provider managed mechanical enclosure design, design for testability and component selection. DfM considerations took into account the EMS provider’s manufacturing equipment constraints and processes, which were aligned with IPC design guidelines. The EMS provider evaluated component lifecycles and approved vendor list (AVL) choices. In terms of component lifecycle analysis, semiconductors were the primary focus in potential obsolescence evaluation. Recommended AVL choices were based on price competitiveness, track record of supplier performance and availability. When component substitutions were recommended, the EMS provider sent samples and data sheets to the OEM’s design house for evaluation. This particular EMS provider also had strengths in custom wound coil design and manufacture. The design house specified the requirements for an inductive coil, but the actual bobbin was selected and wound by the EMS provider. DfT was another area of focused collaboration. The EMS provider had expertise in both in-circuit test development and RF functional test and fixture development. As a result, it developed the test programming, functional test set and fixtures. It also made recommendations to the design firm for connector placement to support test node accessibility and optimum RF signal integrity during test. Test development was an area of greatest technical complexity. Test node accessibility and RF signal integrity drove specialized focus in both the product design and test fixture development. Additionally, the test process needed to incorporate a software programming step. Product life issues were addressed in the initial design process during component selection and qualification testing. A potting process was used to minimize/eliminate environmental exposure. The EMS provider’s systems for configuration control and traceability supported the high levels of ECO activity and challenges associated with multiple product configurations. Market drivers are creating significant opportunities in RF-based utilities metering applications. For OEMs, the trick to capitalize on these opportunities is combining existing marketing expertise with a strong team capable of rapidly developing, qualifying, manufacturing and shipping products. n Reference 1. R. Allcorn, “Emerging Technologies in RF Design and Implications on Design for Manufacturing and Testability in Outsourced Production,” SMTA International, August 2008. Ed.: This article is adapted from a presentation at SMTA International in August 2008, and is published with permission. Roger Allcorn is senior product engineer-RF products at Syncro Corp. (syncrocorp.com); rogerallcorn@syncrocorp.com. circuitsassembly.com http://www.syncrocorp.com http://www.syncrocorp.com http://circuitsassembly.com

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Circuits Assembly - September 2008 Contents Caveat Lector Industry News Market Watch Talking Heads Focus on Business Global Sourcing On the Forefront Screen Printing Better Manufacturing Reflow Soldering with a SnCu Eutectic Pb-Free Alloy Improving OEE in High Mix Facilities Effectively Managing RF Design in Utility Metering Applications Solder Joint Reliability of Different BGAs Reworked Using Low Melting Point Pb-Free Alloys Tech Tips Wave Soldering Pb-Free Lessons Learned Materials World Process Doctor Equipment Advances Product Spotlight Ad Index Assembly Insider Technical Abstracts

Circuits Assembly - September 2008

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