ipc — whma an inside overview · • in-process inspection, or • end product inspection no...

IPC IPC —IPC — WHMA AN INSIDE —— WHMA AN INSIDE WHMA AN INSIDE OVERVIEWWHMA AN INSIDE WHMA AN INSIDE OVERVIEWOVERVIEWOVERVIEW

Presented by: Constantino J. GonzalezPresented by: Constantino J. Gonzalezacmetino@gwtc.net

Presented by: Constantino J. Gonzalezacmetino@gwtc.netacmetino@gwtc.netacmetino@gwtc.net

Membership and Benefits

IPC is a global industry association dedicated to furthering thecompetitive excellence and financial success for more than 4,300member sites that make, use, specify and design printed boards andassemblies, as well as their suppliers and end-product manufacturers,including those in:

IPC Today

advanced microelectronics aerospace and military automotive computer and business equipment industrial equipment medical equipment and devices telecommunications industries

Who is IPC

IPC TodayIPC Membership Composition

More than 4,300 Member Companies Worldwide

IPC TodayMultifaceted Services and Programs

Training & Certification

Industry Education

Conferences & Exhibitions

Management Programs

Market Research

Statistical Programs

Public Policy Advocacy

IPC TodayIPC – WHMA Events and Conferences

Membership entitles your site discounts to attend, exhibit, or sponsor any of IPC & WHMA’s events and conferences throughout the world.

IPC APEX EXPO SEMI ANNUAL MEETINGS WHMA ANNUAL WIRE HARNEES CONFERENCE ELECTRICAL WIRE PROCESSING TECHNOLOGY EXPO

Most of all, there is peer-to-peer networking at the exhibits and conferences. You can solve issues with your fellow engineers, see the latest in technology, and observe industry trends.

IPC - WHMA StandardsAutomotive Needs

IPC TodayWhy OEMs, Manufacturers shall care about

The basic standards every company should

have.For a complete list of all IPC Standards, go to www.ipc.org/standards.

1. Cable / wire and harness are the arteries and veins of any automotive products.

2. If they are not design per Industry Standards – DFM.

3. Enforcing process control instead of inspection.

4. The need for having a reliable Repair / Rework System as well as a Standard to make up for items 2 & 3.

Basic IPC & WHMA Standards

IPC TodayWhy IPC - WHMA Standards

Developed and approved by industry peers

Supports design and layout of products for manufacturing, reliability and excellence

Provides universally accepted criteria and language for the entire supply chain

Improves reliability and quality of products, manufacturing to a common specification

Drives manufacturing efficiencies, reduces cost, minimizes rework and waste

IPC TodayPopular IPC –WHMA Standards by Market

Segment

IPC TodayIPC-A-610

A collection of visual quality acceptability requirements for electronic assemblies. Presents acceptance requirements for the manufacture of electrical and electronic assemblies.

Acceptability of Electronic Assemblies

IPC TodayIPC-J-STD-001

Describes materials, methods and acceptance criteria for producing soldered electrical and electronic assemblies. The intent is to rely on process control methodology to ensure consistent quality levels during the manufacture of products.

Requirements for Soldered Electrical and Electronic Assemblies

IPC TodayIPC/WHMA-A-620

A collection of visual, electrical and mechanical quality acceptability requirements for Cable, Wire and Harness Assemblies. IPC/WHMA-A-620 can be used as a stand-alone document for purchasing products; however, it does not specify frequency of: • in-process inspection, or• end product inspection No limit is placed on the number of process indicators or the number of allowable repair/rework of defects. Such information should be developed with a statistical process control plan.

Requirements and Acceptance for Cable and Wire Harness Assemblies

IPC TodayIPC-D-620

This document provides design and critical processes requirements and technical insight that have been removed from the acceptance standards for cable and wire harnesses assemblies.IPC-D-620 intent is to set forth the general design requirements for electrical wiring harnesses and cable assemblies.

Design and Critical Processes Requirements for Cable and Wiring Harnesses

IPC TodayIPC-HDBK-620

This handbook is a companion reference to IPC-D-620 & IPC-WHMA-A-620.The intent is to provide supporting information, guidance and technical insight into the design and acceptance requirements for electrical wiring harnesses and cable assemblies.

Handbook and Guide to IPC-D-620 and IPC-WHMA-A-620

IPC TodayIPC-REPAIR & REWORK-620

This guidelines is in the process of submitting a pin for development.

Repair & Rework Guidelines to IPC-D-620 and IPC-WHMA-A-620

IPC TodayIPC-630

First acceptability standard for electronic enclosureIt contains acceptability criteria that pertain to the “box build” of the assembly processProvides best practices for manufacturers and end users of electronic enclosures of electrical and electronic equipment Ensures the reliability and function of the end-item assembly for its intended design life.

Guidelines for Design, Manufacture, Inspection and Testing of Electronic Enclosures

IPC TodayIPC-7711/21

Procedures for repairing and reworking printed board assemblies.Revision includes expanded coverage for lead free processes, and additional inspection guidelines for operations such as repair that may not have other published criteria. Does not limit the maximum number of rework, modification or repair actions to a Printed Circuit Assembly.

Rework, Modification and Repair of Electronic Assemblies

IPC TodayIPC-6012C

Qualification and Performance Specification for Rigid Printed BoardsOne of the most widely used standards for printed circuit board fabrication.Covers qualification and performance of rigid printed boards including:

• Single-sided, double-sided, with or without plated-through holes• Multilayer with plated-through holes and with or without buried/blind vias

Other standards for printed circuit board fabrication include:• IPC-6011, Generic Printed Boards• IPC-6013, Flexible Printed Boards• IPC-6015, Organic Multi-Chip Module• IPC-6016, High Density Interconnect• IPC-6017, Embedded Passive Devices• IPC-6018, High Frequency Printed Boards

IPC TodayIPC-A-600

Acceptability of Printed Boards

Describes the preferred, acceptable, and nonconforming conditions that are either externally or internally observable on printed boards.Represents the visual interpretation of minimum requirements set forth in various printed boards.

IPC Today IPC-2221BCoupon Generator

• The IPC-2221B Gerber Coupon Generator is a subscription service• Easy-to-use “Design Parameters/Input File,” utilizing auto quality check feature• Design rules are automatically maintained for the test designs as established in IPC-2221B • Generates coupons in minutes• Test coupons currently available (AB, AB-R, and D) • Used for acceptance of production lots of printed boards• Meets the criteria as presented by; IPC-2221B, Generic Standard on Printed Board Designs

Appendix A test coupon designs, as called out in the IPC-6012C-TC Test Coupon Addendum to IPC-6012C, Qualification and Performance Specification for Rigid Printed Boards

IPC Training and Certification

IPC–WHMA Training & Certification Program Goals Foster a professional workforce

Provide uniform training programs to enhance understanding of IPC standards

Enhance an individual’s ability to correctly apply criteria from a given standard

Increase proficiency to achieve acceptable workmanship

Demonstrate the ability to apply the criteria appropriate for class or classes of production

IPC Certification Program Office IPC Training and Certification Advisory Committee IPC Technical Training Committee IPC Authorized (Licensed) Training Center Master IPC Trainer (MIT) Certified IPC Trainer (CIT) Certified IPC Application Specialist (CIS) Certified Interconnect Designers (CID/CID+)

Training and Certification SourcesIndustry Guided — Consensus Driven — Reliability Proven

Training and Certification SourcesThe IPC Certification Program Office is responsible for:

Approve and administer training center licenses Approve and administer translation licenses Facilitating development meetings Provide Periodic audits Distribution of training material Tracking certified program participants Policy interpretation and problem resolution

Training Program Structure — “Train the Trainer”

MIT

CIT

CIS CIS

CISCIS

CISCIS

CIT

CISCIS

CISCIS

CISCIS

CIT

CISCIS

CISCIS

CISCIS

Certification PortalThe ultimate secure platform for certification in our industry

Certification Portal

Benefits of the Certification Portal Integrity Flexibility Security

The features of the Certification Portal An online examination accessibility Multiple versions of exams Will allow printing of exams Secure login Class management Purchase bulk credits for future use

Professional Education

IPC-DFX (Design for Excellence) Course

Design for Manufacturability Design for Reliability Design for Test IPC Standards-based technical education: knowledge

enhancement and assessment Delivered by an IPC-qualified Instructor in a three-day on-site

workshop-exam session 400+ individuals worldwide participate in the program every year

IPC EDGE

What is IPC EDGE?

IPC EDGE is a Learning Management System (LMS) Online Learning Platform

• A Platform to Deliver Knowledge and Education• Response to IPC member feedback to offer more online

education An eLearning Experience for All

• From Executives to the Production Operators Supports one of IPC’s aspirational goals — Education

• IPC will become the world's leading electronics education and knowledge provider to the electronics industry

Courses on IPC EDGE

Validation Services

IPC Core Competencies

Validation Services Vision

Purpose Verification that companies can manufacture, assemble and supply

in accordance with IPC standards

Focus Products that demand high reliability

Goal Build the Network of trusted source in the electronic supply chain

IPC QML/QPL … Filling the Gap

What is QML/QPL

QML – Qualified Manufacturers List Examples: PCBs, PCBAs, Cable and Wire

Harness, and IP Protection

QPL – Qualified Products List Examples: Solder Fluxes, Solder Pastes,

Solder Alloys, and Conformal Coatings

IPC QML/QPL Programs

QML: IPC J-STD-001/610

• IPC-J-STD-001 Space IPC/WHMA-A-620 IPC-1071 and IPC-1072 IPC-6012/600

QPL: IPC-J-STD-004, 005, 006 IPC-4101

Standards Gap Analysis (SGA)

SGA: A Total Evaluation

Incoming• Procurement/Supplier Audits• Component Handling and Storage (MSD’s)

Printed Board Assembly Processes• ESD• SMT and PTH Assembly (Sn/Pb and Pb-Free processes)• AOI and AXI Inspection• Process Control (defined in J-STD-001)

Soldering (all types) Cleaning and Conformal Coating Wire and Cable Harness Assembly Rework and Repair Shipping

• Labeling

SGA Wire & Harness Program Approach

SGA Wire & Harness Program Approach

Internal training and certifications General production facility (appearance) ESD Assembly materials (solder, flux, adhesives) Process Control documentation Rework & Repair General Manufacturing Quality Preventive Maintenance Storage and Packaging

SGA Wire & Harness Program ApproachAssembly Processes: Wire Prep Solder Termination Crimping and Crimping Tools Insulation Displacement Connections Ultrasonic Welding Splices Hardware Mounting Over-Molding/Potting Marking/Labeling Coaxial Cable Shield Securing and Braided Hardware Insulation Solderless Wrap

Testing: Continuity and Shorts Dielectric Withstanding Voltage Insulation Resistance Crimp Height Pull Force RF Connector Shield (pull force)

SGA Case Studies

SGA Case Studies (OEM)

Pull Force Test Verification (per IPC/WHMA-A-620) Reviewed the wire crimp and pull test results from an internal

audit and compared all data to IPC standards Customer pull values exceeded IPC specs by an average of

45% Wire crimp tool calibration and verification exceeded IPC specs Result — Differentiated from competition by exceeding

customer’s requirement

SGA Case Studies (OEM)

Solder Wetting Issues (per IPC-A-610) Reviewed and made recommendations related to the product design

• Changed drilled hole size for stranded wire insertion• Proper pre-tinning of the stranded wire was implemented• X-Ray equipment was suggested for inspection

Complete re-design was suggested long term• Rigid-flex technology is being considered

Result – Renewal of Business Contract with a Current Customer

SGA Case Studies (OEM)

DFX Product Review (per IPC-2221 and IPC-2222) Reviewed Printed Board layout and DFX report from the printed board

fabricator• Suggested thermal relief options and the use of stitching vias

Reviewed and made recommendations related to the product design• Selective Soldering clearances were added

• SMT components were too close to plated mounting holes• Lead to hole ratio was reviewed

• Concerns about achieving proper barrel fill Result – New Product Development Program stayed on scheduled

SGA Case Studies (OEM and EMS)

Solder Splashes and Excessive Voiding (per J-STD-001 and IPC-A-610) New product design was using a very heavy component (Power Brick)

• QFN type package that weighted over 10 grams• Supplier information was lacking manufacturing recommendations• OEM company needed support and the EMS company was looking for answers

Reviewed and made recommendations related to the product design• Suggested Solder mask Defined Pads• Verified SMT placement force• Reviewed the solder paste material and suggested changes to the Reflow oven profile

Made suggestions to the Supplier on either adding a spacer or to pre-bump the component pads of the package

Result — OEM is modifying package to accommodate heat dissipation

COMMITTEES FORMEDTHREE COMMITTEES FORMED DURING ROUNDTABLE SESSIONS AT WHMA DALLASThese topics were discussed in my roundtables and I came up with volunteers [e-mails, names, phone #s] to work on the content and development of the topics below

REWORK CRITERIA FOR CABLE & HARNESS

DESIGN FOR MANUFACTURING FOR CABLE & HARNESS

OPERATOR TRAINING PROGRAM FOR CABLE & HARNESS – INTRODUCTORY

Constantino J. González Management & Process Improvement Expert, IPC Acceptability Committee Chairman Master IPC Instructor – AIAG/CQI-17 Chairman IPC Automotive Vice-Chairman

ACME CORP. American-Hispanic Company — USA

acmetino@gwtc.net www.acmetino.com USA Mobile #: 605.381.5963

GLOBAL PROCESS IMPROVEMENTS, MATERIALS, DFM SOLUTIONS TO EMS-OEM ELECTRONIC INDUSTRIES.

Management – Process Improvement Solutions• Scrap, rework reductions, process control

• Supplier process audits• DFM Systems

• Repair & Rework Systems• Technical/Engineer On-Call

IPC Certif ication & Workshops• Instructors, Specialists • Automotive Addendum• CQI-17