inemi project on pcba reliability qualification processes for...
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©2012 iNEMI
iNEMI Project on PCBA Reliability Qualification
Processes for Enterprise Products
SOW Review Session
October 18, 2012
Co-chairs -
Tom Homorodi (Dell)
Aamir Kazi (Dell)
1 ©2012 iNEMI
PCBA Reliability Qualification Process
Statement of Work Review
• Introduction of Project Chairs
• Overview of iNEMI Project Selection Process
• Company participation in Statement of Work (SOW)
development
• Introduction
• Review of SOW
• Summary and next steps
• Q&A
Agenda
Note: All phones will be on mute until the end of the presentation
2 ©2012 iNEMI
PCBA Reliability Qualification Process for Enterprise Products
• Tom Homorodi… Dell, Director Enterprise Reliability Engineering.
– Lead Design for Reliability, Subsystem Qualification & ORT, New Technology Qualification, Predictive and
Inferential Statistics, Validation Testing, S&V, and Failure Analysis teams for Dell Server, Storage and
Networking products.
– Previous experience includes High Reliability and Automotive quality/reliability program leadership in:
– Semiconductor wafer fab and assembly/test processes
– PCB assembly, in circuit, and final test processes
• Aamir Kazi… Dell, Enterprise Reliability Engineer
– New technology/ process/ materials reliability engineer for enterprise products.
– Previously responsible for reliability qualification for Lead-free/ RoHS transition for enterprise and client
products.
Project Chairs
©2012 iNEMI
Project Management
Project Selection Process
4 ©2012 iNEMI
STRATEGY
RESOURCE
ANALYSIS
&
PLANNING
COMPANY
COMMITMENT
Resource Skills
& Utilization Maps
PROJECTS
PROJECTS
ALIGNED TO
STRATEGY
PROJECTS
REALISTICALLY
POSSIBLE
Filter Filter MARKET
OPPORTUNITIES
BUSINESS
GROWTH
Project Selection Process
5 ©2012 iNEMI
Questions to Ask:
• VALUE:
– What is the value?
• TEAM:
– Does the team have the right leadership?
– Does the team have the right
membership?
– Does the team have the necessary
experience and skills?
• PRODUCTS / RESULTS:
– What are the essential specifications?
– Is existing technology usable?
• STRATEGIC ALIGNMENT:
– Why is the project strategic?
– Is it identified as a key thrust?
– Why must we do it now?
• PROJECT SCHEDULE:
– Is the schedule achievable?
– Has a detailed work breakdown structure
been derived?
– How does “time-to-market” compare with
industry benchmarks?
• RESOURCE REQUIREMENTS:
– Are all resources identified and
committed for the schedule?
– Will all of the skills needed be available
when required?
• RISK AND ISSUE MANAGEMENT:
– Are all risks regularly identified,
monitored and managed?
– Are the probability and impacts realistic?
– Are clear action plans established for high
risks?
– Are all issues identified promptly and
escalated as appropriate for decisions?
6 ©2012 iNEMI
The Project Process - 5 Steps
SELECTION
DEFINITION
PLANNING
EXECUTION / REVIEW
CLOSURE
1
2
3
4
5 Limited to iNEMI Members
Open for Industry input
------------------- iNEMI Technical Committee (TC) Approval Required for Execution
©2012 iNEMI
Company Participation in
SOW Development
8 ©2012 iNEMI
Statement of Work (SOW) Development
Company Participation
©2012 iNEMI
Introduction
iNEMI Project on PCBA Reliability Qualification
Processes for Enterprise Products
10 ©2012 iNEMI
Multi-OEM Qual Process: Current Problems • Inadequately qualified product or process changes
• Inadequately qualified new and/or emerging technologies
– Product and technology changes are not sufficiently validated
• Opaque, non-standard qualification test suites
– Opacity allows suppliers/ ODM’s to set unacceptably low qualification levels
– Each supplier does something different and all say it is okay
– Lack of a standard test suite
– Uncorrelatable test results
• Multiple qualification cycles add time, costs and delay time-to-market
• ODMs receive diverging and conflicting guidance from the multiple
OEMs
• Inconsistent OEM requirements and ODM responses
11 ©2012 iNEMI
Project Summary
• Problem Statement
– Inconsistency in the qualification of new technology, materials,
suppliers/factories at EMS and ODM firms by OEMs (Each OEM has
their own, and different, qualification process).
• Opportunity
– “Level the playing field” -- Standardize PCBA reliability qualification
methods at the ODM/CM level
– Improve supplier capabilities
• Goal
– Develop an industry-wide set of common qualification elements and
processes for consistent ODM/CM PCBA reliability
– Consistent OEM Product and Process change qualification process
12 ©2012 iNEMI
Outline of Statement of Work (SOW)
• Background/Context
• Scope of Work
• Purpose of Project
• Project IS / IS NOT Analysis
• Business Impact
• Outcome of Project
• Previous Related Work
• Project Plan
• Project Monitoring Plans
• Future Project Plans
• Next Step – Project Sign-up
©2012 iNEMI
Review of
Statement of Work
iNEMI Project on PCBA Reliability Qualification
Processes for Enterprise Products
14 ©2012 iNEMI
Background/Context
• Reliability is a key customer and market concern in computing products in
enterprise, client and mobile spaces.
• In some cases, new technologies, materials and assembly processes may
be introduced and/or qualified in a manner that is inconsistent with typical
OEM requirements.
• Various industry standards and procedures exist today to assess
acceptability and test the quality and reliability of electronic soldered-
assemblies (PCBs and PCBAs).
• Due to this variety, any given CM/EM/OEM manufacturer’s product reliability
qualification methodology and results are not easily correlated with their
peers’ results and OEM expectation.
• A common qualification framework is desired.
15 ©2012 iNEMI
Scope of Work
• A qualification process document already exists at Dell which is being proposed as the starting point for the enterprise-product-wide applicable document.
• The team will review these documents for
– Applicability to the charter
– Qualification will be at the PCBA level: PCB materials are presumed qualified (starting point) but will include tests/evaluations that look at PCB risk sites for assembly; not qualifying at the un-soldered PCB-level resin/construction
– A single project for qualification of Enterprise products
– Flow, of qualification
– Qualification procedure and process
– Pass/Fail criteria, for individual tests, not for the qualification-suite as a whole
– Establish minimum recommendations/guidelines for sample quantities and related test conditions
– Enhancement, of relevant sections
– Omissions, sections/procedures that need appending
– Exceptions, to certain sections
16 ©2012 iNEMI
Scope of Work
• These reviews may be done in the context of members’ existing
qualification process framework.
• Agreement on the reviewed items and revisions thereof.
• Editing/rewriting sections with team’s agreed-upon modifications.
• Invite CM/EMS/ODM feedback – incorporate as needed.
• Approval by team.
• Release completed document.
• Decide on the visibility: current direction is for it to be public
17 ©2012 iNEMI
Purpose of Project
• The project serves to establish a common hardware
reliability qualification process for suppliers
manufacturing computing hardware (servers, storage
and switches) to be deployed in offices, datacenters, as
well as environmentally controlled telecom datacenters.
• This is projected to deliver a complete solution
addressing new product T/M/P Reliability Qualification
Process.
18 ©2012 iNEMI
Expected Benefits of Project
• Level the playing field for qualification requirements.
• Reduce ambiguity with qualification processes at
CMs/EMSs to satisfy customers’ qualification demands.
• Limit complexity of negotiating qualification
requirements.
• Reduce effort to have suppliers accept responsibility for
qualification work.
• Reduce cost for EMSs/CMs/ODMs or repeated full qual to
comply with variegated demands of similar goals.
• Allow for leveragability of previous qualification work for
ceteris paribus (all other things being equal) technology.
• Document will serve as suite baseline for existing CMs’
re-qualification efforts for new sites moves and transfers.
19 ©2012 iNEMI
IS / IS NOT Analysis
This Project IS: This Project IS NOT:
To define an OEM/industry-wide set of PCBA reliability qualification methods and processes
(toolbox) for:
• new suppliers
• new technologies
• new materials
• new processes
… as applies to ODM/CM PCBA manufacturers
- Primary focus will be on Enterprise products (including telecom data centers)
Not intended for
• High Rel:
• Outdoor-telecom
• Military/aerospace
• Medical
Reliability evaluations are done for designs and materials. Supplier qualifications are intended
to evaluate capability and quality. This document is meant to qualify new technologies for which
the process definition/development work is complete.
Early R&D for new technology/process or
materials’ viability
Is not process definition/development or material
evaluation
Review/identification of Best Known Methods/Best Known Practices in reliability of electronic
OEMs for “new” qualifications.
Developing new reliability test
standards/procedures/test methods
Testing/materials resources commitment
Utilizing existing industry standards/procedures wherever appropriate. Regulatory/environmental materials compliance
Decide on whether the output will culminate in a guideline (that may/may not evolve into a
standard, e.g., QS9000).
Re-creation of component qualification test
methods and processes
For reliability qualification of new solder assembly processes, technologies, materials at
manufacturing facilities of new and existing suppliers. Definition of test-level failure criteria.
Failure Analysis requirement/procedure
development
Definition of qualification-suite level failure criteria
– This is the domain of each OEM, and defined by
them
PCBA-level qualification, with evaluation of risk sites on PCB’s that depend on solder-assembly
process
Raw PCB material/construction evaluation
20 ©2012 iNEMI
Business Impact
• Resolving ambiguity with qualification processes at CMs/EMSs to
satisfy their various customers’ qualification demands.
• Have suppliers accept responsibility for qualification work.
• Reduce cost for EMSs/CMs/ODMs due to varied test
protocols/qualification process flows to comply with variances
between multiple customers’ qualification requirements for similar
hardware.
21 ©2012 iNEMI
Outcome of Project
• A one-stop-shop unified qualification process document for new
process/technology/materials reliability qualification
• Sharing Project Results: the expectation is that information will be shared
as a public domain document.
22 ©2012 iNEMI
Previous Related Work
• The project team will continue to identify any related research or
development within the industry and academic communities.
– Existing OEM/Industry documents for qualification processes
– Standard industry testing practices (ASTM, IPC, etc)
23 ©2012 iNEMI
Project Schedule & Tasks
• The Timetable for this project is 9-12 months
TASK LIST Q1 Q2 Q3 Q4 Q5
Task 1: Disseminate current document
Task 2: Review OEM documents
Task 3: Gap analyses
Task 4: Develop Flow, of qualification
Task 5: Develop agreement/modifications
Task 6: Editing/rewriting
Task 7: Approval by team
Task 8: Invite EM/CM/ODM feedback
Task 9: Release completed document
24 ©2012 iNEMI
Project Monitoring Plans
• Ensure open lines of communication among participants
• Project participants will meet a minimum bi-weekly to review various aspects of
the project and make plans for next phases of the project
• Meeting minutes provided through e-mail
• Follow-up with individuals on an as-needed basis
• Project team will identify specific monitoring or communications plans to
accommodate project team member locations, e.g., multiple project meetings to
cover multiple regions (EMEA, Asia, Americas)
• Workshops and face-to-face meetings as determined by the project team
• Progress reports will be provided upon request for presentation at regularly
scheduled iNEMI meetings (e.g. a short series of PowerPoint slides showing the
work in progress at member council meetings)
• Track and document approximate man-months per quarter per team member
(this will require the active members of the team to provide estimates)
• Track and document approximate number of people on the project per quarter
(this can be tracked through iNEMI's WebEx account)
25 ©2012 iNEMI
Summary and Next Steps
• Project has been approved by the iNEMI Technical Committee
• Open Enrollment for Project Sign-up will continue until November 16, 2012
• More information can be found at http://www.inemi.org/project-page/pcba-reliability-qualification-project
• Steps for Joining the Project
– Please note: iNEMI membership is required to participate in the iNEMI Project for
PCBA Reliability Qualification Processes. The period for becoming a founding
member of this project will close on November 16, 2012. Steps for joining the
project are outlined below.
• For iNEMI members:
– Complete and sign the project statement
– Fax the completed statement to +1 (703) 834-2735 or scan + email to [email protected]
• For non-members:
– Discuss annual membership fees with Bill Bader in North America
([email protected]), Haley Fu in Asia ([email protected]), or Grace O'Malley in
Europe ([email protected]).
– Complete the iNEMI membership application. (www.inemi.org)
– Fax the completed documents to +1 (703) 834-2735 or scan + email: [email protected].
– Complete and sign the Project Statement
– Fax the completed statement to +1 (703) 834-2735or scan + email to [email protected].
26 ©2012 iNEMI
Q&A
