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TRANSCRIPT
Patrick McGoff
Reducing Design Cost and Time with Concurrent DFM Verification
Market Development Manager
May 2011
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Agenda
The Need for DFM
Technology Differentiators
Value Proposition
Resolving manufacturability issues during design…
so they don’t cost you time and money
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
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Reduced development budgets
Demand for more feature-rich products
Demand for higher quality products
Demand for lower cost products
Need to launch products quickly
Top Business Pressures Driving Improvements in PCB Design
Aberdeen Group, Why Printed Circuit Boards Matter to the Executive, February, 2010
The Need for DFM
DFM addresses four of these pressures
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
The Need for DFM
Recently had a design scrapped in manufacturing
Not meeting product release schedules
Taking too many revision spins per design
Labor costs for product development are too high
New product introductions are over budget
Have to maintain larger staff than necessary to manage issues
What pains are you feeling today?
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Using NPI and production to uncover DFM issues is time consuming and expensive
At each step, it costs 10 times more to fix a problem than the previous step
The most expensive failures are the ones that you find in the field
Prototype Fabrication
Prototype Assembly
Small Lot Fabrication
Small Lot Assembly
ProductionAssembly
ProductionFabrication
Product Release
PCB Design
$ $ $ $ $ $ $ $
The Need for DFM
Time Measured in Months
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Causes for Fabrication Hold
0.0%
2.0%
4.0%
6.0%
8.0%
10.0%
12.0%
14.0%
16.0%
18.0%
20.0%
Percent of Total Issues
Courtesy of P. D. Circuits, Hampstead, NHData collected over six months, 2008
• 26% of jobs put on hold• Not including array approvals
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Causes for Fabrication Hold
0.0%
2.0%
4.0%
6.0%
8.0%
10.0%
12.0%
14.0%
16.0%
18.0%
20.0%
Percent of Total Issues
Courtesy of P. D. Circuits, Hampstead, NHData collected over six months, 2008
• DFM could have prevented 66.7% of the holds• And eliminated array approval
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
DFM Interests
Subject Design Organization Supplier
Product costs Minimize costs Maximize profit
DFM trade-offs Wants control of decisions Wants control of decisions
Form factor Miniaturization Maximum manufacturing yield
Design revision spins Wants to minimize/eliminate Makes money off of each spin
PCB design integrity Wants PCB built as designed
Wants/needs to edit PCB
design for manufacturing
processes
Communication
Expects full disclosure of all
edits Will communicate as required
Component sourcing
Wants control for quality
reasons
Wants control for costs/profit
reasons
The Need for In-House DFM
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Analyzes design for manufacturability issues
Formerly known as Valor’s Enterprise 3000
More than 1000 seats installed
Version 9 is most significant release in 12 years
Industry’s Best-in-Class DFM verification
software
vSureResolving manufacturability issues during design so they don’t cost you time and money
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Technology Differentiators
Concurrent integration with design
Integrated Design through Manufacturing
Comprehensive analysis
Accurate library for assembly analysis
Understanding the manufacturing risk
Synchronized with your supply chain
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Doing DFM only at the back-end of PCB design is too late
Any issue found there requires some level of re-design
Component Placement
Route Critical Nets
Route Non-Critical Nets
and Test Points
Release to Manufacturing
DFM Verification
Concurrent Integration with Design Flow
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Concurrent DFM allows issues to be found at the earliest possible stage
Analyze design data while you are still in design— Uses intelligence of design properties, e.g.
area maps— Eliminates “loop-backs” in design cycle
DFM analysis results linked to CAD layout tool for resolution
Helps PCB Designers become more “manufacturing aware”
Preliminary Assembly Analysis
Preliminary Fabrication Analysis
Assembly, Fabrication,
Test and Netlist
Analysis
Component Placement
Route Critical Nets
Route Non-Critical Nets
and Test Points
Release to Manufacturing
Concurrent Integration with Design Flow
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Integrated Design through Manufacturing
Cost to find & fix a problem increases 10X with each process step
Finding manufacturing errors during layout saves time & money
Layout & Output
NPI / Manufacturing
Interface
Fabrication Execution
Fabrication NPI
Process Prep.
Assembly / Test NPI
Process Prep.
Assembly / Test
Execution
Schematic Design
NPI Processes
Manufacturing Execution
Product Design Process
Design
Manufacturing
(Supply Chain)
(Execution)
Design-Through-Manufacturing Product Lifecycle
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Tight integration between Expedition PCB & vSure— Reduces time to evaluate design for manufacturability— Ensures accuracy of data to/from DFM analysis— Enables PCB designer to review & fix errors within their
familiar toolset/environment— Provides two modes for error review (graphic sync, hazards list)
Integrated Design through Manufacturing
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Number of DFM Categories Available
Fabrication 293
Assembly 347
HDI 83
Microvia 40
Plus:Netlist ValidationBOM ValidationApproved Vendor List (AVL) Validation
Comprehensive Analysis
763 Total
Checks
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
0
50
100
150
200
250
300
350
400
Fabrication Checks Assembly Checks
vSure Altium Cadence Allegro
Mentor Board Station Mentor Expedition Mentor PADS
Zuken CR-5000 w/ADM
Comprehensive Analysis
Number of Checks by CAD Flow
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Over 35 million manufacturing part numbers
2 ½ D component data plus pin contact areas
Created using ISO 9001 process
Only way to assure quality solder joints
Identify issues that cannot be found using CAD libraries
Accurate Library for Assembly Analysis
Insufficient heel is the number one cause for
poor solder joints
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Identifies yield and reliability issues, not just manufacturing violations
Prioritizes the severity by your weighting
Manufacturing violations
Yield & reliability issues
Understanding the Manufacturing Risks
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
More than 80% of all PCBs are fabricated using Valor-developed CAM system
All of the 10 largest and more than half of the top 50 EMS companies worldwide use Valor’s DFM software
Synchronized with Your Supply Chain
Fabricator Customers EMS Customers
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Same analysis as your suppliers use
Same rules settings to know their process capabilities
Same data format streamlines the Design-to-Manufacturing flow
Modifications done by fabricator can be analyzed to validate correctness
Synchronized with Your Supply Chain
PCBDesign
(vSure SP)
Fabrication(Genesis,InCAM)
Common checks, rules & data
formatAssembly(Trilogy,vPlan)
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Valor DFM users average 57% fewer revision spins than non-Valor users
The average savings in material costs alone equates to $20,800 per design
0
0.5
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1.5
2
2.5
3
Valor Users Non-Valor Users
1.2
2.8
Number of Revision Spins per Design
Value Proposition
Aberdeen Research, Printed Circuit Design Integrity, May, 2007
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
"By using vSure, we help ensure that our designs meet our
manufacturing requirements. The implementation of the new Design
Process Wizard has reduced the amount of internal
customization, which will lower our cost of ownership. Our
users have also reported an improvement in the review
procedures through the implementation of the new Manufacturing Risk
Assessment."
San Diego, CA
Value Proposition
Low Cost of Ownership
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
$-
$100,000
$200,000
$300,000
$400,000
1 2 3 4 5 6 7 8 9 10 11
Payback Period in Months
Cost Savings (Material and Labor)
Cost Savings (Material Only)
System Cost
0 2 4 6 8 10
Proposed Time
Current Time
Development Cycle Time in Months
Initial Prototype Revisions
Virtually every customer is able to show a payback period of less than 1 year
and a reduction in the number of revision spins
Value Proposition
Return on Investment
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.com
Fewer revision spins per design
Fewer major production issues
Time savings in release schedule
Low cost of ownership
Intuitive to use
Value Proposition
Resolving manufacturability issues during design…
so they don’t cost you time and money
© 2010 Mentor Graphics Corp. Company Confidential
www.mentor.comPM, vSure DFM Verification, November, 2010
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