StencilScan™: Process Control & Inspection for Electronics Industry

1. StencilScan™

2. Process Control & Inspection, Assembly Programming, Reverse Engineering Products for the Electronics Industry

3. Agenda • COMPANY OVERVIEW • Introduction • Product Philosophy • TECHNOLOGY • Flatbed Scanners • Process Control • Hardware Configuration • Stencil Inspection and Data Creation Products • StencilScan • StencilScan Lite • SUMMARY

4. “Applying Low Cost, Multi-Purpose Vision Systems to the Electronics Manufacturing Industry” versus High Cost – Single Function

5. Introduction • ScanCAD Founded in 1990 • Global Sales & Support Network • Smart Sonic – OEM Partner since 2001 • Over 900 Customers in 46 Countries • First Systems Installed in 1987 • Vision Systems • PC- Based • Low Cost, Easy to Use, • Multi purpose

6. Product Philosophy • Newest Technology • Consumer driven scanner hardware platform • Customer investment protected since 1987 – upgrade path • Applications • From board design to fabrication, assembly and test • Process control for stencils, screens, artwork, printed & dispensed materials • Niche applications… no reason to reinvent the wheel..! • Flexible • Many applications on one system • In line or off line configurations • Low Cost • Best price/performance ratio in the industry • Prices range from about US$3K to $80K • Easy-to-use • Golden board or CAD programming in minutes • 80-20 rule providing low false call rates

7. Inspection vs. Measurement Inspection SystemMeasurement System Check 100% of Part Sample Portions of Part Output is Pass/Fail Output is Measurement Low Cost Higher Cost Scanner Based Highly Accurate/Granite base Overlay CAD and Image Point to Point Measurement Fast Not as Fast Multi-Purpose Single Purpose Can Measure, but Not as Accurate Can Inspect 100%, but Very Slow No system available that can do both…..inspect 100% and perform very accurate measurement at a price the market is willing to pay. Systems are complimentary…..many customers have both.

8. Technology

9. Flatbed Scanner Technology • Existing Vision Platform • Camera, lighting, motion control “all” in one unit • PC technology product cycle benefit • Worldwide availability and support • Excellent price/performance ratio • Low risk – not proprietary hardware • Very High Resolution • 200 – 12,800 dpi, Color or B&W • A3 size scan area – inspect up to 800 X 800 mm • Accurate • Calibrated system with glass plate • Software performs self diagnostic test • Robust Hardware • Small footprint • High MTBF “…a very smart package”

10. Scanner Evolution (1990 – 2010) True Optical MpixelsTotal YearScannerResolution(DPI)per sq. in.MPixels 1990 Model F1 400 x 400 0.16 31 1998 Model E8 800 x 1600 1.28 247 2001 Model E16 1600 x 3200 5.12 988 2004 Model E24 2400 x 4800 11.50 2224 2006 Model E32 (A4) 3200 x 6400 20.50 2002 1 Model E24 Scanner equal to 440 5 Mpixel Cameras!

11. Process Control Philosophy • Catch problems BEFORE production floor – PRE-Production • Design (holes, slots, real estate, manufacturability…) • Components (multi vendor, shape , color, size….) • Boards (multi vendor, variables…) • Stencils/screens (stretch, wear, missing, blocked or damaged apts.) • Work instructions (clear, current, precise, multi-language…) • Catch problems REAL TIME - Production • Close the loop • Direct Feedback • Watch the process • Detect trends BEFORE they reach failure • In-line or Off-line SPC • Traceability at all steps of production, including manual operations NO SURPRISES…!!!

12. Hardware • Table • Contact System • Scanner Faces Up • Part Faces Down • Dry parts or • 3D & wet parts with standoff • Lighting • Top or bottom • Calibrated System • Glass plate • Programming • CAD, Gerber or golden parts

13. StencilScan™ A powerful inspection, measurement, process control and data creation tool

14. StencilScan Products • Two Versions of stencil inspectionproducts • StencilScan – Inspection and Data Creation • StencilScan Lite – Inspection Only

15. Stencil Screen StencilScan™ • 100% automatic inspection of stencils and screens for absence / presence, position and size of apertures • 4000 dpi allows inspection of apertures as small as 2 mils / 50 microns • Guarantee stencil & screen accuracy • Compare board to stencil prior to production • Supply production with required Gerber data • Create stencil files from boards, films and stencils

16. Why Smart Sonic Inspection Systems? • Systems are the standard in the industry for stencil/screen/film/PCB inspection – it’s the leading system in the world! • Inspection is needed- It is not acceptable to ship or use defective film/PCB’s/stencils! • StencilScan Lite is the lowest cost complete stencil/screen inspection system in the industry • 100 % inspection of stencils/screens/film/PCB versus both the original customer Gerber data and the modified Gerber cut file or a Golden Part • No limits to the maximum part size • Inspect very small features, half or partial etch features and other complex shapes • Also create or modify Gerber data to match PCB with full StencilScan • Inspection of stencils/screens/film/PCB in any material including disposable plastic or paper stencils, diazo, glass, chrome, electroform, stainless, etc • Systems are very easy to use and based on a standard PC platform

17. StencilScan™ Inspection Process In seven quick and easy steps! • Import Gerber file • Scan stencil or screen at appropriate dpi • Super-impose scanned image and Gerber • Fine align scanned image and Gerber • Inspect automatically • Review errors • Print certification report

18. 1. Import Gerber File The imported Gerber is displayed in green

19. 2. Scan The stencil or screen is scanned at the appropriate dpi and displayed in blue

20. 3. Overlay Scanned Image and Gerber The scanned image and Gerber image are super-imposed at a common point

21. 4. Fine Align Any remaining skew between the two images is corrected using the “Fine Alignment” function

22. 5. Inspect The automatic inspection process offers a variety of inspection levels and options to verify aperture position, shape and size

23. 6. Review Errors Errors are highlighted in red and sequentially numbered for easy viewing

24. 7. Print Certification Report Add the report to any letterhead or certificate

25. Examples:

26. Partially blocked or undercut aperture flagged as an error against 6 mil (150 micron) Gerber

27. Undercut and missing 2 mil (50 um) apertures

28. WAFER BUMP STENCIL inspected in less than 9 minutes 53,900 APERTURES @ 5.5 mils X 10.5 mils

29. Under developed 2 mil traces (50 microns)

30. 1 mil blockage Photo Tool Inspection • Check new Photo Tool vs. CAD/Gerber data • Compare to part design or photo tool design with compensation for over/under etch • Check existing Photo Tool for scratches, pinholes, damage, etc. 2 mil protrusion

31. Other Metal Parts - Partial Etch • Color imaging for partial etch inspection

32. Gerber Bareboard Film Stencil or Screen StencilScan™ Data Creation Process Create Gerber files from boards, films, stencils or screens

33. Bareboard Stencil Gerber StencilScan™ Verification Process Compare actual board to stencil and Gerber data

34. StencilScan™ Unique Benefits • Top or bottom light capability • Inspect step or half etch stencils • Image actual PCB for verification & data creation • Color and B&W imaging capability • Inspect stencils, screen, PCB’s, etc. • Multi-purpose system • Inspection and data creation • PC based • Low cost • Low initial purchase price • Low annual maintenance • Small footprint

35. SMT Magazine Article • GOOD NEWS:  ScanINSPECT VPI  ROI ARTICLE: • “Using Stencil Design to Reduce SMT Defects” - SMT Magazine, April 2006 • http://smt.pennnet.com/Articles/Article_Display.cfm?Section=ARTCL&ARTICLE_ID=252912&VERSION_NUM=2&p=35 • Case Study of benefits of making a STENCIL that matches the PCB • 125,000 units over three weeks to obtain the data • Board measurements made using CMM at 6 reference points • Modify Gerber data to match board • Stencil made to PCB instead of Gerber • 43% solder paste defect reduction…..!!!

36. Figure 5.Pad positional deviation measurements (mils) between a stencil and PCB prior to scaling. Relative to the original Gerber data, some pads were off by as much as 0.005”-0.006”. Figure 6.The same X, Y pad aperture deviation after scaling the stencil to the PCB. SMT Magazine Article - continued

37. Summary

38. Smart Sonic™ Process Control Tools • Catch problems BEFORE production floor – “Virtual problem” • Catch problems REAL TIME – before failure – “Close the loop” • Eliminate REWORK • Environmentally friendly • Maximize existing capital investment • Reduce operator, engineer & management stress Eliminate SURPRISES…!!!

39. Smart Sonic Systems • Proven - 900+ Systems Installed in 46 Countries • Economical - Low Cost Systems - Quick ROI • Easy to use - User Friendly, PC Based • Off-line - Small Footprint Desk or Desktop • In-line - Small Footprint Conveyor • Accurate - Calibrated System • Flexible - Many Inputs / Outputs • Multi-purpose - All Software on Same Platform • Powerful - 50 micron (2mil) Features • Upgradeable - Annual Releases Since 1990 • Environment - Minimize Scrap and Rework

40. SMART SONIC CORPORATION837 E. 79 Street · Cleveland, Ohio 44103 · U.S.A.TEL: +1-818-610-7900 · FAX: +1-216-881-8950E-mail: smt@SmartSonic.com · Web Site: www.SmartSonic.com