Manas Bajaj, Dr. Russell Peak, Miyako Wilson, Injoong Kim Thomas Thurman, M.C.Jothishankar, Mike Benda Dr. Placid Ferrei

1. Semicon West 2003 SEMI Technology Symposium: International Electronics Manufacturing Technology Session 210: Factory Simulation, Automation and Integration SEMI and IEEE/CPMT San Jose, CA July 18th, 2003 Towards Next-Generation Design-for-Manufacturability Frameworks for Electronics Product RealizationPhase 1: Rule-based Manufacturability Verification of Circuit Board Designs Recipient of the “Best Paper Award” in Session 210, IEMT, Semicon West 2003 Manas Bajaj, Dr. Russell Peak, Miyako Wilson, Injoong Kim Thomas Thurman, M.C.Jothishankar, Mike Benda Dr. Placid Ferreira, Dr. James Stori Updated web version:http://www.eislab.gatech.edu/pubs/conferences/2003-ieee-iemt-bajaj/

2. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

3. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

4. System Engineer Package Data Supplier Analysis Model Supplier EE/ME Product Designer Assembly Vendor PDM / Library Device Supplier Known Good Data Fabrication Vendor Simulation for Flexible Manufacturing (SFM)Project Vision • Enable a collaborative environment for engineers (design, manufacturing, producibility, test etc.) to work together and negotiate for a robust product model

5. Simulation for Flexible Manufacturing (SFM)Project Timeline Teams • Teams • Rockwell Collins (RCI) • Thomas Thurman, M.C.Jothishankar, Mike Benda • Georgia Tech (GIT) • Dr. Russell Peak, Manas Bajaj, Miyako Wilson, Injoong Kim • University of Illinois at Urbana Champaign (UIUC) • Dr. Placid Ferreria, Dr. James Stori, Dong Tang, Deepkishore Mukhopadhyay • SFM Project Timeline • Initiated in August 2002 • Completed Phase 1.1 in December 2002 • Completed Phase 1.2 in April 2003 • Developed Framework used for production at RCI in May 2003

6. Simulation for Flexible Manufacturing (SFM)Project Phase 1 • Develop a DFM Framework • Enable designers, manufacturers, assembly and test engineers to work collaboratively • Domain of Interest • Printed Circuit Assembly design process • Motto of the DFM Framework • Develop a generic and modular architecture • Core components customizable for specific enterprises

7. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

8. Motivation for building a DFM frameworkSimulation-based Design General Overview • “Systems Approach” to product realization -- organizing the “smorgasbord” • Capturing mutual interaction amongst design, manufacturing, assembly, testing, packaging etc. related activities • Building product and associated process models • Creating smart configurations – adaptable to changing technology and business needs • Reduce cycle time and possibilities of redesign • Capturing activity specific knowledge and utilize it for enhancing related activities and tasks • Learning from today’s experience to improve performance tomorrow – Intelligent Systems

9. Doc/Proc/Reg Guidelines Layout Requirements Design Part Symbol & Footprint Functional Learn today Utilize tomorrow Placement Routing Review Corrections Release Environmental Build Fabricate Assemble Test/Inspect Motivation for building a DFM frameworkSimulating Process Emulating Knowledge • Simulate Printed Circuit Design process • Emulate expertise of manufacturers, test and producibility engineers for robust designs

10. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

11. Core Ingredients of a DFM Framework1. Electronics Product Design Model • Need of an Integrated Design Model • Ability to support different dimensions of product design • Functional Model • Part - Assembly Structure • Configuration Management • Requirements Specification • Formal data specification for higher fidelity across engineering domains • Semantically rich in content and coverage – ability to expand to the ever rising complication in product and process data structure

12. Core Ingredients of a DFM FrameworkChallenges towards an Integrated Design Model Existing Tools Tool A1 Tool An ... Legend Content Coverage Gaps “dumb” information capture (only human-sensible, I.e., not computer-sensible) Example “dumb” figures • Smart Product Model • Building Blocks • Models & meta-models • International standards • Industry specs • Corporate standards • Local customizations • Modeling technologies: • Express, UML, XML, COBs, … Content Semantic Gaps

13. Core Ingredients of a DFM Framework2. Manufacturing Expertise • Need to capture the expertise of manufacturers • To be able to gather manufacturing knowledge • To be able to represent this genre of knowledge • To be able to use these knowledge sets to guide design decisions • To be able to share this knowledge across enterprise specific manufacturing facilities

14. 1 Manufacturability • >10 • <9 • “strong” high low Core Ingredients of a DFM FrameworkChallenges towards capturing manufacturing knowledge • Design Parameters • geometrical dimensions • -- gd_1 • -- gd_2 • -- …. • material properties • -- mp_1 • -- mp_2 • -- … • …… • Fuzzy nature of manufacturability knowledge 2 • “weak” • >”tensile” • > 10 MPa Manufacturability Knowledge

15. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

16. Functional Foundation of DFM Framework1. Answering integrated design model challenge • Use of STEP AP210 standard specifications to build the semantically richer and higher fidelity integrated design model

17. Interconnect Assembly Printed Circuit Assemblies (PCAs/PWAs) Product Enclosure Die/Chip Packaged Part Printed Circuit Substrate (PCBs/PWBs) Die/Chip Package External Interfaces STEP AP 210 (ISO 10303-210) Domain: Electronics Design(ap210.org) ~800 standardized concepts (many applicable to other domains) Development investment: O(100 man-years) over ~10 years

18. Functional Foundation of DFM Framework2. Answering knowledge capture challenge • Use of Expert Systems Technology • Expert Systems are computer programs to emulate human expertise and take decisions to the best of current knowledge. • Used for problems / scenarios that are complex (abstract, deeply branched decision tree etc.) enough to require human expertise. • Facility to add knowledge • Explanation facility to track the chain of logic – serves as a conformance test

19. Core Advantages of Expert Systems • Separation of knowledge from control • Better foundational architecture • Ease of maintenance • Ability to add new knowledge and refine functionality • Ability to handle abstraction • Support decision making in the design process in the absence of knowledge – to the best use of as-available information • Trace the tree of design decisions • Ability to track the logical steps in process • Serves as an explanation facility • Used for conformance testing

20. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

21. Auxiliary design information ECAD tool STEP AP210design model i Design view ij Design Manufacturability Report ij Enterprise Database Manufacturability Knowledge-base Conceptualizing the DFM ArchitectureFundamental Framework: “Pulling it all together” End User View Manufacturability Feedback ijof a given design i Design Integrator Results Manager Design View j Generator Rule-based Expert System

22. Auxiliary Product Information ECAD tool PCA parts library database Step - 1 Step - 2 Step - 3 Step - 4 ECAD tool (Zuken, Mentor etc.) RCI RCI SFM Design Integrator AP210 part 21 file LKSoft Design view SFM Design View Generator GIT STEP AP-210 Kappa design SFM Rule based Expert System DFM violation results End user view SFM Results Viewer Boeing + GIT UIUC Building the SDF (SFM DFM Framework)

23. Integrated Design Model: STEP AP210Example view in STEP Book – AP210 Browser (LKSoft)

24. SDF Rule-based Expert SystemRule authoring tool Rule checking tool DFM document j (human sensible) Rule Description Facility (RDF) rules in RDF (computer sensible) Design View ij Manufacturability Knowledge Base j Rule Execution Facility (REF) Results ij

25. SDF Results ManagerViewing DFM violations in the Results Browser Results Log (from SFM Rule-based Expert System) Results Viewer (highlighted features have DFM violations)

26. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

27. Future Architecture Standards-based Framework Computer Integrated Manufacturing Product Definition Dataset Fit-Check Machine Simulator Rules Repository Rules Engine AP 210 LKSoft AP 210 3D Viewer Exceptions ECAD Design Visula Package Library CIM Package Library Simulation for Flexible Manufacturing Converter AP 203 AP 203 3D Viewer CAM Application MCAD Part Design MCAD Assembly Design PDF 2D Viewer Inspection Application

28. Future ArchitectureExpanding the scope of the current architecture • Enhancing the scope of the DFM Framework to a generic DFX Framework • DFX: Design for X • where X: Manufacturing, Testing, Assembly etc. • Expanding the downstream application of the 210 design model • Rule-based Manufacturability analysis • Finite Element based PWB Warpage analysis • Engineering economy based analysis (Design-to-Cost)

29. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

30. Conclusion • Achievements of the SDF: SFM DFM Framework • Demonstrated the ability to build an integrated design model to support manufacturability constraint check • Use of STEP AP210 standard • to support product life cycle related tasks • foundation for building semantically richer and higher fidelity product models • Demonstrated the ability to capture and utilize manufacturing expertise • Integrating core functionalities for developing a collaborative environment for designers and manufacturers

31. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

32. Acknowledgements • Rockwell Collins • Kevin Fischer, Floyd Fischer, Wayne Foss, Dick Postma, Jennifer Waskow, Ian Wicke, Jim Lorenz, Jack Harris • LKSoft (lksoft.com & intercax.com) • Lothar Klein, Viktoras Kovaliovas, Giedrius Liutkus, Kasparas Rudokas • PDES Inc. Electromechanical Team (pdesinc.aticorp.org) • Greg Smith (Boeing), Mike Keenan (Boeing), Craig Lanning (Northrop Grumman) • Arizona State University • Prof. Teresa Wu • Georgia Tech • Prof. Robert Fulton, Prof. Nelson Baker

33. Contents • Introduction -- Simulation for Flexible Manufacturing • Design-for-Manufacturability (DFM) Framework • Motivation • Core Ingredients • Functional Foundation • Building the SDF (SFM DFM Framework) • Future Architecture • Conclusion • Acknowledgements • Questions?

34. Questions?