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Unlocking the Mystery of Circuit Board Failures A Case Study

Unlocking the Mystery of Circuit Board Failures A Case Study. Presented By: Alaa Arif EDTC 560 January 15, 2007. Terms & Definitions. Board: Printed Circuit Board (PCB). ESD: Electro-Static Discharge.

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Unlocking the Mystery of Circuit Board Failures A Case Study

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  1. Unlocking the Mystery of Circuit Board Failures A Case Study Presented By: Alaa Arif EDTC 560 January 15, 2007

  2. Terms & Definitions • Board: Printed Circuit Board (PCB). • ESD:Electro-Static Discharge. • It is the release of a build up of charge, similar to the shock some people experience when touching a metal surface or another person.

  3. Terms & Definitions • FPY:First Pass Yield. • The percentage of boards that pass the test during the first trial. • NDF: No Defect Found failure. • Failure without any apparent cause.

  4. Problem Statement • Boards Failures: • For the first time in the company’s history, a newly released product failed to reach FPY goals. • Quantity of boards failures exceeded all expectations.

  5. Analysis • Analysis revealed that 2 types of failures are mainly responsible for the low FPY: • ESD Failures • NDF Failures

  6. Analysis - ESD • ESD Failures: • Caused by unsafe ESD practices. • ESD could damage sensitive components on the PCB. • Increased over the first 3 months.

  7. Analysis - ESD • ESD Failures: • Caused by unsafe ESD practices. • ESD could damage sensitive components on the PCB. • Increased over the first 3 months.

  8. Analysis - ESD • ESD Failures: • Caused by unsafe ESD practices. • ESD could damage sensitive components on the PCB. • Increased over the first 3 months.

  9. Analysis - NDF • NDF Failures: • Caused by operator error. • Malfunction of test equipment. • Decreased over the first 3 months.

  10. Analysis - NDF • NDF Failures: • Caused by operator error. • Malfunction of test equipment. • Decreased over the first 3 months.

  11. Analysis - NDF • NDF Failures: • Caused by operator error. • Malfunction of test equipment. • Decreased over the first 3 months.

  12. Solution - ESD • Addressing ESD Failures at each level: • Work station. • Operators.

  13. Solution - ESD • Work Station: • Properly ground the work station. • Coat floor with ESD-safe material. • Cover workbench with ESD-safe mat.

  14. Solution - ESD • Operator: • Wears ESD-safe smock. • Uses ESD-safe wrist strap. • Cover shoes with ESD-safe heel straps.

  15. Solution - NDF • Addressing NDF at each level: • Test Equipment. • Operator. • Procedures.

  16. Solution - NDF • Test Equipment: • Train maintenance technicians. • Increase frequency of preventive maintenance. • Provide ample quantity of spare parts.

  17. Solution - NDF • Operator: • Share with operators the test results. • Explain the consequences of the excessive amount of boards failures. • Train and re-train operators.

  18. Solution - NDF • Procedures: • Document test procedure. • Add illustrations to test procedures. • Make test documents easily accessible.

  19. Trend line Results • December test data showed improvement:

  20. End of the Presentation!

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