The Choice of Publication for the Electronics Industry

Sanmina - Pushing the boundaries for automotive electronics manufacturing

Dynalab’s Secret to Success

red carpet

Who’s doing what, where?

inside

SMT HYBRID PACKAGING

NUREMBERG,

GERMANY

5TH - 7TH MAY 2015

meet the CEos Page 8

Bryan Gass, OK International Inc. (cover)

Mike Nelson of Etek Europe

Craig Arcuri of Rocket EMS

Bruce Weaver of Great Lakes Engineering Tuomo Rekila of TDR

| JUNE 2015 ISSUE smttoday.com

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welcome

to smt today

Welcome to June’s edition of SMT Today – the leading global magazine for the electronics industry which provides the best content and largest distribution using the latest technology channels.

Earlier in the year we were at the very successful IPC APEX EXPO in the US and the NEW Show in the UK. As a team, it was good to meet up with many of our readers and contributors and, at the same time, share what SMT Today can o er in the form of media exposure, inclusion in a quality printed magazine, multi-platform compatibility and complimentary videoing capabilities.

This edition of SMT Today includes technical articles, interviews and the latest product announcements with contributions from many of the electronic industry’s leaders and technology experts.

It also focuses on the SMT Hybrid Packaging Exhibition in Nuremberg, a platform on which the industry’s principal companies will show the latest trends and developments, in addition to showcasing up-to-date solutions.

We’re delighted to have a stand at this show, 7A-135 within the UK Technology Pavilion, to which we extend an open invitation to exhibitors and visitors.

The next issue of SMT Today will be published in July and will focus on Printing vs Dispensing and NEPCON China, Shenzhen. If you’ve any articles that you’d like included, please don’t hesitate to send them to me at [email protected].

Looking forward to seeing you in Nuremberg!

Lin Ramsay, Editor

Email: [email protected] Skype: lin-smttoday Call: +44 1292 834009

Page 3

inside this issue...

Shows/Events

Industry experts share their knowledge

6 SMT Hybrid Packaging, Nuremberg, Germany

Director Spotlight

Interview with industry experts

10 Bryan Gass, OK International Inc.

Technology Today

Industry experts share their knowledge

14 Pushing the Boundaries for Automotive Electronics Manufacturing by Kim Sauer

18 Dynalab’s Secret to Success: How to Win Big in Today’s Electronics Assembly Industry

20 Selective Soldering – How it has evolved to become an Integral Method in Today’s Manufacturing Processes

24 Innovative Systems Engineering

30 New Generation of Extraction and Filtration Systems for Dust, Laser Fume and Welding Smoke

31 Interview with Jim Williams, Director of Process Support Products, ASM DEK

34 THT Production and the Search for the Optimum Production and Inspection Strategy

36 Europlacer Star Headlight and Lantern Co Inc.

38 Interview with Mark Goodwin, COO USA & Europe, Ventec International

42 TDR - Putting their Customer-Focused Approach into the Repair and Assembly Service

44 Nikon Metrology - the past, the present, the future

46 Adding Technologies to keep Customers Competitive: Interview with Eddy Lin of Scienscope

48 IEC/DRTL’s Commitment to Quality, Technology, Service and Trust Make the Company a Good Fit for the Hi-Rel Sector

50 Interview with John Gilby of G2

26 Industry News

What’s happening in the world of electronics

32 New Products Exciting new industry innovations

52 Red Carpet

Photo gallery of industry personalities and events

Articles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every e ort is made to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers for loss arising from articles/information contained and published.All rights reserved. No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.

6

10

14

6

SMT Hybrid Packaging, Nurember, Germany

8

Meet the CEOs

10

Director Spotlight

26

Industry News

44

Nikon Metrology - the past, the present, the future

magazine contacts...

Editor

Design Website

Lin Ramsay [email protected] +44(0)1292 834009 skype: lin-smttoday

BBD Creative bbdcreative.com +44(0)1292 280022

smttoday.com

Advertising Enquiries

To enquire about available advertising opportunities, please use the contacts below for more information.

NEXT EDITION

August’s edition will focus on NEPCON China in Shenzhen.

European Advertising UK Advertising

USA Advertising

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SMT Hybrid

Packaging 2015 Nuremberg, Germany 5th - 7th may

BTU

PRODUCT PYRAMAXTM with ENERGY PILOT Software

booth #7-421

BTU International,

Inc., a leading supplier

of advanced thermal processing equipment

for the electronics manufacturing and alternative energy markets, will highlight

the proven PYRAMAXTM and the award winning DYNAMOTM convection re ow ovens, both equipped with the new ENERGY PILOT software, designed to reduce the consumption of electrical power and process gas.

Count On Tools Inc.

PRODUCT SMT Nozzles, StripFeeder & New StripFeeder Mini booth #7–100

Count On Tools Inc.,

a leading provider of precision components and SMT spare parts, will display the full range of Count On Tools’ SMT Nozzles (standard and custom), as well as the original StripFeeder and all new Stripfeeder Mini, which features the same award-winning design

of the StripFeeder in a smaller package (134mm x 152mm) in the Adopt SMT booth.

Essemtec AG

PRODUCT Paraquda and Scorpion booth #7-135

Essemtec AG, the

Swiss manufacturer

of production systems for electronic assembly and packaging, will demonstrate the latest generation of Paraquda pick-and-place system and Scorpion dispensing system. Other highlights will be the new SMT storage device Cubus Large and the new highly exible and cost-e ective pick-and-place

system Lynx.

Paraquda G2 is the world’s rst machine

that combines three di erent processes within one platform (jetting of solder paste, jetting of glue and placing of SMD components).

EVS International

PRODUCT EVS 500LF booth #7-101L

EVS International, the leader in solder recovery, will showcase the new EVS 500LF lead-free version which has been designed to be the same size as a printer and is aimed at multiple markets.

Users can quickly recover up to 80 percent of pure solder with a higher ROI from the waste dross.

The simple but ruggedly designed unit is highly ISO14001 compatible as it complies with the ISO mantra of reduce – reuse – recycle, enabling the customer to reduce solder consumption by up to 50+ percent, an unheard of reduction in the electronics production industry.

Metcal

PRODUCT Scarab Site Cleaning System booth #7-321

Metcal will be exhibiting the new Metcal Scarab Site Cleaning System (APR-2000-SCS) on their SmartTec stand, together with the Solder Ball Replacement Kit and MX-HPDC dual cartridge hand-piece.

The Scarab ensures accurate and repeatable cleaning of the component pad in one user-friendly system. It rede nes performance and addresses the technical demands presented by component manufacturers today. Additionally, the Scarab addresses the industry needs with an automated system capable of cleaning components pads without contact.

Page 6 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

SMT Hybrid Packaging is Europe´s leading event on system integration in microelectronics.

Scheduled to take place between the 5th and 7th May 2015 in Nuremberg, Germany, the show oor promises to be full of technologically advanced products and innovations.

It is the ideal platform for the industry’s leading companies to show the latest trends and developments as well as up-to-date solutions. With 33% foreign exhibitors, the event o ers not only a wide, but also an international spectrum.

From SMT equipment to components and services, please nd below just a small sample of what some of the exhibitors will be showcasing:

MIRTEC Europe and pb tec solutions

PRODUCT

Revolutionary 2D/3D AOI Technology booth #7A-504

MIRTEC, the global leader in inspection technology, announces that it will highlight its award-winning 2D/3D In-Line AOI Series con gured with MIRTEC’s exclusive OMNI-VISION® 3D Inspection Technology in its distributor pb tec solutions’ booth.

On show will be MIRTEC’s new MV-6,

an extremely compact 2D inline AOI system with a high inspection performance for a very attractive price. It’s ideal for companies with a smaller budget who want to invest in an inline AOI system.

Rehm Thermal Systems

PRODUCT Innovative systems engineering booth #7-451

Rehm Thermal Systems is a leading manufacturer of energy-e cient manufacturing equipment for the electronics and photovoltaics industry and has represented

the highest levels of quality, innovation and technological know-how for 25 years. In addition to celebrating their 25 year anniversary, they

will also be presenting their latest product developments in thermal system solutions.

Scienscope International

PRODUCT X-SCOPE 2000

booth #7-221

Scienscope’s X-ray inspection systems division o ers X-ray cabinet systems with the highest performance-to- price ratio in the industry today. The company’s advanced X-ray systems feature state-of-the-

art micro-focus high resolution X-ray tubes up to 130kV, high-resolution digital detectors, a

large inspection stage with 360° rotation, and oblique angel inspection. The user interface is

very simple and includes advanced features

such as automatic BGA inspection.

ULT AG

PRODUCT Systems for Air Puri cation and Pollutant Removal booth #6-313

ULT AG, vendor of extraction and ltration systems for airborne pollutants, will introduce solutions designed to protect employees, manufacturing equipment and products.

Vi Technology

PRODUCT SPI and AOI booth #7A-331

The company’s extraction and ltration units remove hazardous substances that occur during laser and solder processes in electronics production. ULT AG develops air puri cation systems, which achieve optimum lter performance

PI is the only inspection system to program automatically, therefore inspection quality is not reliant on the training of the programmer. Being the new SPI generation, Pi is fully connectable and provides solutions to improve processes. Combined with Sigma Link and AOI solutions, Pi enables the user

and a high degree

of separation. This improvement results from the utilisation of highly e cient ltration media that complies with statutory limit values for hazardous substances.

to improve processes through a complete analysis of the solder joints versus solder paste deposit. Pi also is compatible with all major printers.

meet the CEOs

the people who make it happen

Our industry is driven by a global network of CEOs with the energy and vision that brings new technology and innovation down the line. Every edition, we will introduce you to the faces behind the companies.

Etek Europe

Mike Nelson is the Managing Director and Owner of Etek Europe Ltd., a quality provider of products and services to the aerospace, automotive, defense, medical and European electronic manufacturing industries.

With more than 1,600 customers that include numerous leading global electronic companies, Nelson and the Etek team pride themselves on the strength of relationships with both suppliers and clients, which has proven paramount to the continued growth and success of the company. This also ensures the company continues to deliver premium solutions at highly competitive prices.

Nelson and his sta have many years of quality experience in the factory production environment, equipment sales and engineering support, enabling it to provide comprehensive service and support that focuses on quick response times, clear communication and complete customer care.

Rocket EMS

Headquartered in San Jose, CA, Rocket EMS is an electronics manufacturing services (EMS) company specializing in a full suite of new product introduction (NPI) services to fast-growth, high-technology companies.

Rocket is led by President Craig Arcuri, an industry expert with numerous years of experience in electronics manufacturing services. Rocket EMS is a full-service partner, delivering ultra quick-turn (24-48 hours) manufacturing of printed circuit board assemblies, layout and complementary value-add services.

The company’s core team has a proven track record of investing in and using advanced technology, equipment and software to manufacture customer products rapidly with the highest quality.

Great Lakes Engineering

Bruce Weaver is the owner of Great Lakes Engineering, a distributor of Henkel Solder Paste and a cutting-edge manufacturer of surface mount stencils, precision laser cut parts, photo chemical machined parts, and Lucon Squeegee Blades.

With experience in the defense, medical, electronics, aviation, energy, telecommunications, and computer industries, Great Lakes Engineering is now positioning itself to gain more traction in the electronics manufacturing industry due to the increased demand for small, precision-cut parts. Great Lakes Engineering o ers state-of-the-art laser technology that enables customers to experience positional accuracy unattainable with conventional technology.

Weaver and his team have the experience to determine which process is appropriate for a customer’s application, tolerance, longevity, durability and cost.

TDR

TDR was started a little over four years ago in an e ort to provide outstanding and unrivalled dedicated repair, engineering and assembly solutions to a wide range of segments in the telecom and industrial markets. Since its beginnings in 2011, founder and CEO, Tuomo Rekila has built up the business at an impressive rate with the help of an experienced and knowledgeable team.

With its headquarters in Tallinn, Estonia and additional o ces in Finland and Poland, TDR is leaving its mark across Europe and establishing itself as a leader in the eld.

Starting his career at Nokia Networks, where he worked for over 12 years, Tuomo began his journey on the ‘telecoms road’. This was followed by a number of years at Omron Europe in Holland setting up new business in the Radio Frequency Identi cation (RFID) and Automated Optical Inspection (AOI) sectors, a good grounding for the implementation of TDR and its principles.

Page 8 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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director

spotlight

an interview with Bryan Gass, OK International Inc. by SMT today editor

Founded in 1946, OK International Inc. (OK) is a global manufacturer of bench tools and equipment that are used in 3D printing, electronics and industrial product assembly. OK focuses on developing, manufacturing and marketing its own proprietary products, primarily in the circuit board solder/desolder business.

In 2000, OK became part of Dover Corporation, which has served to strengthen OK’s core competencies in the manufacturing and development of soldering systems as well as dispensing and fume ltration products. This also helped in the expansion of its customer base, markets and geographic presence.

Our editors recently spoke with Bryan Gass, the VP Global Sales and Marketing of the OEM Division, to discuss how OK International is keeping its four main divisions – Metcal, Techcon, Quant 3D and ProWorks – not only strong but growing.

A. OK International closed on a minority investment and product development agreement with 3D printing company TierTime Technology in the rst quarter of 2014. At the same time, Quant 3D, a new brand focused on 3D printing for the professional and industrial markets, launched by OK International. TierTime is a technology leader in the 3D printing market and provides a strong platform for our 3D printing business. The investment in TierTime aligns with OK International’s strategic focus to develop innovative and industry-leading products for the industrial and commercial manufacturing markets. By leveraging our expertise in thermal management and material dispensing, we intend to develop and market a broad line of industrial printers across multiple 3D printing technologies.

In addition to the Quant 3D bench top printers currently available, both companies entered into a technology agreement to co-develop a line of 3D industrial printers that are scheduled to be launched later this year. The Quant 3D brand encompasses both bench top and industrial 3D printers for prototyping and manufacturing applications. We are very excited about the opportunity in this market segment and believe the Quant brand will become a core part of our growth in the coming years.

Q. How did ProWorks become a part of the OK International family and when was it added?

A. The ProWorks business unit was acquired from Everett Charles Technologies (ECT) and brought into the OK International family of products in June 2014, making it the fourth brand in OKI’s existing portfolio. ProWorks is a multi-user process management software tool that enables businesses to deploy and manage the execution of best practices and industry-speci c capabilities throughout their organizations.

This product, like our other brands, is based around improving the production assembly process. ProWorks software allows users to o er and distribute work instructions more e ciently than the typical tools that

Q. Bryan, we understand that you oversee OK International’s four Brands: Metcal, Techcon, Quant 3D and ProWorks. How long have you held this position and what is your main role?

A. I have been with OK international for more than 10 years and have held numerous roles within the organization. OK International (OKI), a Dover Company, is a leading global manufacturer of bench tools, equipment and related products that are used in the electronics and industrial assembly marketplace.

In 2014, I was promoted to VP Global Sales and Marketing for OK International, covering Sales and Marketing functions across all OKI brands. I am ultimately responsible for creating and implementing the global sales strategy for OK International and making sure the sales teams across all regions are aligned and executing to the corporate strategy to meet our goals. I also work closely with Product Management and Sales to drive product development initiatives, ensuring that we are meeting customer needs with our product o ering and application support.

Q. Tell us a little more about the di erent product o erings for OK International.

A. Currently our core business revolves around the two brands that have been around the longest: Metcal and Techcon Systems.

Metcal is a leading global brand of professional-grade bench tool solutions that deliver the optimal balance of

performance and reliability for electronics production assembly. Since 1982, Metcal has been a recognized worldwide leader in advanced conduction soldering and convection rework applications, broadening its product o ering to a full electronics bench tool single-source solution. Metcal product lines currently include hand soldering and desoldering, convection rework products, fume extraction and uid dispensing systems for the cost-conscious buyer to the most demanding applications.

Techcon Systems is a leading manufacturer for precision uid and adhesive dispensing solutions that has been servicing multiple industries since 1961. They provide products which help customers achieve accurate, reliable dispensing results through our equipment and consumables. Whether your dispensing application is using material as thick as solder paste or as thin as solvent, Techcon o ers a variety of dispensing solutions to meet your application requirements. Our uid dispensers and automated equipment are designed and manufactured to provide strict control and accuracy to increase productivity in the manufacturing process. Our selection of dispensing valves provides reliability and accuracy in uid control for the hard-to-handle applications. If your production requires handheld dispensing by operators, we also o er consumable products including industrial dispensing syringes, cartridges and dispensing tips to improve yields and reduces costs.

Q. When was Quant 3D acquired and for what purpose?

Continued...

Page 10 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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AIM, a leading global manufacturer of solder assembly materials

for the electronics industry, introduces M8 SOLDER PASTE, a high

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director

spotlight

feature continued...

are most commonly used. The application is geared towards creating content with graphical information (pictures & video) and acts as a portal to retrieve and store all process-related data.

ProWorks’ database allows for a true multiuser environment that enables the collection and distribution of knowledge and centralizes all Work Instruction information. ProWorks can share data with ERP/MRP/PLM systems to ensure the information on the shop oor is accurate and up-to-date.

Process Documentation helps companies when they experience turnover by providing detailed work instructions, allowing new employees to train more quickly and e ciently. Also, with the fast- changing global marketplace, ProWorks allows users to take the way a product is assembled on the shop oor in one factory and duplicate the process in another, keeping the standards the same and maintaining product consistency at all manufacturing sites globally.

Q. We understand that OK International serves numerous markets. Do all four brands t into the same markets or do they focus primarily on an individual segment?

A. OK International has a very diverse product o ering and each brand is slightly unique: some play more in speci c market segments than others. Our primary markets include electronics assembly, aerospace, communications, 3D printing, military, medical, automotive and energy. The diversi cation allows us to take advantage of markets that are growing at faster rates than others. Some markets such as medical are less cyclical than others and repeatedly outperform the market when economic growth slows, “defending” against the e ects of economic downturn. These markets provide great places to invest when the economic outlook is unfriendly.

A more diverse product o ering allows us more options about which markets we chose to deploy our resources to help drive our initiatives. Our portfolio takes advantage of the diversity of the market. As one business line may experience challenges, the others might be ourishing. There is de nitely market crossover between the brands, but each brand provides an array of products and services for its targeted markets. The markets in which we are seeing the most opportunity today include 3D printing, communications and aerospace. 3D printing is a great example of us broadening our portfolio and expanding into a rapidly growing segment

that some industry experts predict will grow 17 percent annually over the next several years. That is one of the reasons why we are so excited about entering into the 3D printing market.

Q. In regards to the two core brands Metcal and Techcon, which technologies and products are important to the industry?

A. At the core of Metcal is the SmartHeat® technology. SmartHeat® soldering technology is built into all of our Metcal soldering systems. This technology is designed to automatically ensure a consistent soldering iron tip temperature under a wide range of thermal loads. SmartHeat® senses the thermal requirement for each solder joint and responds by delivering the precise amount of energy needed to create a reliable joint without external adjustments.

This approach is di erent from conventional variable temperature soldering irons. This means that soldering, desoldering and rework are always performed at safe and controlled temperatures. Metcal soldering tips are uniquely built to sense the speci c thermal demand directly at the solder pad and to deliver the precise quantity of energy without any adjustment and calibration. Fixed temperature soldering tips and cartridges o er a safe solution and complete process control. SmartHeat® soldering changes how the industry solders today.

Techcon also has unique technology and strives to have products that are user friendly like the patented Disposable Material Path (DMP) valve that contains a disposable feed screw for easy maintenance and reliable dispensing. The removable path can be removed, disposed of and replaced within seconds while the line is still in operation. No cleaning or refurbishment of the valve is required, reducing downtime as well as the maintenance cost associated with most other valves. These, together with other innovative technologies, help drive the success of our brands.

Q. What trends are you seeing in the marketplace?

A. We are seeing the market continue to evolve but at a much quicker rate than in the past. Labor costs and in ation is causing cost-down initiatives, with most companies triggering more businesses to look at automation as a possible cost savings solution. Automation is being used more often for greater consistency and higher yields. Miniaturized parts are becoming di cult for operators to assemble and the falling robotics prices

have created a trend towards automation assembly and rework processes not only in higher cost regions but also in low-cost regions.

Component Rework is also growing as components on electronic boards become more expensive. These higher cost components are causing companies to increase their yields through improved processes and driving a higher number of rework applications as users look to salvage high-cost components. We expect automation and rework to continue to grow globally and OKI will continue to broaden its o ering in these areas.

Q. Having a global presence is important to a company’s success today. We understand that OK International is no di erent. Can you tell our readers about your global sales channel? What makes it so successful?

A. One of OKI’s strengths is it sales channel. Our sales team is split into three regions: Americas, Asia and Europe. A major reason all of our brands have had success is our strong global sales team and distribution channel. Over the years we have worked very hard to develop and train our internal and external teams not only on the products but, even more importantly, on the applications.

Our wide application knowledge and our commitment to high service levels have helped us grow. Through geographical expansion we will look to strengthen our channel coverage in uncovered regions to ensure that our customer base has the required support to meet their demanding needs. Most of our regions have very good distribution partners but there are some strategic areas in which we will look to increase our coverage during 2015 to help strengthen our support. As business continues to become more and more competitive, we need to uncover ways to assist customers and help them to further gain a competitive edge over their competition.

Q. What do you most want the industry to understand about OK International?

A. What really makes OK International so unique is the commitment and passion that our employees have for our customers. OK International is committed to operational excellence and delivering core technological advantages with best- in-class performance. We continue to build our business by broadening our product o ering, using the strength of quality products and our unsurpassed application support with localization to meet regional market needs.

Page 12 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Pushing the Boundaries

for Automotive

Electronics

Manufacturing

By Kim Sauer (@kimsauermedia)

There is a dramatic shift occurring in the manufacture of automobiles. Electronics are taking over in every aspect, even to the point of connecting the car with the Internet and even other automobiles. The implications and challenges for the manufacturer are far reaching. A visit to Sanmina’s Hungarian electronics manufacturing plant in Tatabanya shed some light on how one EMS company is navigating the highly regulated and competitive automotive manufacturing environment.

The electronic content in cars is expected to increase to around 35% by 2020 and by 2030 even more. Vehicles today are already lled with all types of electrical devices and functions as standard. There are for example, integrated GPS systems, infotainment systems and control devices. Park assist, safety features, lighting and many other controls are driven by the demand for greater comfort, connectivity, e ciency and safety.

Figure 1. Sanmina SMT Manufacturing Line

Going forward, further digitalization and connectivity with hybrid and fully electric cars, as well as the driverless car, will further equip vehicles with an unprecedented number of advanced electronics. At the same time the regulatory requirements for functional safety, traceability, environmental aspects and end-of-life recycling are all contributing to the proliferation of high density complex electronics in and around the vehicle of the future.

So what are the implications for car manufacturers as mechanics intertwine with electronics? How does the supply chain need to adapt to the growing technological complexity and strict regulatory requirements?

To investigate further I travelled to Tatabanya in Hungary to visit a highly sophisticated electronics manufacturing plant run by Sanmina. Just a short 45 minute drive from Budapest, Sanmina Tatabanya is strategically located in the heart of Hungary’s Technology Triangle of Győr, Budapest and Székesfehérvár.

Hungary itself lies within the Schengen Zone, in the Eastern part of the EU and enjoys direct access to a well-developed logistics and utility infrastructure that connects Hungary to Western Europe and the rest of the world. In 2004 Hungary became a

member of the European Union with a fully harmonized legal system that is aligned to European safety and quality regulations for automotive manufacturing. With such a strategically important geographical location it is no wonder that many of the world’s leading automotive OEMs settled in Hungary like Mercedes Benz in Kecskemét, Audi in Győr, Opel in Szentgotthárd and Suzuki in Esztergom and, in support, suppliers and outsourcing partners are in close proximity.

Sanmina has been in Tatabanya since 1997. Alongside its established complex automotive electronics manufacturing capabilities, the facility also provides a wide range of NPI (New Product Introduction), manufacturing and test services for both complex and high-volume products in the Communications and Networking, Medical and Industrial sectors with all the required certi cations in place (ISO 9001, ISO 14001, TS 16949, TL 9000, ISO 13485, AEO- Authorized Economic Operator).

The Sanmina campus covers 40.000sqm with 1,000 sta supporting the facility and 14 SMT lines in operation 24/7.

But of course capacity, people and certi cations alone won’t su ce to compete in the highly complex automotive manufacturing sector. What is called for is a robust manufacturing environment, in terms of equipment, experience, best practise and access to a sophisticated supply chain.

Today, the challenge is to build reliable electronic products with increasing density, complexity and sophistication whilst, at the same time, meeting the many automotive regulatory requirements and optimizing the investment in the choice of SMT equipment and their feature sets. As devices get smaller in size, density and miniaturization increases signi cantly in integrated circuits demanding a need for greater capability, accuracy and reliability from manufacturing equipment.

Sanmina has invested in additional high technology equipment such as SPI (Solder Paste Inspection), AOI (Automated Optical Inspection) and AXI (Automated X-Ray Inspection) as well as best-in-class printers, high-speed, high-accuracy pick and place machines and re ow ovens, in order to harmonize the complexity and durability demanded from sophisticated automotive manufacturing.

SPI for example, measures the true solder paste volume on each and every pad to ensure perfect joints even for ultra- ne pitch components in high density PCBA’s. Although AOI machines aren’t new to the production line, the latest 3D technology has revolutionized this tool, making testing more robust by increasing the test coverage and reducing false calls.

Machines form the backbone of any manufacturing operation but knowledge and experience of technology, processes, applications and supply chains can be a key competitive advantage in today’s manufacturing environment where OEM’s are looking for a commitment of Zero Defects from their manufacturing partners.

Continued...

Page 14 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Figure 2. Sanmina Employee Testing PCB Assembly

Forexample,largethrough-holeconnectors mounted on PCB’s are traditionally hand- loaded prior to a wave soldering process. This adds additional labor cost and an additional process step. By leveraging their expertise from other industries, Sanmina Tatabanya pioneered the use of pin-in-paste technology as part of the SMT process for large automotive connectors and was able to improve reliability and cost. Over two years of development and testing were invested to ensure the solution met the required standards and cost e ciencies. It paido withthereceiptofaQualityAward and a Pin-in-Paste Solution that provides greater reliability at a lower cost than more traditional processes. In order to inspect the hole- ll rate of the through-hole components using pin-in-paste technology and to inspect thesolderjointsunderBGAcomponentsin- line, AXI machines have been strategically added to the SMT lines in the facility. The additional features o ered by the latest generation 3D equipment are balanced with the requirements of test coverage, level of false calls and takt rates. The carefully implemented approach achieves an optimum solution that reduces cost and maximizes quality.

This is just one example of the many ways Sanmina leverages their experience inside and outside the automotive sector to improve processes and outcomes, saving money, increasing yield and improving quality.

New Product Introduction

A further challenge for today’s manufacturers is the speed at which products are required to be ready for market release. As complexity, density and miniaturisation of components increase and the lines between consumer and automotive electronics blur, high-tech manufacturers are increasingly under pressure to shorten product lifecycles and drive innovation in an ever more competitive environment with a growing mix of more complex products.

The risks are high. Manufacturers without proper product lifecycle management, strict

operational processes and tight supply chain control, will not succeed in balancing the need for consistent product quality and compliance to regulatory requirements such as TS 16949 with the equally critical need for fast product introduction.

The days of a year or two being available for electronic manufacturing industrialization arelonggone.Sixmonthsandeventhree months are becoming the norm and that is where an in-depth technical understanding gained through years of manufacturing experience in multiple markets once again takes center stage.

Sanmina Tatabanya ful ls those credentials. With direct access to Sanmina’s established global footprint of 75 operating locations, with more than 20 years’ experience in the automotive market and an in-depth knowledge of automotive regulatory requirements, Sanmina Tatabanya is able to work closely with its customers to introduce new products in a very short timeframe and can even achieve a three-month turnaround when required by the customer, including process validations and, with such tight time-lines for New Product Introductions (NPI), Sanmina’s robust process is a critical key to success.

The initial validation phase sets out to examine the entire manufacturing process with di erent methods to develop optimum processesandmanufacturingrequirements for a speci c product. Detailed testing and measurements determine and con rm the optimum manufacturing process in accordance with customer and regulatory requirements. Beyond the process validations, the product itself can also be validated by means of thermal shock testing, aging and cross section analysis and various other tests, to ensure full lifecycle product reliability and quality compliance.

For the manufacturing process, equally rigorous and robust parameters and controls are set to meet and ful l automotive standards and requirements. Tooling, mounting programs, inspection programs, re ow pro les and every key process parameter is veri ed continuously in order to ensure optimum balance between product quality, cost and delivery. Both automated and manual assembly solutions using standard or speci c custom designed handling equipment are validated by applying intelligent testing and inspection methods at the end of the lines.

Where non-conformances call for a repair process, highly skilled and quali ed operators are used for repair, along with specialized equipment such as automated vacuum controlled equipment for high value/high complexity components like BGAs and processors. After replacement of through-hole or BGA components the hole- ll-rate and the solder joint of the BGA balls are checked by trained operators with 3D X-ray machines.

Smart Factory

Traceability has generally been a requirement for many industry sectors including automotive and medical. Principally in these market segments, production is impossible without strict adherence to regulatory requirements such as TS 16949 and ISO 13485, and with it the necessity for disciplined measures and processes that track and record each manufacturing step to achieve compliance. Evenparttraceabilityisarequirementforall automotive, and medical products.

Sanmina Tatabanya’s processes are strictly controlled. Upon material receipt all boxes up to the lowest packaging unit level are opened and veri ed. Each item then gets assigned a designated Sanmina ID, which acts as its unique identi cation during the entire manufacturing process. From that point onwards all further handling is paperless and fully automated by using intelligent bar code readers driven by Sanmina’s sophisticated ERP (Enterprise Resource Planning) system. These processes ensure complete component and process traceability from receiving to nal product shipment.

Based on 30 years’ experience in traceability business segments such as medical and automotive, Sanmina in fact developed its own system which it calls SFDC (Shop Floor Data Collection) and PTS (Part Traceability System) which, in combination with Fuji’s TRAX software on their SMT equipment, provides fully integrated and complete traceability throughout the entire manufacturing process.

EachrawPCBisalsomarkedwithaunique bar code and, after every process step, automated or manual bar code readers send a con rmation to the SFDC system to con rm that the process step has been performed and completed. Any results from testing functions are logged in the system and the next process step is determined by the result. None of the process steps can be performed until the previous was successfully completed. During the nal packaging stage, the history within the SFDC is re-veri ed to ensure non- conforming products are not shipped.

The PTS system works together with SFDC and determines the connection between the component part number, the SMT feeder ID, the particular machine position and the PCB bar code for full component traceability. This combination provides full component batch traceability.

The direction for electronic content within vehicles is clear. Complexity, diversity and miniaturization are set to increase at an unprecedented pace. For the manufacturer, only strict conformity and process control will ensure that products can be launched within ever tighter schedules, comply with strict regulations and adhere to the cost and quality requirements demanded by customers.

Page 16 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Dynalab’s Secret to Success:

How to Win Big in Today’s Electronics Assembly Industry

By Melissa Porter, Program Manager at Dynalab EMS, Inc.

Headquartered in the Columbus, Ohio area, Dynalab Inc. is a design and manufacturing organization serving the electronics industry. Since 1981, it has built many long-term partnerships with Fortune 500 companies by providing outstanding engineering and manufacturing support. As a full-service Electronics Manufacturing Services (EMS) provider, Dynalab o ers the technical capabilities, nancial resources, and customized supply chain management programs typically found with larger EMS companies; along with the agility, exibility and responsiveness usually found with smaller companies.

Although printed circuit board (PCB) assembly and test is its strongest area of growth, the company o ers complete turnkey services, including wire harness/ cable construction and electromechanical assembly, also referred to in the industry as “box build”. Since the company is continuously presented with unique manufacturing opportunities, its capabilities have stayed diverse and vertically integrated. Remaining exible and in control of these unique requirements has led to the development of many hard to coordinate, integrated processes. For PCB assembly, these include test development and design related to in-circuit test, functional test, thermal stress screening, conformal coating and chip programming.

Over the past 10 years, Dynalab has tripled its production. Many people have asked what Dynalab’s secret is – how does an EMS provider triple its production, especially during the “air of caution” environment of recent years? ____________________________________

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Craig Reiselt, Director of Manufacturing at Dynalab, said there are many important aspects to the company’s success; however, the following are what Dynalab focuses on most heavily:

Accessibility: The company moved to working seven days a week. Happy customers are the key to the company’s success. Dynalab is focused on keeping them happy and exceeding their expectations.

Flexibility: Dynalab is there for its customers. Period. If a customer requests a change (that makes sense and is realistic), Dynalab will make it happen.

Goodwill: Craig said, “If we can help them, we will.” This sounds simple ... but so many companies today do not actually deliver on that promise. Dynalab does. Craig said that he and the team often will stay late or even jump on a ight to help a client personally. Additionally, Dynalab does not charge excessive fees.

Competitive pricing: The Company brought product back from o shore through automation, which has helped to reduce cost signi cantly. So much so that Dynalab is able to match total landed cost with numerous tier-one companies.

Work ethic: The company works hard to complete orders on time. If an order is needed quickly, the team will work through the night, take the product on a plane and personally deliver it to the customer. Dynalab’s CEO Gary James pilots a private plane to help make this happen. Craig credits Dynalab’s personnel with having a great work ethic also. “Without our capable team that is always willing to go the extra mile, we would not be able to meet our customers’ needs as regularly as we do,” Craig added.

Long-term partner relationships:

Dynalab only works with partners whose low-maintenance, high-quality equipment runs reliably for many years. It is because of this stance that Dynalab rst started working with Kurtz Ersa North America more than 11 years ago.

Dynalab Inc. is a leading EMS provider in the Columbus, OH area. The company strives to provide solutions for its customers that exceed their needs, in the timeliest and most exible way possible.

Dynalab takes pride in using only the latest, most reliable technologies on its production oor. This is another example of how the company puts customer needs rst. Successful customers are happy customers.

Page 18 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

Dynalab’s Chad Cosma, Engineering Manager, and Craig Reiselt with the VERSAFLOW. Dynalab has worked with Kurtz Ersa North America since 2004 and has run 7.5 million boards through Ersa’s equipment during that time.

SincethebeginningofDynalab’srelationship with Ersa in 2004, it has run 7.5 million boards through Ersa’s equipment. Today, Dynalab has two Ersa VERSAFLOW 40/50 dual pot selective soldering machines, and a new VERSAFLOW 345 is to be delivered second quarter 2015. Craig said that Ersa’s customer service principals are in line with Dynalab’s: “They have always bent over backwardstomakesurethatweareupand running. Ersa is top notch all the way.” He added that Dynalab uses Ersa’s technology for all of its selective soldering needs and the company plans to continue using Ersa into the future because it yields the best results.

VERSAFLOW is the industry’s most widely used in-line selective soldering

platform. This platform is the most repeatable system on the market with technology highlights such as maintenance-free electromagnetic solder pumps, servo-driven gantry systems, expandable modularity, multiple solder pots in various combinations, ducial recognition, board warpage detection, process camera, auto nozzle cleaning, top-andbottom-sideheatingando ine programming.

In 2003, Ohio’s economy signi cantly declined; however, Dynalab’s CEO Gary James had the foresight to use the downtime to retool the entire plant down to the screws. Because the economy was down, he was able to update the 100,000

sq.ft.facilityfor40percentofnormalcost. When the economy rose again, Dynalab was ready. The facility was state-of-the- art and impressive where competing facilities were worn and outdated. As a result, Dynalab won much business from its competitors. The company has kept the business over the years and continued growing. It also continues renovating the facility and updating to the latest technologies.

To say the company goes over and beyond is an understatement. The privately-held companyplacesover2.5millionSMTparts a day and employs 280 people. Dynalab has a “never say no” attitude that extends to all 280 people, from the CEO to the janitor. The above-and-beyond mentality of the company even extends to strangers. Craig recently took a small EMS company owner under his wing. He explained how the business works, gave the owner a tour of the facility, showed him how to choose/ use the best equipment, and now Craig acts as a mentor.

As a leading EMS company in the growing global economy, providing jobs for 280 associates, Dynalab is continually challenged by the many unique manufacturing opportunities presented by its customers. It works to exceed those demands, challenges and opportunities by focusing on hard work and quality, and by working closely with partners like Ersa.

Selective Soldering -How it has evolved to become an Integral Method in Today’s Manufacturing Processes

by Patrick McWiggin, Technical Director at SolderStar

Since regulations were bought in from the European Union’s Waste Electrical and Electronic Equipment (WEEE) and the Restriction of Hazardous Substances (ROHS) to enforce lead- free soldering, the use of selective soldering techniques have increased greatly.

This military company was already using the existing Solderstar WaveShuttle PRO system for process control on their conventional wave soldering processes. The measurement of wave contact time, immersion depth, wave parallelism and temperature pro le are all required to set up the wave solder machine correctly and these measurements could be captured in one single pass with the WaveShuttle PRO.

Manufactured from 10mm anti-static composite and tted with durable titanium side rails, the system was designed to work with daily production testing. The measurement xture also incorporates titanium contact sensors on the underside which captures wave parameter data as it moves through the solder wave, including a true measurement of wave height. Additionally the system measures preheat pro les and solder pot temperatures.

All key process parameters are captured with a single run through the machine. Data is then downloaded via USB or wireless interface for analysis on the engineer’s computer. All parameters can be quickly analysed by using the unique Solderstar Process Checker function showing the good/bad limits to allow periodic process veri cation to be performed without the need for specialist knowledge.

Selective soldering is the method of soldering selectively through-hole (TH) components on a mixed technology assembly, which would otherwise need to be hand soldered, or passed over a wave soldering machine following the soldering of the SMT elements within a re ow oven. It is commonly used where a number of conventional technology components or connectors need to be added to high quality medical, automotive or aerospace SMT assemblies. To combat the potential damage to the surrounding parts on the PCB, the requirement for the selectively soldered region needs to be exact; this resulted in the need for process control technologies to be developed which would ensure the procedure was carried out within a de ned production speci cation.

TH components appear in many complex mixed technology PCB assemblies and several methods of selective soldering are available that address the necessity for site speci c TH soldering, including tooled dip soldering systems and programmable mini- wave machines.

Figure 1. Mini-Wave Front & Back

The use of selective soldering for lead- free TH soldering applications requiring higher process temperatures has many advantages over other methods like conventional wave soldering due to the potential of increased reliability. Because components are exposed to lower thermal contact during the process it eliminates the potential internal thermal damage.

Some mixed-technology assemblies soldered with standard wave solder equipment would need to use custom designed carriers and masking. However many assemblies, for example, stacked and double-sided SMT assemblies, and even some TH devices, are too complex to be processed this way. The carriers required are also quite complex to produce and may render this approach prohibitively expensive.

If a board assembly cannot run through the wave soldering process, there is an option to hand solder, but this process can be inaccurate and cause failure which would require re-work. It is also prohibited in high reliability applications commonly found in the automotive and military production. To reduce this inaccuracy, specially designed selective soldering systems have been developed.

With the need for selective soldering increasing, SolderStar has developed a dedicated range of process pro ling products for the selective processes. These specialised instruments have been developed, in conjunction with a leading global military and aerospace company, to provide a standalone and comprehensive setup and veri cation tool for their chosen selective soldering process.

Figure 2. Mini-Wave Software Screen

By capturing data on the temperature pro le, as well as solder wave interaction

Page 20 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

parameters in the same pass, it provides medium and large electronics’ manufacturers with set up capabilities as well as full, cost- e ective SPC of their wave soldering process.

Advantages of the WaveShuttle Pro include:

• It allows for comprehensive parameters measurement with a single pass through a machine

• It is a reliable way to solder in volume

• The titanium contact sensors o er the highest measurement accuracy on wave height, main and chip wave parameters

• Pre-heat and solder pot temperature measurement sensors are included to ensure accuracy

• The 10mm xture provides a robust platform for daily production testing

• It can be adapted with made-to- measure widths and sensor positions available for xed width production lines or special applications

Solderstar Smartlink system, it included a dedicated measurement xture/pallet. This included three arrays of solder contact sensors, including;

- X Speed Sensors – which measure and verify the speed of the X axis of the machine

- Y Speed Sensor – which measure and verify the speed of the Y axis of the machine

- Height Array – Contact sensors that are set at height increments of 0.2mm to 2.4mm to allow the height of the solder ‘bubble’ to be veri ed

In addition to these innovations, a pre- heat temperature sensor and a solder temperature probe was added to verify all key parameters in a single pass.

The SolderStar WaveShuttle Selective is now the tool of choice for setup and daily testing of mini-wave selective machines. What made the SolderStar solution unique was the specially con gured array of titanium

Other common problems reported by manufacturers was crystallisation occurring in the selective uxer nozzle resulting in the mis- uxing of components causing problems with poor wetting or leaving un- activated ux on areas of the assembly. To combat this problem SolderStar developed ux measurement sensors, which can be optionally installed to the measurement xture. This allows for ux presence and position to be obtained as part of the daily tests.

All parameters can be quickly analysed with the good and bad limits de ned easily to allow periodic process veri cation to be performed without the need for specialist knowledge.

System bene ts of this process include:

• Veri cation X/Y speed and positioning

• Measurement of nozzle solder height

• All titanium wave contact measurement

• A ux measurement option

• Pre-heat and solder temperature measurement sensors

• Custom widths and sensor positions are available for xed width production lines or special applications

The other main method seen in selective soldering is the multi-wave selective/dip soldering machine, which trades exibility for increased throughput. With this style of machine custom wave tooling is produced to expose the molten solder selectively to the area required in a single dip. Analysis of the performance of this process needed a di erent approach as it was found that engineers needed the ability to produce their own analysis sensor con guration to match the tooling design.

Figure 4. Multi-Wave Pro

SolderStar’s Multi-Wave PRO was developed and comprises compact and exible instrument design to allow dedicated test xtures to be produced quickly and cost e ectively for multi-wave soldering machines. Measurement sensors are tted to a customer’s speci c location, which corresponds to the soldering areas within the multi-wave solder pot tooling, this technique provides contact time and di erence data quickly allowing engineers to identify any problem areas within the tool design. Any

Figure 3. Mini-Wave Test Report

The new system for selective soldering was designed to analyse, improve and gain control of the mini-wave selective soldering process quickly - an important requirement put forward by the military systems manufacturer. The xture was unique due to it incorporating two measurement systems ensuring that the most comprehensive and repeatable measurement results were obtained.

A new xture was designed which extended the use of their existing SolderStar datalogger’s and could be used on the selective soldering machines. Using the

wave contact sensors arranged on the underside of this measurement xture to allow quick and comprehensive veri cation of the machine functionality.

Nozzle strikes on clinched components of the PCB due to PCB warp or general tolerances can result in the positioning mechanism of the machine becoming misaligned. X and Y positioning mechanism and speed on the WaveShuttle Selective are veri ed by sweeping the selective soldering nozzles between pre-de ned datums. A range of stepped contact sensors are employed to allow nozzle wave height measurements to be made and periodically veri ed.

Continued...

feature continued...

di erences in nozzle to PCB contact can be easily measured providing a powerful platform for process capability analysis, improvement and on-going testing.

Features of this system include:

• Flexible design allowing measurement systems to be installed to multiple xtures

• Solder Nozzle / PCB Contact Time

• Solder Nozzle Wave Height / Immersion Depth

• Time of rst contact delta

• Pre-heat pro lers

• Solder pot temperature

• Heating rates

High-speed measurements required to yield accurate results

The X/Y speeds in selective soldering machines can be fast which requires a quick responding measurement system to provide accurate and repeatable results.

Figure 5. Multi-Wave Software Screen

The contact sensor system used with SolderStar’s development scans every 10 milliseconds and measures digitally to give extremely accurate results.

The innovative contact measurement system relies on a ‘Ground’ contact to be made to the machine, to detect any contact with a solder wave and it was found that on some mini wave machines the ground was not easily achievable. To combat this a ground pin was produced and placed next to each measurement sensor so repeatable and accurate measurement was always attained.

This measurement and veri cation is paramount in the soldering process. To produce electronic assemblies without a known thermal pro le is detrimental, as you ‘cannot manage what you do not measure’. There can be changes in preheat performance, settings can be accidently edited, or nozzle build up can occur. Also, if the nozzle strikes the PCB during

production, either due to PCB warpage or incorrect machine setting, the X/Y mechanism can be thrown out of alignment and soldering will be o position.

SolderStar’s X/Y speed measurement method is performed by programming the machine to sweep from sensor X1 to sensor X2, and a measurement of the time it takes for this process is calculated to verify the speed. The sensors are just 1mm and can be aligned accurately on a CNC machine xture, allowing for alignment issues to be detected.

Having developed and evolved the selective soldering process with this ground- breaking technology, SolderStar trialled the new system with a customer, who reported all pre-heat and nozzle measurements to be accurate. It was also noted that the wave height measurement was accurate to 0.1mm. But the one area of the machine that was not tested was the uxing stage. This is notoriously di cult to analyse electronically.

Fluxing-the difficulty with Selective Soldering Process

Flux facilitates the soldering process and has the primary purpose to clean the components that are to be soldered. To obtain a successful solder any impurity including dirt, oxidation or oil must be removed.

Flux can be removed through mechanical or chemical cleaning, but the increased temperatures required to melt the solder can make the assembly re-oxidize. This can be accelerated as the soldering temperatures increase and can prevent successful soldering.

On a conventional wave solder machine, the entire assembly generally is uxed, preheated and passed over the solder bath. With selective soldering, only the area to be soldered by the nozzle is uxed, with dropjet technology to spray small amounts of ux onto the PCB.

As the assembly only comes into contact with the solder nozzle in those places, any ux deposited elsewhere will not be burned o and are left on the assembly, which is not desirable and can cause failures.

The main problems reported in uxing within the selective process is the X/Y positioning of the uxer or crystallisation build up in the nozzle resulting in ux being deposited in the wrong areas. This problem is twofold; insu cient uxing of necessary components resulting in poor soldering, and additionally the potential of un-activated ux seeping under sensitive electronics, producing in- eld failures.

After six months of intensive development and trials due to the many types of ux, which all perform di erently, SolderStar found a way to prevent this problem. The nal solution was a new sensor, manufactured from high temperature thermoplastics, with an embedded stainless steel surface resistance sensors. It was developed as a con gurable measurement system which has the option to be trained on di erent ux compositions, which can detect ux spots of 2mm upwards, a real break-through in the selective soldering process.

Selective Soldering – is it the best method?

Selective soldering utilises many of the concepts of other methods, but it bene ts from its ability to localise soldering and uxing with minimal pre-heating required, making it an innovative and unique technique.

Figure 6. Selective Soldering

The use of selective soldering for lead-free TH and PCB soldering applications includes many advantages over traditional methods like wave soldering, as the thermal shock to sensitive assemblies is potentially reduced. It is a exible and adaptable process which can be applied to a range of soldering tasks and, with companies like SolderStar developing tools to help setup and further maintain the process to reach speci c requirements, it is seen as the answer to many soldering di culties which are seen more than ever due to the complex designs being manufactured today.

It is now used in the mainstream to give accurate and dependable results in the soldering process and is also used widely in critical assemblies that require precision. It is for this reason that development in this process is ongoing and continues to evolve into a soldering method that is favoured by many.

www.solderstar.eu/

Page 22 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Innovative Systems Engineering

By Rehm Thermal Systems

Rehm Thermal Systems is a leading manufacturer of energy- e cient manufacturing equipment for the electronics and photovoltaics industry and has represented the highest levels of quality, innovation and technological know-how for 25 years. Once again, this year, they are presenting their latest product developments in thermal system solutions at SMT/Hybrid/ Packaging fair in Nuremberg - one of the most important international trade fairs for the micro-electronics industry.

VisionXC – An ideal system with compact dimensions

Small batches? Low throughput? It is important for any electronics manufacturer to maintain high quality levels in module production even when throughput is low. This means maintaining optimal process performance for reproducible soldering outcomes that must be implemented in the long term, without compromise, and must be maintained. It was for this customer group that the VisionXC was designed. This unit is appealingly compact and combines all the important technological features in the smallest space possible. The VisionXC is the ideal convection soldering system for small and medium batch sizes in production, in the laboratory and for demo lines. Our team at the trade fair will be pleased to advise you.

Rehm Thermal Systems celebrates 25 years

In 1990, Managing Director Johannes Rehm took the step into self-employment with an idea that was to bring him success – small, innovative re ow soldering systems with a gas-tight process chamber that can be opened. His process gave an impetus to the eld and his systems engineering proved to be highly successful.

Rehm has been on a course of expansion ever since. Today, over 450 creative minds work for the company worldwide and the product portfolio continues to grow. In addition to re ow soldering systems o ering convection, condensation and vacuum processes, this also includes drying and coating systems, cold and hot function testing systems and systems for metallizing solar cells. Rehm has also gained an international reputation for developing individual special systems matched speci cally to customer requirements. With production facilities in Germany and China and 26 representations in 24 countries, the company is an established entity and technological leader in the production of e cient machines for the economically viable production of electronic modules.

At SMT Nuremberg, they will be presenting the following products on their Booth 7-451:

VisionXP+ Vac – The plus for your SMT production facility

The VisionXP+ convection soldering system is clearly orientated to the trend towards a more environmentally sustainable use of resources. This system combines various improvements to the VisionXP series, particularly in terms of optimised energy e ciency and reduced emissions. The VisionXP+ o ers signi cant operating cost savings, reductions of up to 20 % in energy consumption and an average of 10 tonnes less CO2 emissions per year. The vacuum option also makes void-free convection soldering processes realisable for inline use.

space requirement for the same process characteristics. Use of the injection principle together with control of temperature and pressure enables a precise and diverse re ow pro ling. Void-free soldering can be realised with CondensoX series systems by adding the vacuum option.

Protecto with UV 1500 Dryer – Selective conformal coating applications

The use of protective lacquers improves the quality and service life of your products. Our selective Protecto conformal coating system protects sensitive electronic assemblies from damage caused by corrosion and other environmental in uences such as humidity, chemicals or dust. Thanks to a multi-functional lacquer applicator, even complicated application processes can be completed in a single step, even where there is restricted space between the components. The use of up to four nozzles gives you enormously exible coating options. The system is also available as a production line concept with a lacquer dryer that will make your production facility more e cient. At the trade fair, we will be demonstrating our latest dryer, a UV unit that can be integrated into any production environment thanks to its compact construction. The system is available with either quartz emitters or LED elds and o ers reliable drying of all UV-hardening lacquers.

CondensoXS – High performance in the smallest space possible

The CondensoXS makes e cient condensation soldering processes feasible in the smallest space possible. This system also o ers a signi cantly smaller footprint. The bene t to you: 25 % reduced

Page 24 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Industry News

Keep up to date with what’s new

With each issue we’ll keep you up-to-date with the latest industry news from around the globe.

SMT Electronics Selects Aqua Klean’s T-12 Water Soluble Cleaner

Aqua Klean Systems, a leading provider of advanced PCB cleaning equipment, announced that SMT Electronics has selected its new Typhoon T-12 Water Soluble Cleaner. SMT Electronics chose the T-12 for many reasons: the 24” wide belt, the industry’s safest smart heater, quick and adjustable pressure valves, easy-to-access front valves and the innovative touchscreen software interface.

The Typhoon T-12 Water Soluble Cleaner o ers all of the same features as the well- known Typhoon T-15 in a compact footprint. TheT-15isthecleanerofchoiceformany electronic manufacturing facilities. The T-12 is just 12’ long and has more horsepower than any other cleaner for its size. Equipped with a 15 HP wash and rinse pump, and two 15 HP turbine blowers, the Typhoon T12’s performance is unmatched.

____________________________________

Count On Tools, Inc. Launches MYDATA Feeder Repair Program in Europe

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, has recently announced that it has authorized AdoptSMT Group, its distributor in Europe, to o er repair services for MYDATA Agilis Feeders. This program will be available for the 3.7, 4.0, 4.7, and 5.4 Agilis feeders. This is the only repair option for these feeders on the market and provides signi cant cost savings over purchasing replacement feeders.

All repair components (tape plows and feeder springs) are precision machined

replacements for the original parts using high quality materials and industry leading coatings. COT and AdoptSMT guarantee the functionality of the equipment and the ability to extend the life cycle of worn or damaged feeders.

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Inovar Purchases Ersa’s VERSAFLOW 3/45 with Double Solder Modules

Kurtz Ersa North America, a leading supplier of electronics production equipment, announces that Inovar has purchased a VERSAFLOW 3/45 selective soldering system with dual solder pots. Inovar is a leading contract manufacturer in the Intermountain West located in Logan, Utah. The VERSAFLOW 3/45 will allow Inovar to run two alloys (tin-lead and lead-free) in one machine on-the- y.

The VERSAFLOW 3/45 is the industry’s most widely used in-line selective soldering platform. This platform is the most repeatable system on the market with technology highlights such as servo driven gantry systems, expandable modularity, dual solder pots, ducial recognition, board warapage detection, process camera, auto nozzle cleaning, top- and bottom-side heating and o ine programming.

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Star Headlight and Lantern Co. Purchases IINEO from Europlacer

Europlacer, a manufacturer of market- leading exible SMT placement machines, recently announced that Avon, N.Y.-based Start Headlight and Lantern Co., Inc. have purchased an IINEO II pick-and-place system.

The IINEO machine is the agship of Europlacer’s product range and has won several awards as one of the most exible pick-and-place machines on the market. With a feeder capacity of 264 x 8 mm feeders, placement speeds to approximately 17,000-21,000 actual cph, capability from 01005throughto50x50mmandfor devices as high as 35 mm tall, the Europlacer IINEO has been accepted widely within the global market for both CEM and OEM manufacturers to enable hyper-productivity.

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Scienscope Enters Exclusive Representative Agreement with Horizon Sales in the Midwest

Scienscope International, a complete inspection solutions provider, has appointed Horizon Sales as its exclusive manufacturers’ representative in the Midwestern U.S. Horizon Sales will represent Scienscope’s state-of-the-art X-ray cabinet systems.

Dave Trail, President and principal owner of Horizon Sales commented, “We are very pleased to be able to represent this product throughout the Horizon Sales

Continued...

Mike Mastin and his team are pleased with the bene ts provided by the IINEO machine, and look forward to a mutually- strong relationship with Europlacer for years to come.

Page 26 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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territory. These systems are ideally suited to those companies that need an economical approach to X-ray. We see a very good outlook for sales in the region because so many of the companies here are small to mid-size shops and many of the larger, more complex X-ray systems are just out of their price range. Even though the Scienscope units are very economically priced, they still o er some of the more sophisticated technologies like multi-axis manipulators and digital detectors so now even the smaller shops can integrate these higher level capabilities and processes into their production and QA plans.”

____________________________________

Great Lakes Engineering breaking into the electronics industry in a big way

With experience in the defense, medical, electronics, aviation, energy, telecommunications, and computer industries, Great Lakes Engineering is now positioning themselves to gain more traction in the electronics manufacturing industry due to the increased demand for small, precision cut parts.

As the industry trends towards miniaturization and wearables, standards are being raised and leading to ner pitch requirements, higher tolerances and greater repeatability. Great Lakes Engineering o ers state-of- the-art laser technology which enables customers to experience positional accuracy unattainable with conventional technology. Through this process, they can manufacture a laser cut stencil with aperture openings down to .003 inches. For optimum paste release, all laser cut stencils are tapered to be a 1/2 mil.

____________________________________

Rocket EMS Launches www. rocketems.com

Rocket EMS Inc., a Silicon Valley-based full-service EMS supplier, has announced the launch of its new website. Located at www.rocketems.com, the site explains Rocket EMS’ background while including the company’s core values and philosophy.

The new updated site provides a full description about Rocket EMS’ leadership team, facilities, quality and markets served. While navigating, visitors can expect to nd controversial quotes; in

depth descriptions of all services rendered and even have the opportunity to request some of Rocket EMS’ success stories.

____________________________________

Saline Lectronics purchases a Juki Cube 460 through Horizon Sales

Saline Lectronics, Inc., a leading electronics contract manufacturer, recently purchased a Cube selective soldering system from Juki. Dave Trail, President of Horizon Sales facilitated the sale.

Dave Trail, President of Horizon Sales, commented, “This is the third selective solder system that Saline Lectronics has purchased from Juki. Saline’s existing Juki units have been operating continuously in a multi-shift environment for a few years now and they needed the Cube to meet increased demand.”

“The installation of the Juki Cube 460 batch system has signi cantly increased our selective soldering capabilities and throughput,” said Eric Hassen, Vice President and General Manager of Saline Lectronics. “The top and bottom preheaters, as well as the solder wave monitoring system, are just a couple of the features that have allowed us to increase our capacity to build quality products, and all in a smaller footprint than the W150 models.”

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SAMSUNG Awards Yankee Soldering Technology ‘Most Improved Territory 2014’

SAMSUNG C&T Automation, Inc., the worldwide leader in high-speed, high- precision SMT Machines, is proud to announce the recipient of the “Most Improved Territory” award for 2014 is Yankee Soldering Technology Inc.

Yankee Soldering Technology Inc., established in New England in 1997, has been serving the electronics manufacturing industry in its region for almost 20 years and has established a reputation for productive competence and honesty.

“We are pleased to represent Samsung C&T Automation in our territory, as well as other select manufacturers of equipment, tooling, and materials,” said Don Lockard, Sales Rep at Yankee Soldering Technology. “As an industry leader, Samsung has some of the best Representatives in the market. Yankee Soldering Technology is proud to be among them, and we are delighted to have been fortunate enough to have had the North American 2014 best territorial growth. We have high hopes to continue this success in 2015.”

Page 28 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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Total Manufacturing Management Solution

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T-Sol ution

T-Solution from SAMSUNG intelligently plans, executes, and manages the electronic assembly

process by synergizing hardware, software, and people to maximize quality, efficiency, and

overall productivity of assembly line solutions. In high»mix/low-volume production, where

quick setups and fast changeovers defi ne profitability, T-Solution is active at every step of the

process to ensure that accuracy and quality control is never compromised, regardless of real

world production conditions. T-Solution from SAMSUNG — really SMART.

It's smart. it's your total solution.

www.samsungsmt.com

New Generation of Extraction and Filtration Systems for Dust, Laser Fume and Welding Smoke SMT Nuremberg – Booth #6-313

By Smt today editor

ULT AG, vendor of extraction and ltration technology for airborne pollutants, introduces its next generation systems ULT 1500 and ULT 2500. The units have been designed for removal and ltration of hazardous substances in dust, laser fume and welding smoke. They are based on an ideally con gured device and lter concept that provides users critical space and cost bene ts within their production lines.

energy expenses. Filtered air can be fed back to the working area, avoiding heat loss. These newly developed systems have been designed for extraction and ltration of hazardous substances originating from welding and laser processes, and for dedusting technology.

About ULT AG:

Founded in 1994, the ULT AG is a leading vendor of high e ciency industrial air ltration systems and dust collectors. The broad range of equipment has been designed for use in many industries such as machine construction, electronic and general manufacturing as well as medical covering a wide range of applications. The product range o ers standard products as well as custom-built units for special applications. ULT AG provides customers in Europe, Asia, North America and Australia with extraction and ltration systems for material processing by means of laser, soldering, welding etc. as well as onsite services. The company has been DIN EN ISO 9001 certi ed for more than 15 years.

Both systems appeal through the utilisation of conic lter cartridges, which enable increased lter performance and better cleanability due to their geometry.

Easy dust discharge is another decisive bene t, because dust deposits are collected directly in a 70 litre removal container for low contamination disposal.

ULT 1500 and ULT 2500 can be exibly adapted to various process conditions for extraction and ltration of dust, welding fume or laser smoke. It is possible to select the extraction position, i.e. raw gas intake can be executed on the systems’

right or left sides, which means variable installation conditions.

Furthermore, both systems feature an optional swing check valve to protect pipelines against pollution by possible dirt pushback, and consequently, lter cartridges against premature wear.

Because of their small footprints, the units can be perfectly utilised in limited spaces and, therefore, help to save valuable production oor. This e ciency is optimized by front access to the systems.

Rotary nozzle dedusting additionally reduces compressed air consumption and hence

Page 30 The Choice of Publication for the Electronics Industry

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An interview with Jim williams, Director of Process Support Products, ASM DEk

by smt today editor

Jim Williams, Director of Process Support Products at ASM Assembly Systems, talks all-consuming print performance

In an exclusive interview with SMT Today, Jim Williams, Director of Process Support Products (PSP) at ASM Assembly Systems, discusses his views on the industry ahead of SMT Nuremberg 2015 and describes innovative new ASM process support products designed to address the latest printing challenges.

Ultra coating allows complete coating of both the stencil underside and the aperture walls. The aperture coating delivers great transfer e ciency for Aspect Ratios below 0.6 and initial beta site trials with German and Hungarian based automotive customers have had superb results.

“Nano Ultra stencils will be o cially launched during SMT Nuremberg 2015 and we invite all show delegates to see this amazing new technology for themselves.”

Looking at challenges other than miniaturization, and thinking about manufacturing e ciency and Industry 4.0, ASM is seeing that customers are increasingly looking for less operator involvement in the printing process. “We are investigating a new intelligent stencil which allows much greater traceability. For certain customers, particularly those in the automotive industry, de ning the lifetime of a stencil product and tracking the number of cycles it’s undertaken is important. This new stencil incorporates a Near Field Communication (NFC) device and tracks how many prints the stencil has experienced. It can also automatically reload the printer product les and, as the stencil nears the end of its lifetime, an email requesting replacement stencils is delivered to the stencil provider. ASM is actively investigating the viability of such technology. Initial discussions have yielded very positive feedback and we look forward to continuing these conversations with customers at SMT Nuremberg. ”

DEK became part of ASM Assembly Systems in July 2014 and the integration has delivered many advantages already. Jim believes that the main bene t for customers is that there is now a holistic SMT process approach that leverages the expertise of both the DEK and SIPLACE teams. “DEK and SIPLACE are arguably the top technology brands when it comes to printing and placement solutions. That didn’t happen by accident. Our customers now have total access to that comprehensive knowledge base, ASM’s performance services team and our global resources. Truly, the competitive advantage this delivers is completely unmatched in the electronics market – and this is only the beginning.”

As Jim Williams re ects on an electronics career of more than 30 years, he is still excited by the challenges presented by the SMT printing industry. One of the main challenges facing SMT printing today is miniaturization. Increasingly, there is the need to accommodate ever smaller stencil apertures. This trend is not only a ecting stencil printing machine capability but also the consumable products that are integral to a robust printing process. “At ASM we are addressing the miniaturization challenge in three key ways”, explains Jim.

The rst is through the improved design of consumables products, particularly the design of understencil fabrics. Take for example the DEK Ultra-Fine Pitch Eco Rolls which are specialised fabrics used to clean the underside of the stencil. “The unique fabric design with integrated pockets helps move solder materials out of apertures and traps them away from the underside of the stencil. This prevents smearing and encourages a more thorough and e cient clean. Importantly, with businesses having sustainability as a priority, the use of UFP Eco rolls lowers solvent consumption by as much as 50%. This saves time, money and reduces the impact on the environment.”

Second, ASM has further improved solder transfer e ciency for small aperture ratios, through use of a new material within its already popular DEK VectorGuard High Tension range. With the exception of specialty stencils, the majority of stencils are made from stainless steel. The same holds true for VectorGuard High Tension foils. As Jim explains, “Our new ne grain stencils greatly improve paste release. This ne grain material means a ner grain structure and, because of the tighter grain distribution ne grain laser cut aperture, side walls are much smoother – which ensures that the paste can be released more easily from the

stencil apertures. When combined with the VectorGuard High Tension system, the ne grain material helps deliver a superior print for miniaturized devices in combination with consistent tension throughout the life of the stencil, which is an inherent advantage with the entire VectorGuard range”

Finally, the challenge of miniaturization has led to the commercialization of a new ASM coated stencil technology. When ASM introduced stencil nano coating Nano-ProTek to the electronics market, it was the rst wipe on stencil coating on the market. When coated with Nano-ProTek, stencils become ‘ uxophobic’, enabling an extension in the number of prints between cleaning cycles and a more e ective cleaning process...

As Jim explains, “This is important because every time the stencil is cleaned the aperture is e ectively being emptied of solder paste and it then takes some time to replenish that loss and return to print stability. If cleaning frequency can be reduced, then it follows that there will be a more constant volume of paste being deposited onto the circuit boards and a more stable process will result...

“Nano-ProTek works well for improving cleaning e ciency. However we are always looking to improve. To this end, we have launched the next generation of coated stencils, DEK NanoUltra. With Nano Ultra stencils, a durable spray-on stencil coating is applied and cured immediately following stencil manufacture.

“Nano Ultra stencils deliver cleaning e ciency bene ts, but also have two distinctions as compared to stencils coated with a wipe-on material. First, the coating on Nano Ultra stencils is red in colour so that customers have visual veri cation of its presence. Second, and more importantly, the spray technique used to apply the Nano

new products

exciting new industry innovation

Keeping you informed of the latest developments in technology and innovation within our global electronics industry.

Count On Tools Inc. Unveils the Stubby Seal Scraper from PB Swiss Tools

Count On Tools Inc., a leading provider of precision components and SMT spare parts, now offers PB Swiss Tools’ Stubby Seal Scraper. The new variant with a short blade allows a more precise guiding of the tool and increased pressure on the blade. Additional benefits include improved accessibility in small spaces and less fatigue on the wrist.

PB Swiss Tools’ special tools are known for their precision, hardness, toughness, highest regularity and perfect finish. They are the reliable companions for the safe, efficient performance of daily work. A very high hardness value (58- 60 HrC) and a unique durability and springiness characterize the wear- resistant special steel that PB Tools has developed through the decades with its steel suppliers.

The Stubby Seal Scraper features PB’s Multicraft handle for the toughest use. The Multicraft handle is ideal for assembly or repair workshops where resistance and durability are required. The tough CaB (Cellulose acetate Butyrate) plastic is extremely hard- wearing and can withstand even strong blows. The spherical basic shape permits the highest hand torque and the special surface means a non-slip grip, even with wet or oily hands.

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Kurtz Ersa Customers in the Paci c NW Can Now Place Orders Online

Kurtz Ersa North America, a leading supplier of electronics production equipment, is pleased to announce

that its manufacturers’ representative in the Pacific Northwest, MaRC Technologies, Inc., has launched an online store. Customers in this territory can conveniently order Kurtz Ersa NA’s hand soldering equipment at http:// www.marctechnologies.biz.

Todd DeZwarte, Product Manager, Rework, Inspection & Tools at Ersa, commented, “MaRC Technologies has been, and remains, one of our top distributors of Ersa hand soldering tools in North America. We are very excited about the user-friendly online store that they have created.”

MaRC Technologies is a specialized supplier of tools and supplies for the electronics manufacturing and high- tech industry. Established in 1995, the company’s focus has always been on providing excellent service and products to its customer base.

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Testing and programming of ultra-low power processors

GOEPEL electronics extends the VarioTAP® processor emulation technology for the Kinetis L series by Freescale.

The processor is reconfigured to provide design-integrated test and programming instruments via the SWD port. The user can select the corresponding processor to test and validate the connected hardware as well as program Flash memories.

The Kinetis family is a 32bit microcontroller line by Freescale, specially developed for a wide application range. The L series

particularly aim low power applications. Therefore the Cortex M0+ core by ARM is used. The focus is, for example, on USB devices, Segment LCDs, wearable’s and low power applications in general. The smallest species exist in a 3x3 mm QFN package, whereby they cannot be tested with conventional equipment. The aim of VarioTAP® is to provide design- integrated tools for test, hardware debug, Flash programming and design validation after chip mounting.

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Libra Industries Completes Recerti cation Audit for ISO 9001 and ISO 13485

Libra Industries, a privately held electronics manufacturing services (EMS) provider, is pleased to announce that it has passed the recertification audits for its ISO 9001:2008 and ISO 13485:2012 certifications. With the recertification, Libra Industries is equipped to serve the aviation, space and defense as well as medical device industries with a proven quality management system.

Mike Lynch, Libra Industries’ Quality Manager, commented, “This renewal maintains Libra Industries’ continuous approval of ISO certification since it was first achieved in March 1993. Libra Industries was one of the earliest ISO approved electronic contract manufacturers in the region.”

The ISO 9001:2008 standard specifies requirements for a quality management

Page 32 The Choice of Publication for the Electronics Industry

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system where an organization needs to demonstrate its ability to consistently provide product that meets customer and applicable statutory and regulatory requirements. Libra Industries demonstrated its continued effort to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable statutory and regulatory requirements.

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Seika Machinery Introduces McDry HM-1002BN Nitrogen Auto-Flow Cabinet

Seika Machinery, Inc., a leading provider of advanced machinery, materials and engineering services, introduces the new McDry HM-1002BN Nitrogen Auto-Flow Cabinet.

The HM-1002BN dry cabinet saves energy and reduces costs with the low-power mode. It uses less nitrogen compared to standard N2 cabinets due to high-performance drying units. The N2 Auto-Flow system enables quick recovery when opening and closing doors. Additionally, as with all McDry cabinets, the HM-1002BN offers a high quality build, ESD specifications and high performance.

SMART Group’s 2015 European Conference to Focus on Process & Yield Improvement

SMART Group, Europe’s largest technical trade association focusing on surface mount and related technologies, announces that it will hold its two-day European Conference at the National Physical Laboratory, Toddington, Middlesex from September 22-23, 2015. The NPL is an internationally renowned centre of excellence and technology.

Since opening in 1900, NPL has strived to deliver the highest social and economic impact through world-class measurement science, innovative applied research and knowledge services. It is the ideal venue for what will prove to be informative and enlightening for everyone involved in our industry.

The event will be themed around Process and Yield Improvement, and will feature quality papers by international speakers targeted to benefit managers as well as production and quality engineers.

Keith Bryant, SMART Chairman, said, “We are really looking forward to hosting a strong and relevant European Conference in 2015 and welcome technical presentations on this theme.”

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Techcon Systems Updates www.techonsystems.com

Techcon Systems, a product group of OK International and a leading provider of fluid dispensing systems and solutions has launched a new web site – www. techconsystems.com. The new site features an updated design that makes learning about the company’s products and services easier.

The new design will make it easier for current and prospective customers to learn more about Techcon’s products and services.

The new site has an intuitive navigational structure that makes browsing and selecting products simple. Additionally, enhanced graphics and a new layout provides visitors with an improved user experience.

Additionally, with Techcon’s web store, customers from North America and Europe can easily order Techcon’s range of fluid dispensing products online.

Valtronic Holding Introduces Business Development Team

Valtronic, manufacturer of miniaturized electronic products for trusted medical device partners, announces the new Corporate Business Development team. Funded by the Valtronic Holding company, the team will work to secure business for Valtronic but will also offer the opportunity to expand in research and development, intellectual property evaluation, product development and will leverage its global identity in other markets. “Our commitment is still focused on our customers and the nurturing of new business. The decision to expand in business development is not only to secure business for Valtronic globally, but to make our mark as leaders in the industry, focused on our vision, ‘to be the worldwide recognized partner for innovative personal healthcare devices’,” says, Valtronic’s CEO, Martin Zimmermann.

Valtronic Holding is building a long-term proprietary portfolio of innovative medical device technologies. With a unique business model for long-term value creation, these projects will not compete with Valtronic’s existing customers. The Business Development team will assist in invention or in-licensing, adding value through an innovative development strategy and implementation, and/ or partnering to maximize the commercialization potential.

The fully integrated team of scientific, technical and business experts are focused on building a strategic partnership to take projects to the next level. With proven experience and capabilities to ensure needs are met as an inventor, researcher, start-up, or investment partner, the Business Development team will add value by providing services focused on in/out licensing of proprietary technologies, mergers and acquisitions, joint ventures and co-investments.

THT production and the search for the optimum production and

inspection strategy

By Goepel electronic

THT production – old principle, new quality!

If one considers the diversity of all electronic assemblies, one thing is clear: despite constant miniaturisation and increasing integration density, THT components are still present on a signi cant number of assemblies. The answer to the question of ensuring the manufacturing quality of these components seems all the more strange, however. Traditionally, visual inspections are carried out either manually or not at all. Both approaches are no longer acceptable in today’s quality standards. This fact is all the more serious because THT assemblies are still used in sensitive areas – particularly in the area of power electronics.

at this point and reworked. A major advantage of this strategy is that only one visual inspection system is necessary for all assembly workstations. Disadvantages are, rstly, that an additional repair workstation must be set up and sta ed for the necessary reworking and, secondly, that there is no direct feedback between detected faults and their origin. Although any moments of inattention during assembly can be safely identi ed and eliminated, they occur repeatedly since the origin of these faults is not responsible for eliminating them.

After soldering, the solder joints of the assemblies are inspected and the abnormalities identi ed are classi ed at another station. There is no time for direct repair at this point, because the bu er size is limited and the workpiece carriers are required to further assembly.

The assemblies are removed from the workpiece carriers following classi cation and fed to the next stage in the process. The faulty assemblies are repaired at one or more separate stations.

AOI for THT – what are the advantages?

To signi cantly shorten this control loop, which exists only to a limited extent, a visual inspection system can be installed after each manual assembly station. The advantages

The use of THT in the solar industry

These assemblies are indispensable in many elds, including the solar industry. Here, for example, inverters are produced using THT technology. Put simply, these inverters convert the direct current coming from the solar modules into alternating current that can be fed into the grid. Because such inverters are in some cases used in very remote areas and replacement is time-consuming and expensive, smooth operation must be ensured.

At SMA Solar Technology AG, the world’s leading manufacturers of inverters, a very high value is placed on the quality of the assemblies, even at the assembly and soldering stage, which is why the automatic optical inspection (AOI) test method is used. In principle, there are two di erent approaches to the AOI of THT assemblies:

First, the fully pre-fabricated assembly is inspected after the soldering process. Both the solder joints and the components are checked to ensure they are present and in the correct location. It is extremely important for the manufacturing process that the assemblies can be inspected without extra handling of both sides. Faulty assemblies are removed and reworked at a separate workstation.

The second possibility is to test in two steps. The components are rst of all inspected immediately after manual assembly, i.e. before soldering. Any faults that may arise, such as missing or incorrect components

or components with reverse polarity, can be corrected immediately without the need for any tools. Only after this check are the assemblies fed to the soldering process and their solder joints then inspected.

As a rule, the THT boards are assembled at several manual workstations, which results in various options for organising the visual inspection. The most obvious is a central check of the components immediately before soldering.

All assemblies from the manual assembly stations are brought together on the main conveyor belt and inspected there immediately upstream of the wave soldering unit. All faulty assemblies are discharged

Page 34 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

are obvious: immediately after assembly, the assemblies are fed manually into the AOI system and checked accordingly. Faulty assemblies do not make it to the central conveyor belt but are instead removed from the process and reworked immediately at the relevant workstation. Only once the AOI system indicates that there are no more abnormalities is the assembly taken out of the device and fed to the main conveyor belt.

This ensures an extremely short control loop during assembly. The member of sta at the manual assembly station therefore has the option of being noti ed of any faulty assembly. This results in a signi cant perspective reduction in the fault rate and thus the necessary – if also short – time for reworking. This makes it impossible for series faults to creep in.

After the soldering process and subsequent solder joint inspection, the workpiece carriers together with assemblies are transported back beneath the production line and are assigned to the manual assembly stations with the help of RFIDs (radio frequency identi cation) on the workpiece carriers. At the classi cation/repair stations located there, the serial numbers of the assemblies are scanned and the corresponding data records from the fault database are displayed. This allows classi cation and, where appropriate, immediate repair of the faults.

Classification of fault data using serial numbers

How is fault data assigned to the serial numbers in the last two variants then? One option is to integrate a barcode reader in each optical inspection device. This is done more elegantly using the camera which is already in the system. However, since labels and application of labels to the assemblies on this scale is expensive, they are normally a xed to only one side – on the assembly side.

So how can an AOI system detect the correct serial numbers? The option of using an external scanner has the disadvantage that reading multiple serial numbers on one assembly is impossible without immense e ort (moving the scanner in the x- and y-direction).

The solution to the problem is to cache all the serial numbers between the assembly- side AOIs and the solder-joint AOIs.

In the majority of cases, THT assemblies are transported in workpiece carriers. These carriers are furnished with unique numbers on RFID tags or separate barcodes. These small, increasingly widely-used “radio helpers” are used in THT production to adjust the soldering systems to di erent solder pro les according to the assembly. This is necessary because THT production usually does not produce items accurately sorted, as in an SMD line. The individual assemblies can sometimes vary greatly, meaning that a di erent soldering pro le can also be required to ensure the highest possible soldering quality.

The serial number is read with the camera, which checks the assembly sides (upper side of the assemblies) and the RFID is read using a reader. The workpiece carrier ID is then stored, together with the read serial numbers for the assembly, in a database. The camera for inspecting the solder-joint side (underside of the assemblies) likewise reads the RFID and retrieves the corresponding serial numbers from the database. Optionally, the workpiece carrier can of course also be identi ed using a barcode label a xed to it.

Furnished with the correct serial numbers, the data records can be accessed at the relevant classi cation and repair stations. To ensure full traceability of the assemblies, at each station the inspection data of an assembly – furnished with the correct serial number – is sent to a higher-level MES-system.

Everyday practice

AOI systems by GÖPEL electronic have been used successfully for many years in production at SMA Solar Technology for the quality control variants in the THT production process which are illustrated here. Due to the various con guration variants in this system family, they have been optimally adapted to the relevant production process. It can therefore be concluded that the use of AOI systems in the THT process on the one hand represents an important component in the quality control of products but, on the other hand, requires exible integration of these systems with the speci c manufacturing conditions. AOI systems from GÖPEL electronic guarantee both.

Figure 3: GOEPEL electronics THT-Line

Figure 4: Double-side PCB inspection without ipping

Europlacer Helps Star Headlight and Lantern Co., Inc. Light the Way to Success

By smt today editor

Since 1889 Star Headlight and Lantern Co., Inc. has been the leader in emergency vehicle safety lighting products such as STAR amber warning lighting systems, Star Signal Vehicle Products red and blue police vehicle lighting, light bars, backup alarms, LED lighting, vehicle safety lighting, STAR railroad lanterns and personal safety strobes. The company also produces Bradford vehicle dashboard, deck and console mounting systems, and replacement bulbs. Its years of experience and state-of-the-art manufacturing facility in Avon, New York, continue to intensify the dedication to quality and service that customers have expected for the past 125+ years.

advanced technology is key to their success — but just as important is its relationship with its customers. Its treatment of Star Headlight and Lantern Co. is no di erent than any of their installs. The end result is always a satis ed and productive customer.

Mastin mentioned four areas in which he feels the company went above and beyond:

1. Europlacer’s sales people are knowledgeable about their equipment and proposed the best machine to meet Star Headlight and Lantern’s growing needs, in a very professional manner.

2. Europlacer’s support and service is heads above its competition. The install was awless and every Europlacer contact that the company dealt with has been helpful, answered every question to its satisfaction and did so in a timely manner.

3. Every item promised was delivered on time and explained in an informative way. Europlacer has lived up to every expectation and then some.

4. The President of Europlacer North America followed up personally to make sure that Star Headlight and Lantern Co. was being cared for as promised and in a way that was acceptable to the company.

The IINEO machine is the agship of Europlacer’s product range and has won several awards as one of the most exible pick-and-place machines on the market. With a feeder capacity of 264 x 8 mm feeders, placement speeds to approximately 17,000-21,000 actual cph, capability from 01005 through to 50 x 50 mm and for devices as high as 35 mm tall, the Europlacer IINEO has been accepted widely within the global market for both CEM and OEM manufacturers to enable Hyper-Productivity.

“Our experience was great and the next machine I need, Europlacer will be the rst call I make. I welcome any prospective customer looking for SMT equipment to call me personally and I will gladly expound upon my experience,” concluded Mastin.

Star Headlight and Lantern Co., Inc. features an extremely diverse product line of new and legacy products on its production oor that necessitate multiple, full changeovers, every day. As a result, the company must work only with top-rated, reliable suppliers whose equipment will always be running.

The company purchased an IINEO II pick-and-place system.

“I want to say thanks again for providing Star Headlight and Lantern Co. with the IINEO II; it is such a great machine,” Mastin continued. “It has increased production/ productivity and output e ciency on our

Figure 1: Mike Mastin and his team are pleased with the bene ts provided by the IINEO machine, and look forward to a mutually-strong relationship with Europlacer for years to come.

Mike Mastin, VP of Production at Star Headlight and Lantern Co., Inc., said, “We evaluated approximately 10 SMT platforms and companies before deciding upon Europlacer as our supplier. We are two full months into our relationship, and, we sure are happy that we did!”

SMT production line threefold at least.”

For Europlacer, providing a positive buying experience is just the way the company does business. Customer care, support and service are qualities that it provides for the entire lifetime of each system that is placed in a customer’s facility. The company understands that superior quality and

Page 36 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

It's time to look

through smarter eyes.

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An interview with

Mark Goodwin, Chief Operating Officer USA and Europe, with Ventec International Group

by smt today editor

With headquarters in Suzhou, PRC, Ventec International Group is a world leader in the production of high-quality, high-performance copper-clad laminates and prepregs used in a wide range of printed circuit board and associated applications. Ventec International Group is a global company with an extensive footprint of manufacturing, distribution, technical service and sales centres throughout Asia, Europe and USA. Products and services are delivered to Ventec’s global customer base via its overseas operations Ventec-Europe and Ventec-USA, for which Mark Goodwin, Chief Operating O cer USA and Europe, has executive responsibility.

SMT Today had the opportunity to seek Mark’s views on the topical issues of laminate cleanliness and supply chain security.

and customer-reference details, so that the packs can remain sealed all the way into the customer’s lay-up room.

No card or wood is permitted in our prepreg processing rooms, all the work- surfaces are stainless steel and each room has its own set of dedicated handling equipment, colour coded to identify where it belongs and never leaving that area, to eliminate the risk of cross-contamination.

Q. Mark, the European Space Agency have emphasised the critical importance of cleanliness in processing PCBs (Printed Circuit Board) to avoid latent in- service short circuits, and demonstrated in several case studies that lack of cleanliness in PCB laminates has been a cause of failure due to electromigration. They have recommended a tightening of requirements on base materials for the manufacture of high-reliability PCBs for space applications. How has Ventec responded?

A. We have always been very conscious of our responsibility to supply our customers with materials to the highest standards of cleanliness, and the elimination of foreign object debris has been the focus of substantial investment within Ventec International Group. Our laminate manufacturing process has been designed with ultra-cleanliness as a primary objective, from resin preparation all the way through prepreg production, lay-up and lamination, all monitored with advanced inspection technology. We have the capability to inspect, test and release materials in anticipation of the adoption of IPC-4101-D Appendix A, proposed by ESA, which de nes a class of cleaner base materials for high reliability use in aerospace applications.

And I’m not talking just about the primary manufacturing process. In Ventec-Europe and Ventec-USA we provide panel-cutting

and packaging services to customers’ individual requirements, and it’s equally important to ensure that these processes are carried out with the same FOD (Foreign Object Damage) elimination culture. We are determined to maintain critical levels of cleanliness and our fabrication equipment and environment have been speci cally designed to aerospace standards.

For example, in our Ventec-Europe distribution centre we have separate clean-rooms for polyimide and epoxy prepreg cutting and packing, and the only people allowed inside are trained operators in full clean-room clothing. The slitter-sheeters each have certi ed ISO Class 7 laminar down- ow canopies, with real-time monitoring of temperature and humidity. We only work in full rolls of prepreg. Once a roll is transferred from the cold store to a slitting machine, we slit the whole roll so that there is no backwards- and-forwards tra c of part-rolls. When a roll is loaded onto a machine, the outer layer of prepreg is threaded through and discarded. Then we proceed to cut panels until the end-of-roll detector stops the machine and we discard the tail-end of the roll to avoid adhesive transfer. Cut panels are removed from the machine in stacks and the top panel of each stack is inspected before packing. The pre-preg leaves the clean environment in sealed aluminised packs. Our labelling system is fully barcode- and human-readable, with full product-identity, lot-number, quantity

Q. Was Ventec one of the rst to declare support for the ESA proposal?

A. Certainly - there’s no point in making the commitment and the investment and not putting your marker down! A lot of pressure is going to be put on the laminators to deliver clean product. We make clean laminate, we’re con dent we can satisfy the requirements of IPC-4101 Appendix A and we’re fully prepared to meet that challenge. If a customer speci es Appendix A, we will test it in line with the AABUS agreement we have with him as de ned in Appendix A.

Q. Does that mean you will deliver laminate products any cleaner than you supply generally?

A. No, because we don’t get failures anyway. You have to manufacture the quality in, you can’t inspect it in! All we are doing is giving our customers further con dence in the statements we have

Continued...

Page 38 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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made and the statistics and data we have recorded. We’ve made a commitment and we can back-up that commitment with documentation. We did not want to be driven by the customer to do what we’ve done: we had a good understanding of what future requirements would be and took the initiative to lead our capability in that direction.

Q: Which certainly sets a precedent and puts pressure on other suppliers to follow the lead you have established. Mark, we’ve talked about manufacturing, fabricating and delivering a critically clean product. E ectively, that’s risk mitigation by intrinsic product quality, but what about risk management within the supply chain?

A: Supply chain management is a fundamental element of the service we provide. Dealing with Ventec, the customer has the assurance that he is buying laminates and prepregs direct from the primary manufacturer, with full traceability all the way back to the basic raw materials, and the con dence that the entire supply line is meticulously controlled, documented and accredited to Aerospace Supplier Quality System AS9100 Revision C. The PCB fabricator can in turn assure his CEM (Contract Electronics Manufacturer) or OEM (Original Equipment Manufacturer) customers of the provenance of the materials he has used in fabricating circuits in accordance with their speci cations.

But the security of the supply chain can be seriously compromised if laminates and prepreg are bought through channels other than direct from the primary manufacturer. That is not to say that all brokers and third party distributors are bad guys - most are diligent and conscientious traders - but they certainly don’t have the resources of an organisation like Ventec International Group, and many have only very basic quality management systems. And there are some rogues about - I could tell some real horror stories - counterfeit laminate is becoming a serious issue.

Q: Can you elaborate on the subject of “counterfeit laminate”?

A: Counterfeiting of electronic components is well-known and widely reported, and costs the U.S. government and its contractors billions of dollars each year, and the broader electronics industry hundreds of billions. If inferior components nd their way into critical systems they can cause product malfunctions and dangers to users and present huge levels of liability for manufacturers. “Counterfeiting” of laminate can present comparable risks and liabilities, and it’s more widespread than you might think. Laminate might be bought in good faith by a PCB fabricator, from a supplier with apparently satisfactory credentials, but turn out to be of dubious

origin although certi ed as branded material of rst quality. Or an unscrupulous PCB fabricator might knowingly purchase inferior material at low cost but certify the delivered PCBs with ctitious documentation.

Q: Can you give us examples of what you mean?

A: Yes, let me present two cases in point, both of which I know to be factual:

A European OEM ordered design-validation quantities of PCBs for an LED automotive lighting application from an accredited European fabricator on a designated IMS material. The PCBs were made to speci cation, delivered with certi cate of conformity and met all the design performance requirements. The OEM then ordered production quantities from a Far- Eastern supplier, to the same speci cation and on the same designated material as has been quali ed by the design-validation exercise. On receipt, the PCBs were accompanied by an apparently genuine certi cate of conformity. The LED lighting units were assembled and delivered to the automotive manufacturer, who installed them in vehicles. Their initial performance was satisfactory but they began to fail in service through thermal breakdown. The OEM asked the nominated laminate supplier if the speci ed grade of material he supplied to Far-Eastern customers had the same properties as that supplied to European customers, and the laminate supplier con rmed that the material was identical. So what went wrong?

On investigation, it turned out that the Far-Eastern PCB fabricator bought one panel of the material speci ed on OEM drawing, from the nominated, fully- accredited, laminate manufacturer, and was supplied with a genuine certi cate of conformity. This PCB fabricator then purchased production quantities of lower- price, lower-performance material from a non-accredited laminate manufacturer

and manufactured and delivered the OEM order, accompanied by a modi ed copy of the genuine certi cate of conformity. The consequences were that the PCB fabricator increased his pro t margin, the OEM was supplied with inferior and potentially unreliable PCBs, and the nominated and fully-accredited laminate manufacturer stood to lose his good name and reputation.

In my second example, a North American aerospace OEM asked the nominated manufacturer of a speci ed polyimide laminate to identify the supply-chain route to a North American fabricator supplying PCBs to the OEM. When it transpired that the PCB fabricator was buying through a third-party distributor, the OEM insisted that the laminate be purchased direct from the nominated manufacturer. Why? Whether as a result of historical bad experience, or just as a precaution, the OEM was concerned to avoid the potential consequences of counterfeit materials entering the supply chain for his safety- critical applications. And in this context the laminate manufacturer could not a ord to risk his good name and reputation by supplying through a distribution channel not under his direct control.

Q: Your rst example is just scary! Your second example demonstrates an encouraging level of awareness on the part of the OEM. Is this typical?

A: Unfortunately not. Supply-chain security is an area where we are working hard at OEM and CEM level to encourage them to recognise the risks that need to be managed all the way along the line. We can give them the con dence that we have addressed all of the risks related to delivered material quality. They need to have the right management procedures in place to ensure that what they receive is actually what they speci ed: a clean manufactured and fabricated product, delivered via a clean and controlled supply chain!

Page 40 The Choice of Publication for the Electronics Industry

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TDR - Putting their Customer-Focused

Approach into the Repair and Assembly Service

by smt today editor

Not having to deal with customer returns or repairs may sound like an unachievable ideal, but TeleDesign and Repair (TDR) is a company o ering a service that helps to extend the life of products in the telecom and industrial sectors.

a variety of industries to establish TDR, together with a core management team.

____________________________________

‘‘Tuomo Rekila has

built up the business

at an impressive rate

with the help of an

experienced and

knowledgeable team

____________________________________

“The starting point was an acquisition of a company where the history goes back over 20 years. The company needed to be re-focused to ensure its core business was concentrated on repair. Here I ensured that our attention was fully focused on the repair business; we grew the business organically from here. There have been many opportunities over the years to move away from the focus area of repair, but with strict discipline and hard work we have been able to establish the business signi cantly in this sector, the rest as they say is history.”

Combining Technology Know- How and Customer Care Puts TDR on the Map

From those early days, TDR has built up its customer base and pro le at an astonishing rate and has seen a growth of 40% year on year – an achievement many in the industry would be envious of. When asked the reason behind these impressive gures, the answer was simple – customer focus.

Yes, TDR is technically a highly skilled company, following technology development and changes very closely and keeping sta updated and trained in these advancements – a clear

TDR was started a little over four years ago in an e ort to provide outstanding and unrivalled dedicated repair, engineering and assembly solutions to a wide range of segments in the telecom and industrial markets. Since its beginning in 2011, founder and CEO, Tuomo Rekila has built up the business at an impressive rate with the help of an experienced and knowledgeable team.

With its headquarters in Tallinn, Estonia, and further o ces in Finland and Poland, TDR is leaving its mark across Europe and establishing itself as a leader in the eld.

Starting his career at Nokia Networks, where he worked for over 12 years, Tuomo began his journey on the ‘telecoms road’. This was followed by a number of years at Omron Europe in Holland setting up new business in the Radio Frequency Identi cation (RFID) and Automated Optical Inspection (AOI) sectors - a good grounding for the implementation of TDR and its principles.

Rekila comments: “Moving from telecoms to the industrial automation business gave me a real insight into both industries and has grounded my knowledge in two core markets, both of which TDR service today.”

Tuomo’s next move in his career was to Elektrobit, a Finnish design and automation company where he had responsibility for overseeing the sales and marketing in testing and automation parts. “Following my time at Elektrobit, I decided to spread my wings and moved to Holland to become Corporate Development Director at CoActive Technologies helping to create new business and implement key account management. From here I worked with Teleplan, a repair company, to establish the business further. It was after this that I felt I had the extensive business knowledge and essential ingredients in

Page 42 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

advantage. In addition, they also place signi cant emphasis on the customers’ requirements, combining technology know-how with understanding the speci c needs of each and every customer. ____________________________________

‘‘Moving from telecoms to the industrial automation business gave me

a real insight into

both industries and

has grounded my

knowledge in two

core markets

____________________________________

The company has extensive know-how and a proven track record of over 20 years’ experience in the telecommunication market and now serves more than 50 renowned customers all over the world. Those at TDR worked within the industry when the process of ‘repair’ was rst initiated in the early 90’s. Since then the team has honed its skills to provide a service which is not just for telecoms, it also includes the industrial sectors. It is not just new technologies that are concentrated on, older technologies are a focus. “It’s sometimes amazing how many old units are still being used and require repair. In testing development we

focus on new technologies, so we are well prepared to provide a service to both old and new, a string to our bow that we are very proud to play,” said Tuomo.

As more and more companies become aware of services like those in which TDR specialise, repair and assembly is now becoming essential to retain lean manufacturing. In the past,

companies felt that it was an obligation to organise aftersales services, like repair by themselves. Today it’s more or less a burden for them as they want to concentrate on their core functions, which are developing, manufacturing and selling new units. Outsourcing the after sales services is now a standard procedure for many.

Electronics business repair is playing a much bigger role today than many in the industry ever thought would happen. An example of this is that 5% of all manufactured units will fail and come back for repair. OEM’s and ODM’s want to concentrate on their core business, which is not repair and do not possess the expertise to perform repair work and if they do, to repair in-house is not always nancially wise. Having a dedicated process for just repair is a much more e cient method than trying to solve such issues on-site.

It’s Not all about Repair

Although telecoms is a core sector, and is the company’s legacy, the industrial area is a growing part of TDR where they work on repairing, upgrading and assembling electronics units and industrial automation units. Aside from this principle part of TDR, engineering services like reverse engineering, product comparisons and speci cation checks are also becoming a major part of the business.

Reverse Engineering involves examining ‘End of Life’ (EOL) products to see how it operates, then taking it apart to determine what components are used to make it work and how they are interconnected. This service is required more and more as EOL products need technical support from outsourced partners. Companies haven’t always got the time or resources to look after customers who own older technology. ____________________________________

with little or no additional knowledge about the procedures involved in its original production. In our case, reverse engineering is much more than just EOL services, it is a very highly skilled engineering process to nd out how, for example, black box units function. It also o ers di erent types of engineering services, like how to nd new units or components to serve customer requirements. This can include many di erent things for example price, technology or heat creation.

“TDR’s system is agile, fast and exible, using just a small degree of engineering resource, with the facilities to do the job well. The time scale for this process is normally 8-10 working days which no other company can deliver, making us very price competitive in the present market and, of course, adds an extra dimension to the company’s service.” Although centred in Estonia the customer-base of TDR is growing, and future expansion plans are on the drawing board, with TDR looking to dominate the industry in Europe with its customer focused values and industry expertise.

Outsourcing Repair and Assembly is the Future

With the market of repair and assembly becoming more and more common place, TDR has to stand out from their competitors. The key to TDR’s success lies in its drive to meet customer needs. With the bene t of outsourcing repairs it increases OEM and ODM’s customer satisfaction, because these industries can focus fully on new business creation and manufacturing. Tuomo adds; “By outsourcing repair these industries have improved aftersales services to their customers which, in turn, makes these OEM and ODM’s happy to work with us.”

TDR was founded because of the decline in good customer care service due mainly to the consolidation of OEMs and the fast evolution of cellular technology. This has resulted in a downturn in support and knowledge of old telecom products. TDR’s business aim was to save customers’ both time and money whilst, at the same time, supporting the environment through re-designing and repairing those products under ISO 9001 and ISO 14001 standard requirements. In summary, TDR provides a high yield, quality and ecologically friendly, low-cost repair operation, with the ability to meet special requirements. The lesson we have learnt here is that outsourcing repair and assembly is the future and one that bene ts OEM and ODM’s in a variety of ways. It is early days for TDR, but the future of the high-tech global company is looking promising.

‘‘

many opportunities

There have been

over the years to

move away from

the focus area of

repair, but with strict

discipline and hard

work we have been

able to establish the

business significantly

in this sector

____________________________________

Tuomo explains: “The purpose of reverse engineering is to reduce customers’ design decisions from EOL products,

Nikon Metrology –

the past, the present and

the future

by johan Wallentin, European Sales Manager for SMT Today

Johan Wallentin, European Sales Manager for SMT Today, visited Nikon Metrology in Tring, UK, where he learned how the company is moving forward to become a world leader in X-ray and Computed Tomography (CT) inspection systems from Nikon’s Product Marketing Manager Kamran Iqbal.

Modularity

Nikon machines are highly modular and made with the future in mind so that long-standing customers can upgrade their X-ray machines when new options or features are released into the market. They do not have to reinvest a large sum of money to keep their capabilities up-to-date with new technologies.

Nikon utilise Open Tube Technology in their X-ray systems, which comes with lifetime con dence and allows easy replacement of laments. This enables their customers to save money as they do not have to replace or service their X-ray tubes through a dedicated network of suppliers.

In addition, Kamran emphasized that their customer is always at the heart of any pioneering developments which helps to build relationships; a key factor in the company’s success and continued growth.

Software

Development of the software supplied with the machines is also a key feature of their impressive progress. For advanced electronics inspection routines, the software enables the end-user to automatically complete a BGA analysis and inspection. Timescales are signi cantly reduced which can then be spent on other items within the customer’s facility, for example production enhancement.

Customer focus

Nikon has also taken it upon themselves to develop a strategy whereby they o er turnkey solutions to their customers and the opportunity to visit their Centre of Excellence before they choose an X-ray supplier, a very successful addition for Nikon.

Furthermore, existing and potential customers are invited to bring samples to the cutting-edge demonstration application centre, where they can trial the equipment to see how it would bene t them. The company is so con dent in this process that they challenge customers to test at competitors facilities to see just how Nikon’s products would assist in their requirements.

After several decades in pioneering optical inspection systems, Nikon Metrology, as it is known today was formed in 2009 after the acquisition of Metris. As part of this, Nikon acquired the established and globally respected X-ray design facility which, for over two decades was known as X-Tek and is based at the Tring, Hertfordshire site, with global sites covering various operations.

Nikon, which is owned by the globally renowned Mitsubishi Group, has invested heavily in the company to expand its research and development as well as its manufacturing facilities. It o ers global support and a knowledge base at the UK facility. This division was established to advance the company’s innovative measuring and precision instruments and houses the development of the company’s range of product lines including X-ray and Computed Tomography (CT) inspection systems.

Electronics X-ray is built up from substantial expertise in X-ray measurements. The company has been able to showcase their knowledge in a diverse range of projects in this area over the years. For example, the examination of old artifacts including researching one of the oldest known computers, the Antikythera mechanism, where Nikon employed its advanced new X-ray imaging techniques, to working on

ndings from the Titanic and the bones of Richard III. Their technologically advanced equipment crosses to the broadest range of X-ray and CT solutions for precision electronics’ manufacturing applications ranging from miniature electronics to the advanced turbine blades of modern aircrafts.

Nikon Metrology employs over 100 people in the recently refurbished UK facility, which includes the latest in production, CRM tools and an extensive customer demonstration facility. It also accommodates the R&D, manufacturing, product specialists and application engineers.

In addition, the UK location houses their Centre of Excellence (CoE) for X-ray technology which enables the company to work with future technological and global research facilities such as universities, industry drivers and innovators. Exposure to which ensures that Nikon’s technological and global service o erings remain at the forefront of this eld.

With many years of innovative design and research, together with experienced and knowledgeable sta , Nikon Metrology is con dent that their X-ray machines are more advanced than any other products on the market for several reasons:

Open Tube Technology

Competition Comparison

Page 44 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

Nikon also uses the industry standard Line Pair Gauge resolution charts as the measurement tool when performing evaluation of their machines for their customers. This provides the customer with the opportunity to compare machines in a very neutral way and without any subjective view from other suppliers.

Nikon Products for the electronics industry

Nikon Metrology manufactures X-ray and Computed Tomography (CT) inspection systems that get the inside picture of complex industrial parts, by looking into the internal structure.

system and the XT V 160 NF Nanofocus X-ray inspection.

XT V 160 Electronics X-ray system is speci cally designed for X-ray inspection in various environments from research houses and production as well as failure analysis laboratories.

With a precision joystick control or on screen, system users control the fast and accurate 5-axis sample manipulator. Real-time X-ray allows them to intuitively navigate complex printed circuit boards and electronic components and quickly trace defects. In automated inspection mode, samples can be inspected at the highest throughput.

The key features of the system are:

• Leading proprietary micro-focus source technology

• Fast automated component inspection through customizable macros

• Intuitive joystick navigation driving real-time X-ray imaging

• C, Clear advanced real-time image processing engine

maintenance with technology

• Ready for CT

• Ready for advanced laminography – non destructive CT of large boards

The XT V 160 NF Nanofocus X-ray inspection is a high-precision, at- panel based X-ray inspection system that facilitates real-time imaging and defect analysis of next-generation wafer- level, semiconductor device and PCBA applications.

Equipped with an in-house designed X-ray NanoFocus source and ultra-high precision manipulator, this industry-leading inspection system o ers unrivalled feature recognition compared to any product available on the market today. As such, the XT V 160 NF is indispensable for any electronics development and production environment.

Some of the key features of the XT V 160 NF are listed below:

• <0.1 μm feature recognition up to 6 W power

• High precision manipulator with vibration reduction

• 3 Mpixel at panel for ultra high de nition

• Large tray to load multiple components and boards as well as 450 mm wafer ready

• Productivity increase by automation and instant reporting

Another initiative that is paving the way for future demand of adaptable high performance products is the recently released Inspect-X 4.2 software featuring

a user friendly graphical interface, where automation programs can be created without the need to code or program but use graphical icons to create a owchart. This requires less training and skill to automate inspection procedures, delivering a system that can react quickly and e ciently to changing product inspection requirements.

Combining C.Clear, provides next

The CT capability is used to qualify and quantify any inner or outer dimension in a smooth, non-destructive process. X-ray electronics inspection systems respond to a growing demand for exible, detailed and a ordable inspection to cope with the demands of ever-smaller electrical components and compliance with tighter quality standards.

____________________________________

open-tube

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confident that their

Nikon Metrology is

X-ray machines are

more advanced than

any other products

on the market

____________________________________

Nikon currently have several X-ray machines that are o ered to their customers for various applications. For the electronics industry Nikon has three products that are very suitable, the XT V 130C, the XT V 160 Electronics X-ray

• Low cost of ownership and

generation real time image enhancements, meaning that live inspection images are of the highest quality in terms of detail and clarity. C.Clear, is a key function for manufacturers looking for highest performance real-time inspection, enabling easier viewing of any defects present, as well as requiring less operator training, which would normally entail some post-process image enhancement and analysis.

Real-time enhancements and lters can be chosen and stored as user pro les. Defects are detected correctly rst time, especially hard to detect faults within multi-tier BGA or complex bond wires. C.Clear enables manufacturers to increase inspection throughput and to reduce false call rates, leading to improved quality and e ciency.

Technology drivers and future view

Nikon Metrology has several developments in the pipeline and one of these is the 3D stacking measurements technology. This technology enables the end-user to measure and view Microchip components on wafer-level that are manufactured as 3D Packaging technology. The reason for incorporating this is the miniaturization of electronics and the only way to be able to do a quality check is to use X-ray.

Nikon Metrology are continually developing and building the next generation systems of measuring and precision instruments and work on the principle of being a market- leader in its eld by providing innovative state-of-the-art products, underpinned by a complete after-sales service. Having visited the facility in Tring rst hand it is clear to see that this objective is not hearsay. It is happening and changing the industry for the better by meeting the technology demands of the future, as well as the production requirements of today.

Adding Technologies to Keep Customers Competitive: Interview with Eddy Lin, President & CEO, Scienscope

by smt today editor

Scienscope was founded in 1994 to meet the growing need for reliable and a ordable general- purpose optical and video inspection solutions for the electronics and PCB industries. The company began with basic stereo zoom microscopes used for SMT inspection and rework of circuit boards and electromechanical assemblies with a commitment to quality, value and support.

Over the past 20+ years, Scienscope has evolved to become a complete inspection solution provider, o ering both o ine and inline X-Ray systems, Video coordinate measurement systems, Video inspection systems, and microscopes to meet a wide variety of applications and manufacturing quality requirements. Scienscope can tackle tough manufacturing and quality challenges.

Our editors recently spoke with Scienscope’s President and CEO Eddy Lin to nd out how the company has changed since it rst opened its doors 20 years ago.

has carried over to our inline machines. An example of this is the X-Scope 8000 fully automated inline system, which can be seen on display at this year’s NEPCON China show. Another focus of ours is to o er a fully automated machine at a reasonable cost, while still maintaining high-end components that are easy to use.

Q. What prompted the addition of fully automatic inline X-ray inspection to the company’s repertoire?

A. As stated, the current demands of customers with state-of-the- art technology require 100 percent automated X-Ray inspection and we feel that this will be the trend of the future, so we will continue to expand on that.

Q. Eddy, last year you celebrated your 20-year anniversary. In today’s industry, that is no small feat! How has the company’s focus changed since 1994?

A. Scienscope has gone from a post- process solutions provider of visual inspection to more of a full integration solutions provider. We have evolved along with our customer needs, which go hand-in-hand with current technology, and future technology.

Q. Can you brie y describe your X-Scope machine platform? What makes these products stand out from competing X-ray products?

A. Our platform incorporates modern technology such as digital at panel detectors, state-of-the-art micro- focus, high-resolution X-Ray tubes, and exibility. What makes us stand out is our lowest cost of ownership based on simple to use GUI, combined with top-notch technology and, of course, support. The bottom line is that we provide inspection results for today’s common defects.

Q. What types of manufacturers would use the X-Scope line? Are the products available on a global basis?

A. Our main focus is on the electronics

industry but we also are providers to

many di erent technologies. All of our

products are available globally and we

are represented globally. Scienscope is

on the AVL for many of the world’s top Q. We’ve seen in the news that EMS companies.

____________________________________

Scienscope has been expanding its team to improve its North American reach. Is America a market region in which you are expanding?

A. Yes, our goal is to expand our market and become the market leader in automated X-Ray inspection (AXI). Recently, Todd O’Neil joined Scienscope. He brings with him more than 20 years of experience in capital equipment sales. We feel that his knowledge and background will help us achieve our goal.

Q. Where do you see the company in 20 years from now?

A. Our goal over the next 20 years is to continue to stay ahead of technology, including very high-speed AXI for 100 percent inspection.

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hand with current

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future technology.

____________________________________

Q. Today’s buzzword seems to be INLINE for X-Ray. Why is that and what is Scienscope doing to accommodate the market demand?

A. The world’s top manufacturers are moving towards 100 percent inspection. Scienscope is always working to develop cost-e ective X-Ray and that same model

Page 46 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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IEC/DRTL’s Commitment to Quality, Technology, Service and Trust Make the Company a Good Fit for the High-Reliability Sector

by smt today editor

IEC Electronics Corp. is a premier provider of electronics manufacturing services to advanced technology companies primarily in the military/aerospace, medical and industrial sectors. The company is headquartered in Newark, NY and also has operations in Rochester, NY, Albuquerque, NM and Bell Gardens, CA. IEC Electronics features a family of companies, including IEC Wire and Cable, IEC Albuquerque, Southern California Braiding, IEC Celmet and Dynamic Research and Testing Laboratories, LLC (DRTL). DRTL is an ISO 17025 and IPC Validation Services certi ed Test Laboratory specializing in failure analysis, destructive physical analysis (DPA) and component risk mitigation for the military, medical and industrial markets.

is a great bene t because it provides sectioning and layering capabilities similar to its CSAM, both of which create an excellent diagnostic combination.

IEC/DRTL will use the XD7600NT500 Ruby X-ray system for internal troubleshooting and failure analysis activities. Additionally, the system will be available to IEC customers in need of fast, accurate resolution of unique or “one-o ” problems. Head-in-pillow (HiP) defects, package-on-package (PoP) defects and micro-cracks, among other issues, will be addressed. ____________________________________

‘‘Since we have had

the Ruby, we have

never been down

due to equipment

failure. Also, all

our DTRL customers

have commented on

the new resolution

and image quality.

____________________________________

The implementation of the XD7600NT500 Ruby X-ray improves IEC/DRTL’s troubleshooting and failure analysis e orts. The X-Plane technology speeds up the detection of defects that previously were undetectable with conventional X-ray technology without damaging the board. Additionally, the X-Plane software enables users to obtain a non- destructive, virtual cross-section of the area of interest.

With the revolutionary X-Plane option, the superior image quality that Nordson DAGE X-ray systems always provide now can be extended into separating individual layers at a level of excellence that the traditional laminography technique cannot achieve. X-Plane uses a proprietary, patent applied

As a full-service EMS provider, IEC specializes in the custom manufacture of high-reliability, complex printed circuit boards (PCBs), full system integration, custom cable/wire harnesses and precision metal products. To be a successful contender in the high- reliability industry sectors they serve, the company must provide fail-safe electronic assemblies that are guaranteed to work as expected. By developing the testing services laboratory, DRTL, IEC was able to perform the speci c testing

and analysis required to detect and troubleshoot failures, giving its customers a solution for component risk mitigation.

As a result, the company needed more than just a typical inspection system. Its previous equipment could not perform to the necessary standards. IEC/DRTL needed a system that would provide easy operator learning, maximum uptime, resolution for 1 mil bond wires, the ability to measure, and 2D imaging for MIL-STD-1580 voiding requirements (such as MIL-STD-202, -750 and -981). After looking at numerous companies and technologies, the team purchased Nordson DAGE’s XD7600NT500 Ruby X-ray Inspection System with X-Plane.

IEC/DRTL has been working with Nordson DAGE since the beginning of 2015. When asked what needs the X-ray inspection system ful lls for the company, Mark Northrup, Vice President of Advanced Technical Operations and Strategy, simply responded, “All.” He added, “Since we have had the Ruby, we have never been down due to equipment failure. Also, all our DTRL customers have commented on the new resolution and image quality.”

Additionally, the Ruby o ers IEC/DRTL the bonus feature of X-plane for sectioning and layers. Northrup said this feature

Figure 1: The DRTL testing lab is part of IEC Electronics, which is an EMS provider. IEC/DRTL specialize in the military, medical and industrial markets.

Page 48 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

Figure 2: Rachel Garcia, DRTL Laboratory Manager, and Mark Northrup, IEC’s VP of Advanced Technical Operations and Strategy, in the DRTL Lab with the Nordson DAGE Ruby X-ray system.

for, tomosynthesis (or CT technique) to create 2-D X-ray slices in any plane of a PCB assembly without the need to cut or destroy the board.

While the relationship with Nordson DAGE is relatively new, IEC/DRTL plans to continue working with DAGE and anticipates purchasing the micro-CT upgrade in the future.

Some of the company’s distinctive capabilities include on-site analytical laboratories, real-time, automated data surveillance and component tracking systems, clean room manufacturing, and new product incubation centers comprised of custom-con gured, rapid prototyping equipment and dedicated design engineering support. IEC is ISO 9001:2008, AS9100C, ISO 13485 and ISO 14001 certi ed, FDA registered, Nadcap accredited and an NSA approved supplier under the COMSEC standard.

IEC also o ers a comprehensive range of manufacturing and engineering services, in addition to its lab:

● Manufacturing services: custom electronics, wire and cable, and precision metalworking

● Engineering services: electrical and mechanical design, custom test development, product lifecycle management

“We excel where quality and reliability are of paramount importance and when low- to medium-volume, high-mix production is the norm. We use state-of- the art, automated circuit board assembly equipment together with automated, high-reliability manufacturing stress testing methods,” said Northrup. “Our

customer-centric approach o ers a high degree of exibility while simultaneously complying with rigorous quality and on- time delivery standards. We have applied industry-leading Six Sigma and Lean Manufacturing principles to eliminate waste and reduce our customers’ total cost of ownership.”

IEC/DRTL’s emphasis on quality assurance consistently provides customers with outstanding product quality. It maintains this outstanding product quality through continuous improvement, employee training, customer involvement and state-of-the- art technology. Because IEC/DRT places such importance on providing quality and service, they expect nothing less from their partners, and Nordson DAGE delivers. Northrup said that the company has received excellent customer service from DAGE representatives that are experts in their areas, especially Vineeth

Bastin, Sr. Applications Engineer, and that John Travis and Joe Depeter provide strong sales support. DAGE prides itself on being truly accessible to its global base of customers as well as providing clear communications and being fast and exible enough to answer any customer questions or solve any potential system issues.

IEC/DRTL’s processes conform to the industry’s most rigorous standards as illustrated through its numerous certi cations, including IPC QML, IPC Certi ed Test Laboratory, ISO 9001:2008, AS9100C, ISO 13485, ISO 14001, FDA, ISO/IEC 17025, Nadcap, and ITAR. Additionally, IEC’s headquarters operation is an NSA-approved supplier under the COMSEC standard. Its embedded Lean Six Sigma processes have created a culture of continuous improvement.

While capabilities and specialized services like DRTL help place IEC Electronics at the top of its industry, the company knows that it must keep moving forward and investing in on-site training programs and facilities to ensure its customer’s products are built awlessly and work in the eld as intended. The emphasis on quality assurance is built in, Northrup added. “We measure, we monitor it, and we take actions to improve it.” Examples of training programs and facilities include:

● Sta ed IPC 600/610/620 and J-STD-001 certi ed trainers

● IPC 600/610/620/7711 and J-STD-001 certi ed operators at each site

● IPC Class 3 – Multiple facilities

● NASA-certi ed operators

● Six Sigma Black Belts & Master Black Belts

● Lean & 5S initiatives

● A seamless quality management system throughout

“All of our customers expect superior customer service. We emphasize quality in every aspect of our client relationships, delivering work that is absolutely, positively perfect and on-time,” concluded Northrup. Nordson DAGE feels the same way and is pleased that its XD7600NT500 Ruby X-ray Inspection System with X-Plane helps IEC/DRTL achieve this consistent, high-bar promise to its customers.

In the end, a successful partnership comes down to technology t, quality, customer service and trust. Northrup summed it up when he said, “We trust DAGE, just as our customers trust IEC/ DRTL.”

Figure 3: Nordson DAGE’s XD7600NT500 Ruby X-ray system helps IEC/DRTL perform optimally.

An Interview with G2’s John Gilby: Representing Industry Technology Leaders in Western Canada

by smt today editor

G2 was started in 2004 to meet the needs of the electronics manufacturing and technical services industry in the Western Canadian market. Based in Vancouver, BC, the company supports the requirements of the high-technology sector in the largest and most diverse geographic market area in the Americas. Its product lines focus on manufacturing and production processes but G2 also caters to the varied needs of electronic, electrical and industrial manufacturing and repair organizations.

Our editors recently spoke with John Gilby, G2’s founder and President, about how the company best represents technology leaders in the Western Canada marketplace.

changed since G2 was established in 2004?

A. Fundamentally, the qualities that make a good representative today remain the same as they were 100 years ago. Listen to your customers, market yourself and the companies you represent professionally, honestly and always follow up on the commitments you have made to your customers. As for changes, we have noticed since entering the industry in 2004, the main ones are that we are having to take on more lines and that we must travel further than before with fewer people. However, I do not think that is exclusive to our industry.

Q. As a leading representative corporation in the Western Canada marketplace, how do see your business growing?

A. Western Canada has always had a small but strong and stable manufacturing base. Some of our key customers have brought in equipment to manufacture in- house while others have chosen to bring their o shore business back to North America to our local CM market. I would attribute some business growth to this but the majority of our progress is done vertically within our existing customer base. As we continue to grow our line card, we will strive to continue o ering the most innovative turnkey production solutions possible to our valued customers.

Q. Have you had to change or refocus your strategies based on the current industry needs? How will you keep up with future demands?

A. Our core business strategy and goals do not change regularly, allowing us to remain stable for our customers and suppliers. However, our industry is constantly changing so we are always looking for new and improved product lines that we believe our customers need and may be underrepresented in this market. Examples of this can be seen in recent additions of wire processing, PCB stencils, and optical and video inspection systems. From a human resources standpoint, we will continue to add experienced industry professionals to our team that have both the relationships and technical ability to allow G2 to scale rapidly.

Q. Can you tell us a little about your company? Who is on your line card?

A. G2 Manufacturing Inc. is di erent from most traditional manufacturing representative companies in that we o er several avenues to market for our customers, which most other companies do not. We have a distribution segment for solder pastes, uxes, hand tools, soldering irons and ESD materials, as well as production equipment, wire processing and supplies including PCBs. We also bene t from having direct relationships with o shore manufacturing for custom applications with plastics, die casting and CNC metals.

Our line card is very well rounded and includes capital equipment from Juki, MEK, Cogiscan, Sciencscope and Schleuniger. We are the largest supplier of distribution products in Canada with lines such as Alpha Metals, Arlink, Lista, Metcal, 3M/Desco, Vision Engineering, Hakko and Fineline Stencils to name a few. The support lines we o er are quite extensive. For more details and for our full line card, visit our website at www.G2mfg.ca.

Q. What is G2’s company’s mission? How does this set you apart from other manufacturers’ representatives/ distributors?

A. Our mission is simple: “Supply the best products, supplies and service possible to our customers to allow them to manufacture world-class products.” G2 is a very service-oriented company, providing hands-on technical training, service and production assistance to our entire customer base. Having superior

equipment, products and educated customers also allows us to continue increasing market share year after year.

Q. What do you believe is the key to your success? What role does your past industry experience – as well as that of your team – play in G2’s success throughout Western Canada?

A. Customer service, product knowledge and support have always been the key to the success of our company. Our expertise in manufacturing, training, process engineering, mechanical engineering, purchasing, component and technical sales are all key contributors to our success.

Q. As a follow up to that question, in your opinion, what makes a good representative today? How has that

G2 Manufacturing won Juki’s Rep of the Year for best performance because the company knows how important service, value and quality are.

From left to right: Juki’s Carlos Eijansantos, Juki’s Bob Black and G2’s John Gilby

Page 50 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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red carpet

out & about in the industry

In this feature we follow our industry movers and shakers throughout the world. Time to take a bow...

FSInspection has appointed Kirby & Demarest as its manufacturers’ representative for the Paci c Northwestern United States. Kirby & Demarest will represent FSInspection’s complete line of industrial inspection solutions.

Photo: Steve Kirby and Alan Siebenthall of Kirby & Demarest

ZERO DEFECTS INTERNATIONAL Now Represents Ersa in Northern CA Photo: Michaela Brody, ZDI

Metcal today announced that it presented REStronics Metro, its manufacturers’ representative in the New York metro area, with its Representative Group of the Year Award for 2014.

Photo: Ed Zamborksy, Metcal’s RSM, with David Leventhal, REStronics Metro

Microtronic Strengthens Sales Network with the Addition of Kay Antorski Photo: Kay Antorski

Page 52 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

what’s happening in your business?

send your event pictures to red@smt today.com

Andy Mitchell to Head STI Electronics, Inc.’s Texas Training Initiative Photo: Andy Mitchell

Saline Lectronics Appoints Margaret Murdock as Director of Quality and Continuous Improvements

Photo: Margaret Murdock

Valtronic Raises the Bar on Customer Experience with the Hire of Debi Morris Photo: Debi Morris

Techcon Systems Promotes Bret Visciglia To RSM For The Midwest Photo: Bret Visciglia

Page 54 The Choice of Publication for the Electronics Industry

| JUNE 2015 ISSUE

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