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Semicon West 2003 SEMI Technology Symposium: International Electronics Manufacturing Technology Session 210: Factory Simulation, Automation and Integration SEMI and IEEE/CPMT  San Jose, CA July 18 th , 2003.

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Semicon West 2003

SEMI Technology Symposium: International Electronics Manufacturing Technology

Session 210: Factory Simulation, Automation and Integration

SEMI and IEEE/CPMT San Jose, CA

July 18th, 2003

Towards Next-Generation Design-for-Manufacturability Frameworks for Electronics Product RealizationPhase 1: Rule-based Manufacturability Verification of Circuit Board Designs

Recipient of the “Best Paper Award” in Session 210, IEMT, Semicon West 2003

Manas Bajaj, Dr. Russell Peak, Miyako Wilson, Injoong Kim

Thomas Thurman, M.C.Jothishankar, Mike Benda

Dr. Placid Ferreira, Dr. James Stori

Updated web version:http://www.eislab.gatech.edu/pubs/conferences/2003-ieee-iemt-bajaj/


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


Simulation for flexible manufacturing sfm project vision l.jpg

System Engineer

Package Data Supplier

Analysis Model Supplier

EE/ME Product Designer

Assembly Vendor

PDM / Library

Device Supplier

Known Good Data

Fabrication Vendor

Simulation for Flexible Manufacturing (SFM)Project Vision

  • Enable a collaborative environment for engineers (design, manufacturing, producibility, test etc.) to work together and negotiate for a robust product model


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Simulation for Flexible Manufacturing (SFM)Project Timeline Teams

  • Teams

    • Rockwell Collins (RCI)

      • Thomas Thurman, M.C.Jothishankar, Mike Benda

    • Georgia Tech (GIT)

      • Dr. Russell Peak, Manas Bajaj, Miyako Wilson, Injoong Kim

    • University of Illinois at Urbana Champaign (UIUC)

      • Dr. Placid Ferreria, Dr. James Stori, Dong Tang, Deepkishore Mukhopadhyay

  • SFM Project Timeline

    • Initiated in August 2002

    • Completed Phase 1.1 in December 2002

    • Completed Phase 1.2 in April 2003

    • Developed Framework used for production at RCI in May 2003


Simulation for flexible manufacturing sfm project phase 1 l.jpg
Simulation for Flexible Manufacturing (SFM)Project Phase 1

  • Develop a DFM Framework

    • Enable designers, manufacturers, assembly and test engineers to work collaboratively

  • Domain of Interest

    • Printed Circuit Assembly design process

  • Motto of the DFM Framework

    • Develop a generic and modular architecture

    • Core components customizable for specific enterprises


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


Motivation for building a dfm framework simulation based design general overview l.jpg
Motivation for building a DFM frameworkSimulation-based Design General Overview

  • “Systems Approach” to product realization -- organizing the “smorgasbord”

    • Capturing mutual interaction amongst design, manufacturing, assembly, testing, packaging etc. related activities

    • Building product and associated process models

    • Creating smart configurations – adaptable to changing technology and business needs

  • Reduce cycle time and possibilities of redesign

    • Capturing activity specific knowledge and utilize it for enhancing related activities and tasks

    • Learning from today’s experience to improve performance tomorrow – Intelligent Systems


Motivation for building a dfm framework simulating process emulating knowledge l.jpg

Doc/Proc/Reg

Guidelines

Layout

Requirements

Design

Part Symbol

& Footprint

Functional

Learn today

Utilize tomorrow

Placement

Routing

Review

Corrections

Release

Environmental

Build

Fabricate

Assemble

Test/Inspect

Motivation for building a DFM frameworkSimulating Process Emulating Knowledge

  • Simulate Printed Circuit Design process

  • Emulate expertise of manufacturers, test and producibility engineers for robust designs


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


Core ingredients of a dfm framework 1 electronics product design model l.jpg
Core Ingredients of a DFM Framework1. Electronics Product Design Model

  • Need of an Integrated Design Model

    • Ability to support different dimensions of product design

      • Functional Model

      • Part - Assembly Structure

      • Configuration Management

      • Requirements Specification

    • Formal data specification for higher fidelity across engineering domains

    • Semantically rich in content and coverage – ability to expand to the ever rising complication in product and process data structure


Core ingredients of a dfm framework challenges towards an integrated design model l.jpg
Core Ingredients of a DFM FrameworkChallenges towards an Integrated Design Model

Existing Tools

Tool A1

Tool An

...

Legend

Content

Coverage Gaps

“dumb” information capture

(only human-sensible,

I.e., not computer-sensible)

Example “dumb” figures

  • Smart Product Model

  • Building Blocks

  • Models & meta-models

    • International standards

    • Industry specs

    • Corporate standards

    • Local customizations

  • Modeling technologies:

    • Express, UML, XML, COBs, …

Content

Semantic Gaps


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Core Ingredients of a DFM Framework2. Manufacturing Expertise

  • Need to capture the expertise of manufacturers

    • To be able to gather manufacturing knowledge

    • To be able to represent this genre of knowledge

    • To be able to use these knowledge sets to guide design decisions

    • To be able to share this knowledge across enterprise specific manufacturing facilities


Core ingredients of a dfm framework challenges towards capturing manufacturing knowledge l.jpg

1

Manufacturability

  • >10

  • <9

  • “strong”

high

low

Core Ingredients of a DFM FrameworkChallenges towards capturing manufacturing knowledge

  • Design Parameters

  • geometrical dimensions

    • -- gd_1

    • -- gd_2

    • -- ….

  • material properties

    • -- mp_1

    • -- mp_2

    • -- …

  • ……

  • Fuzzy nature of manufacturability knowledge

2

  • “weak”

  • >”tensile”

  • > 10 MPa

Manufacturability

Knowledge


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


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Functional Foundation of DFM Framework1. Answering integrated design model challenge

  • Use of STEP AP210 standard specifications to build the semantically richer and higher fidelity integrated design model


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Interconnect

Assembly

Printed Circuit Assemblies

(PCAs/PWAs)

Product Enclosure

Die/Chip

Packaged Part

Printed Circuit

Substrate (PCBs/PWBs)

Die/Chip

Package

External Interfaces

STEP AP 210 (ISO 10303-210) Domain: Electronics Design(ap210.org)

~800 standardized concepts (many applicable to other domains)

Development investment: O(100 man-years) over ~10 years


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Functional Foundation of DFM Framework2. Answering knowledge capture challenge

  • Use of Expert Systems Technology

    • Expert Systems are computer programs to emulate human expertise and take decisions to the best of current knowledge.

    • Used for problems / scenarios that are complex (abstract, deeply branched decision tree etc.) enough to require human expertise.

    • Facility to add knowledge

    • Explanation facility to track the chain of logic – serves as a conformance test


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Core Advantages of Expert Systems

  • Separation of knowledge from control

    • Better foundational architecture

    • Ease of maintenance

    • Ability to add new knowledge and refine functionality

  • Ability to handle abstraction

    • Support decision making in the design process in the absence of knowledge – to the best use of as-available information

  • Trace the tree of design decisions

    • Ability to track the logical steps in process

    • Serves as an explanation facility

    • Used for conformance testing


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


Conceptualizing the dfm architecture fundamental framework pulling it all together l.jpg

Auxiliary design information

ECAD tool

STEP AP210design model i

Design view ij

Design Manufacturability Report ij

Enterprise Database

Manufacturability Knowledge-base

Conceptualizing the DFM ArchitectureFundamental Framework: “Pulling it all together”

End User View

Manufacturability Feedback ijof a given design i

Design Integrator

Results Manager

Design View j Generator

Rule-based Expert System


Building the sdf sfm dfm framework l.jpg

Auxiliary Product Information

ECAD tool

PCA parts library database

Step - 1

Step - 2

Step - 3

Step - 4

ECAD tool (Zuken, Mentor etc.)

RCI

RCI

SFM Design Integrator

AP210 part 21 file

LKSoft

Design view

SFM Design View Generator

GIT

STEP AP-210

Kappa design

SFM Rule based Expert System

DFM violation results

End user view

SFM Results Viewer

Boeing + GIT

UIUC

Building the SDF (SFM DFM Framework)


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


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SDF Rule-based Expert SystemRule authoring tool Rule checking tool

DFM document j (human sensible)

Rule Description Facility (RDF)

rules in RDF (computer sensible)

Design View ij

Manufacturability Knowledge Base j

Rule Execution Facility (REF)

Results ij


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SDF Results ManagerViewing DFM violations in the Results Browser

Results Log

(from SFM Rule-based Expert System)

Results Viewer

(highlighted features

have DFM violations)


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


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Future Architecture Standards-based Framework

Computer Integrated

Manufacturing

Product Definition Dataset

Fit-Check

Machine

Simulator

Rules

Repository

Rules

Engine

AP 210

LKSoft

AP 210

3D Viewer

Exceptions

ECAD

Design

Visula

Package

Library

CIM

Package

Library

Simulation for

Flexible Manufacturing

Converter

AP 203

AP 203

3D Viewer

CAM

Application

MCAD

Part

Design

MCAD

Assembly

Design

PDF

2D Viewer

Inspection

Application


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Future ArchitectureExpanding the scope of the current architecture

  • Enhancing the scope of the DFM Framework to a generic DFX Framework

    • DFX: Design for X

      • where X: Manufacturing, Testing, Assembly etc.

  • Expanding the downstream application of the 210 design model

    • Rule-based Manufacturability analysis

    • Finite Element based PWB Warpage analysis

    • Engineering economy based analysis (Design-to-Cost)


Contents29 l.jpg
Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


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Conclusion

  • Achievements of the SDF: SFM DFM Framework

    • Demonstrated the ability to build an integrated design model to support manufacturability constraint check

    • Use of STEP AP210 standard

      • to support product life cycle related tasks

      • foundation for building semantically richer and higher fidelity product models

    • Demonstrated the ability to capture and utilize manufacturing expertise

    • Integrating core functionalities for developing a collaborative environment for designers and manufacturers


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?


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Acknowledgements

  • Rockwell Collins

    • Kevin Fischer, Floyd Fischer, Wayne Foss, Dick Postma, Jennifer Waskow, Ian Wicke, Jim Lorenz, Jack Harris

  • LKSoft (lksoft.com & intercax.com)

    • Lothar Klein, Viktoras Kovaliovas, Giedrius Liutkus, Kasparas Rudokas

  • PDES Inc. Electromechanical Team (pdesinc.aticorp.org)

    • Greg Smith (Boeing), Mike Keenan (Boeing), Craig Lanning (Northrop Grumman)

  • Arizona State University

    • Prof. Teresa Wu

  • Georgia Tech

    • Prof. Robert Fulton, Prof. Nelson Baker


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Contents

  • Introduction -- Simulation for Flexible Manufacturing

  • Design-for-Manufacturability (DFM) Framework

    • Motivation

    • Core Ingredients

    • Functional Foundation

    • Building the SDF (SFM DFM Framework)

    • Future Architecture

  • Conclusion

  • Acknowledgements

  • Questions?



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