PCB Manufacturability Design
What is manufacturability design
Manufacturability -- also known by all parties as concurrent or simultaneous engineering or design for productivity or assembly of production lines -- is comparable to having R&D engineers build their own prototypes and then produce workers without a front line. The traditional manufacturing method of sending it to the production department to assemble on-line has great advantages. On the other hand, members of a manufacturing team include designers, manufacturing engineers: marketing representatives, financial managers, R&D personnel, raw material suppliers and other planning stakeholders (including customers). Because it includes people from all walks of life, it also helps to accelerate the completion of the plan and avoid delays encountered by traditional production methods.
It mainly studies the relationship between the physical characteristics of the product itself and the parts of the manufacturing system, and applies it to product design, so as to integrate the whole manufacturing system and optimize it, so as to reduce costs, shorten production time, and improve product manufacturability and work efficiency. Its core is to participate in the whole design process from preliminary product planning to product production without affecting the function of the product, so as to standardize and simplify the design, and make the design beneficial to production and use. Reduce the manufacturing cost of the whole product (especially components and processing technology). Reducing process flow, choosing high throughput process, standard components, choosing to reduce the complexity and cost of dies and tools.
Process method of manufacturability design
In introducing manufacturability design, we should first recognize its necessity, especially the leaders of production and design departments should be more convinced of the necessity of DFM. Only in this way, designers can consider not only the function to achieve this primary goal, but also the production and manufacturing aspects. That is to say, no matter how perfect and advanced the function of the product you design is, it can not be manufactured smoothly or it will cost a lot of manufacturing costs to produce, which will cause the cost of the product to rise, the difficulty of sales and the loss of the market.
Secondly, unifies the information before the design department and the production department, and establishes an effective communication mechanism. In this way, designers can consider the production process while designing, so that their own design is conducive to production and manufacturing.
Thirdly, people with rich production experience are selected to participate in the design, test and evaluate the manufacturability of the design results, and assist designers in their work. Finally, arrange reasonable time for designers and DFM engineers to go to the first line of production to understand the production process and equipment and the problems in production. In order to better and more systematically improve their own design.
1. Seeking and establishing the company's DFM series normative documents: DFM documents should be reasonably formulated according to the company's production design characteristics, process level, equipment hardware capabilities, product characteristics, etc. In this way, in the design process, the selection of assembly technology should take into account the current and future factory production capacity. These documents can be very simple terms, and then a complex and comprehensive design manual. In addition, the documents must be maintained timely according to the company's production development, so that they can more accurately meet the current design and production needs.
2. While planning the product design, the DFM checklist is established according to the company's DFM specification documents. Checklist is a tool for analyzing product design systematically and comprehensively. It should include checking items and handling of key links. In terms of content, it mainly contains the following information:
A. Product information and data (e.g. circuit schematic diagram, PCB diagram, assembly diagram, CAD structure file, etc.)
B. Choose the roughly manufacturing process: AI, SMT, wave soldering, hand welding, etc.
C. PCB size and layout.
D. Selection of components and design of pads and through holes.
E. The design of process edge, positioning hole and reference point is suitable for production.
F. Implement the requirements of mechanical assembly.
3. Make DFM report: DFM report reflects the problems found in the whole design process. This is similar to the audit report in ISO 9001. It mainly draws up the unqualified items in the design according to the DFM specification documents and checklist. Its content must be intuitive and clear, and the reasons for non-conformity should be listed, or even the requirements for corrective results can be given. Its report is timely and runs through the whole design process.
4. DFM Testing: The results of DFM design will have a great impact on production assembly and what role it plays. This is verified by DFM testing. DFM testing is designed by a design tester using a production process similar to the company's production model to build design samples, which may sometimes require the help of the producer. Testing must be rapid and accurate and make test reports, so that the designer can immediately correct any problems tested and speed up the design cycle.
5. DFM analysis and evaluation: This process is equivalent to summary review. On the one hand, it evaluates the reliability of DFM in product design, on the other hand, it can simulate and compare the manufacturing of non-DFM design with that of DFM design. From the analysis of production quality, efficiency and cost, it is concluded that the cost savings of DFM can play a reference role in the formulation of annual production objectives and capital budget. On the other hand, it can also enhance the Leaders'determination to implement DFM.
Significance of Manufacturability Design
1. Reduce costs and improve product competitiveness.
Low cost and high output are the eternal goal of all companies. By implementing the DFM specification, we can effectively utilize the company's resources and produce products with low cost, high quality and high efficiency. If the product design does not conform to the company's production characteristics, the manufacturability is poor, that is to say, more manpower, material and financial resources will be spent to achieve the goal. At the same time, we have to pay a heavy price for delaying delivery, or even losing the market.
2. It is conducive to standardization, automation of production process and improvement of production efficiency.
DFM organically links the design department with the production department to achieve the goal of information mutual transmission and coordinate the design, development and production preparation. Unified standards, easy to achieve automation, improve production efficiency. At the same time, it can realize the standardization of production test equipment and reduce the repeated investment of production test equipment.
3. It is conducive to technology transfer, simplify product transfer process, and strengthen cooperation and communication between companies.
Now many enterprises are limited by the scale of production, a lot of work needs to be processed outside. By implementing DFM, manufacturing technology between processing units and processing units can be transferred smoothly and production can be organized quickly. The universality of manufacturability design can enable enterprises to achieve global production of products.
4. The basis of new product development and testing.
Without proper DFM specification to control product design, assembly problems of one kind or another are found in the later stage of product development, even in the stage of mass production. At this time, if we want to amend them through design changes, it will undoubtedly increase development costs and prolong product production cycle. Therefore, besides focusing on function first, DFM is also very important in new product development.
5. The challenges of new technologies suitable for electronic assembly are becoming more and more complex.
Nowadays, the development of new electronic assembly technology is becoming more and more complex. In order to seize the market and reduce costs, the company must use the latest and fastest assembly technology to develop. Only by standardizing DFM, can it keep pace with its development.
