Experience of procurement of PCBAs for Readout Units

Experience of procurement of PCBAs for Readout Units Gianluca. Aglieri. Rinella@cern. ch EP-ESE-FE

Outline 1. The ALICE Inner Tracking System Readout Unit Board 2. Mass production of the Readout Unit, selected experience from the procurement process 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 3

ALICE Inner Tracker Readout Unit The Board to be Produced Production volume: ~350 units Main features 1156 -pin Xilinx Ultrascale FPGAs 484 -pin Pro. Asic FPGA 3 optical transceivers, 3 GBTx chips 5 Gb/s signaling 28 Input links 1. 2 Gb/s Multiple mezzanine boards Congested front-side PCB 233 mm * 220 mm 10 layers 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 4

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Brochure Block Diagram 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 6

True Block Diagram 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 7

Prototyping and Production Prototypes RUv 0 RUv 1. 1 (10 units, no GBTx on board, SEU studies, lab developments) (8 units, 233 mm*160 mm all features) (13 units, 233 mm*160 mm, fixes and improvements) Production Readiness Review April 2018 Based on RUv 1. 0 and RUv 1. 1 Board for mass production RUv 2. 0 Essentially RUv 1. 1 with larger form factor: 233 mm*220 mm Gerber files ready end of April 2018 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 8

Timeline 2018 April 13 PRR May June July 20 Documents Preparation Feb Batch 1 manufacturing 16/10/2018 Sept 3 Oct Nov Dec 14 Proto Building RUv 2 Design 2019 Jan Aug Mar Apr Pre-series manufacturing Price Enquire May June Batch 2 manufacturing gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 9

By Algotruneman [CC 0], from Wikimedia Commons 16/10/2018 Step 0: the Technical Officer (TO = you) shall be a best friend of the Procurement Officer (PO) gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 10

Tender Form (written by Proc. Officer) Technical Specification Annex 1: PCB and PCBA Tech Spec 16/10/2018 Annex 2: Technical Questionnaire gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 11

Technical Documents Writing HOWTO 1. Ask colleagues for previous experience 2. Discover the template on procurement webpage 3. Read a good dozen of IPC standards to understand the template 4. Re-write a good part of the template for your needs, merge the experience of your compassionate colleagues Hint: Put in a Technical Annex all PCB and PCBA technical requirements. Separate the requirements on the manufacturing and contract execution processes (how) from the pure technical specification of the product (what) 5. Write a technical questionnaire for the bidders This can actually be very useful 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 12

With compliments from Eric Van Der Bij 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 13

Technical Specification 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 14

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Eligibility Criteria are the handle to specify the desired characteristics and competence of the supplier Very important section. I would try to expand improve this next time Certifications Capabilities Comparable previous contracts and references The only objective criteria that can be used to select companies 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 16

Deliverables 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 17

Activities 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 18

IPC Standards and key criteria 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 19

PCB Technical Annex (spec sheet) 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 20

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Technical Specification + Annex + Questionnaire Ready !! You have them approved by the project leader You happily send them to PO expecting the Price Enquiry is published the very same day … But at this point you are told that all must be checked and approved line by Procurement Hierarchy and Safety Team … Takes few or more days. Expect corrections and requests of changes! Develop huge skills of nerve control … 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 22

Price Enquire Ongoing !! The companies A short list of companies to initially invite is prepared by TO and PO The PO needs to balance countries. The TO might have already worked with reliable providers in previous projects or for the prototyping The ILOs (Industrial Liaison Officers) will ask to invite many more companies You need to check and approve one after one Question and Answers Companies ask for clarifications CERN (the TO, i. e. you) provides a public written answer to all bidders Some companies ask intriguing questions I. E. showing they do not read the technical specifications or do not know the standards themselves. Good to know who you do not want to work with. Some companies decline the invitation (even complaining) 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 23

Opening the bids The range of prices can be big Almost factor 2 between min and max offers!! The PE is useful Best three offers all lower than initial budget Best offer also technically complete and sound Order placed rather quickly If the best offer is Technically Compliant to specification, there are no discussions 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 24

Some Lessons Learned It takes a lot of time Plan well in advance the whole study, prototyping, design, construction phases Design early (already when prototyping) with mass production as requirement. Can easily end up with different manufacturers between prototype and mass production Study and use IPC standards Provide language, knowledge, quality criteria Get them from CERN Library. Use them in managing the whole electronic project, design, layout, procurement, manufacturing Selection of companies Can be done most effectively through certifications of the company and of their personnel Pre-technical objective criteria Careful with impact on price, tradeoff cost vs risk Use extensively the Technical Annexes and Technical Questionnaire Ask the how, in addition to what. E. g. ask to detail how a certain required quality is going to be achieved In addition to the prescriptions of IPC standards, ask for specific processes and methods and ask to describe the equipment (e. g. Solder Paste Inspection, AOI, Xray inspection, …) 16/10/2018 gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 25

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Design Assembly 16/10/2018 PCB Quality Check gianluca. aglieri. rinella@cern. ch EP-ESE-FE Section Meeting 29