Semicon West 2003 SEMI Technology Symposium International Electronics

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 Recipient of the “Best Paper Award” in Session 210, IEMT, Semicon West 2003 Towards Next-Generation Design-for-Manufacturability Frameworks for Electronics Product Realization Phase 1: Rule-based Manufacturability Verification of Circuit Board Designs 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/ Manas Bajaj, Georgia Tech - Slide 1

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? Manas Bajaj, Georgia Tech - Slide 2

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? Manas Bajaj, Georgia Tech - Slide 3

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 System Engineer Package Data Supplier Analysis Model Supplier EE/ME Product Designer PDM / Library Device Supplier Assembly Vendor Known Good Data Fabrication Vendor Manas Bajaj, Georgia Tech - Slide 4

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 Manas Bajaj, Georgia Tech - Slide 5

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 Manas Bajaj, Georgia Tech - Slide 6

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? Manas Bajaj, Georgia Tech - Slide 7

Motivation for building a DFM framework Simulation-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 Manas Bajaj, Georgia Tech - Slide 8

Motivation for building a DFM framework Simulating Process Emulating Knowledge Doc/Proc/Reg Guidelines Layout Functional Part Symbol & Footprint Placement Design Requirements • Simulate Printed Circuit Design process • Emulate expertise of manufacturers, test and producibility engineers for robust designs Routing Learn today Utilize tomorrow Review Corrections Release Environmental Build Fabricate Assemble Test/Inspect Manas Bajaj, Georgia Tech - Slide 9

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? Manas Bajaj, Georgia Tech - Slide 10

Core Ingredients of a DFM Framework 1. 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 Manas Bajaj, Georgia Tech - Slide 11

Core Ingredients of a DFM Framework Challenges towards an Integrated Design Model Existing Tools Tool A 1 Legend “dumb” information capture (only human-sensible, I. e. , not computer-sensible) Example “dumb” figures . . . Tool An Content Coverage Gaps Smart Product Model Building Blocks Content • Models & meta-models Semantic Gaps • International standards • Industry specs • Corporate standards • Local customizations • Modeling technologies: • Express, UML, XML, COBs, … Manas Bajaj, Georgia Tech - Slide 12

Core Ingredients of a DFM Framework 2. 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 Manas Bajaj, Georgia Tech - Slide 13

Core Ingredients of a DFM Framework Challenges towards capturing manufacturing knowledge • Fuzzy nature of manufacturability knowledge Design Parameters • geometrical dimensions -- gd_1 -- gd_2 -- …. • material properties Manufacturability 1 • >10 • <9 • “strong” 2 -- mp_1 • “weak” -- mp_2 • >”tensile” -- … • > 10 MPa high low • …… Manufacturability Knowledge Manas Bajaj, Georgia Tech - Slide 14

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? Manas Bajaj, Georgia Tech - Slide 15

Functional Foundation of DFM Framework 1. Answering integrated design model challenge • Use of STEP AP 210 standard specifications to build the semantically richer and higher fidelity integrated design model Manas Bajaj, Georgia Tech - Slide 16

STEP AP 210 (ISO 10303 -210) Domain: Electronics Design (ap 210. org) ~800 standardized concepts (many applicable to other domains) Development investment: O(100 man-years) over ~10 years Interconnect Assembly Printed Circuit Assemblies (PCAs/PWAs) Product Enclosure Die/Chip Packaged Part Printed Circuit Substrate (PCBs/PWBs) Die/Chip Package External Interfaces Manas Bajaj, Georgia Tech - Slide 17

Functional Foundation of DFM Framework 2. 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 Manas Bajaj, Georgia Tech - Slide 18

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 Manas Bajaj, Georgia Tech - Slide 19

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? Manas Bajaj, Georgia Tech - Slide 20

Conceptualizing the DFM Architecture Fundamental Framework: “Pulling it all together” End User View Auxiliary design information Enterprise Database ECAD tool Manufacturability Feedback ij of a given design i Design Integrator Results Manager Design View j Generator STEP AP 210 design model i Design view ij Manufacturability Knowledge-base Rule-based Expert System Design Manufacturability Report ij Manas Bajaj, Georgia Tech - Slide 21

Building the SDF (SFM DFM Framework) ECAD tool Step - 1 Auxiliary Product Information Step - 2 PCA parts library database Step - 3 ECAD tool (Zuken, Mentor etc. ) Step - 4 RCI SFM Design Integrator LKSoft Design view SFM Design View Generator AP 210 part 21 file GIT Kappa design STEP AP-210 End user view SFM Results Viewer UIUC DFM violation results SFM Rule based Expert System Boeing + GIT Manas Bajaj, Georgia Tech - Slide 22

Integrated Design Model: STEP AP 210 Example view in STEP Book – AP 210 Browser (LKSoft) Manas Bajaj, Georgia Tech - Slide 23

SDF Rule-based Expert System Rule authoring tool DFM document j (human sensible) Rule checking tool Rule Description Facility (RDF) rules in RDF (computer sensible) Design View ij Manufacturability Knowledge Base j Rule Execution Facility (REF) Results ij Manas Bajaj, Georgia Tech - Slide 24

SDF Results Manager Viewing DFM violations in the Results Browser Results Log (from SFM Rule-based Expert System) Results Viewer (highlighted features have DFM violations) Manas Bajaj, Georgia Tech - Slide 25

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? Manas Bajaj, Georgia Tech - Slide 26

Future Architecture Standards-based Framework LKSoft AP 210 3 D Viewer ECAD Design Exceptions Rules Engine Rules Repository Simulation for Flexible Manufacturing Machine Simulator Visula Package Library CIM Package Library Computer Integrated Manufacturing Converter AP 203 Product Definition Dataset Fit-Check MCAD Assembly Design MCAD Part Design AP 203 3 D Viewer PDF 2 D Viewer CAM Application Inspection Application Manas Bajaj, Georgia Tech - Slide 27

Future Architecture Expanding 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) Manas Bajaj, Georgia Tech - Slide 28

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? Manas Bajaj, Georgia Tech - Slide 29

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 AP 210 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 Manas Bajaj, Georgia Tech - Slide 30

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? Manas Bajaj, Georgia Tech - Slide 31

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 Manas Bajaj, Georgia Tech - Slide 32

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? Manas Bajaj, Georgia Tech - Slide 33

Questions? Manas Bajaj, Georgia Tech - Slide 34