Automating the In-Circuit Test in Your Factory

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Edwin Montgomery
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1 Automating the In-Circuit Test in Your Factory Measurement Test Division Keysight Technologies July 23, 2015

2 Agenda Page 2 Overview of Inline ICT automation - Introduction to Keysight & In Circuit Test - Test automation and ICT automation - Keysight engagements in ICT automation Considerations that impact the decision to automate in-circuit test - Products - is your product suitable for automation? - Manufacturing and test processes - Organization - who will be involved? Benefits of automation - Improved product quality - Lower costs - Other automation considerations

A Brief History of Keysight 1939 1998: Hewlett-Packard years A company founded on electronic measurement innovation 1999

In September 2013, it announced the spinoff of its electronic measurement business 2014: Keysight begins operations November

and Dave Packard s original vision launched Silicon Valley and shaped our passion for firsts 75 years ago.

3 A Brief History of Keysight : Hewlett-Packard years A company founded on electronic measurement innovation : Agilent Technologies years Spun off from HP, Agilent became the World s Premier Measurement Company. In September 2013, it announced the spinoff of its electronic measurement business 2014: Keysight begins operations November 1, Keysight is an independent company focused 100% on the electronic measurement industry We believe in Firsts Bill Hewlett and Dave Packard s original vision launched Silicon Valley and shaped our passion for firsts 75 years ago. Today we are committed to provide a new generation of firsts software-oriented solutions that create value for our investors and valued insights for our customers. Page 3

4 Keysight in Electronic Measurement The industry leader Communications Industrial, computer, semiconductor Aerospace/defense FY13 $2.9 billion revenue 18.9% operating margin 31% ROIC best in class financial profile (1) Presented on a non-gaap basis; reconciliations to closet GAAP equivalent provided. See reconciliations for definition of ROIC. Page 4

researchers including multiple IEEE Fellows creating new measurement IP to address emerging customer needs ASIC design

5 Keysight Technologies Measurement Research Instrumental to our customers success in a rapidly changing world World-class applied research driving tomorrow s innovations Ph.D. researchers including multiple IEEE Fellows creating new measurement IP to address emerging customer needs ASIC design center and proprietary fabrication facility Technology centers for MMICs, optical components, and microelectronic packaging Aligned to product divisions to accelerate customer solutions Page 5

6 Consistent ICT Market Leader * SII S i3070 #1 Market Share * with 7000 systems deployed globally Pioneer in maintaining high test coverage with limited access Key OEM, CEM, ODM customers globally $70K ~ $400K range of products to suit all needs and budgets 2009 i3070 Series i1000D 2012 i3070 HNC 2013 i3070 E9901EL i1000 Inline 2013/4 i3070 S5i Continuous product evolution & upgradability for greater ROIC. * Market Leader as per Prime Research Page 6

7 Keysight Automation History 1970s 1980s 1990s 2000s 2010s HP 3060 HP 3065 HP EFS- Express Fixturing System inline 3070 JOT Handler 3070 inline i1000 inline Partnership with major inline automation companies such as JOT, IPTE, CRS, etc. > 1100 automated ict systems (including robotic arms) Page 7

8 In-Circuit Automation Configurations Page 8 Externally Integrated Handlers Automation with Robots Fully Integrated handlers

External Integrated Handlers ICT External integrated handlers can be categorized in two groups: Bridge type handlers Go across the system with a long

19 inch handlers Functional + ICT Customized fixture interface and solution These handlers are using motorized or pneumatic press.

9 External Integrated Handlers ICT External integrated handlers can be categorized in two groups: Bridge type handlers Go across the system with a long board travel distance In-feed needed to reduce handling time. 19 inch handlers Functional + ICT Customized fixture interface and solution These handlers are using motorized or pneumatic press. Vacuum based fixtures need modification Pros Flexible configuration and customization to needs Potentially works with existing systems and fixtures Cons Multiple suppliers to complete the automation Restricted fixture options such as fixture suppliers Page 9

10 Automation with Robots Robots purely replace operators and handle boards in the same way. Requires different types of grippers such as suction, craw, etc. to lift the board. Number of moving axis in the robots affects the effectiveness of handling against cost. Pros Potentially lower cost if factory robot expertise is leveraged Works with existing systems and existing fixtures can be re-used Dual well fixtures possible to further reduce handling time. Cons Large production area needs to be fenced Robot arm programming and configuration time Optimizing axis movement for handling time and accuracy Gripper change shape, weight/center of weight, and type of grip Potentially slower handling time (except for dual well) Follow up support cost of the robot and engineering Page 10

11 Fully Integrated Inline ICT Fully Automated Inline ICT provides best support model with balanced cost. Uses the same conveyor transport like the bridge handlers Normally come in press-down style. Pros Single contact window for support needs Easy maintenance Zero foot print Upgradable from existing systems Cons Limited node count and configuration May not be compatible with existing fixtures Difficulty in customization Page 11

12 Considerations for Going to Automation Page 12 Efficiency is the foundation testers and handlers needs to run without interruption. High number of false fails and handling problems can make automation a nightmare. Two areas should be considered. Board Characteristics Manufacturing and Test Process

Board Design Considerations Automation Friendliness from Physical Board Design Size/dimension Max board size and the dimension limits of the handler.

that affects auto alignment Size of test points and PCB tolerance PCB tolerance affects the position of test points.

13 Board Design Considerations Automation Friendliness from Physical Board Design Size/dimension Max board size and the dimension limits of the handler. Weight balancing affects effectiveness of robot arms gripping as well as conveyor transport Warpage can be significant on thin PCB as well as large boards that affects auto alignment Size of test points and PCB tolerance PCB tolerance affects the position of test points. Normally test access size needs to be greater than 20mil Odd shape boards might not work perfectly with board stoppers Board carriers needs to be implemented. Requires 3mm straight board edge for transport Page 13

14 Board Design Considerations Number of test access and node count Normally handlers are good with 2,000~2,500 nodes and first pass yield drops significantly for 3,000 nodes or above. For 10ppm risk of off-target - Contribute 1% false call at 1,000 nodes - 2% at 2,000 nodes If 50ppm risk - 5% false call at 1,000 nodes - 10% false call at 2,000 nodes Additional efforts to handle the fall outs from the inline station Page 14

15 Board Design Considerations Single side vs. double side Topside and bottom side probing alignment makes testing double side boards more difficult. Panelization Panelized board normally increase the efficiency Some parallel testing can be performed to further improve output. Component height - especially tall components on both sides of the DUT. Topside is normally not an issue as high as 100mm Bottom side normally is 25mm as IPC standard. Flow direction considerations 40mm R C 60mm? Page 15

SMT and Test Process Considerations Semi automated Semi Automated Manual insertion and wave soldering Test after depanelization/routing Manual placement/removal

16 SMT and Test Process Considerations Semi automated Semi Automated Manual insertion and wave soldering Test after depanelization/routing Manual placement/removal of carriers Full Automated Full Automated Automated through hole insertion Reflow oven with pin-in-paste ICT Automation is easier for a fully automated line Page 16

17 SMT and Test Process Considerations Wave soldering vs. Reflow Oven Wave soldering requires carriers and may not be suitable for ICT (test access blocked) Loading DUT to carriers is manual not automatic Depanelization and Routing Routing/depanel can remove the board edges. Routing before ICT will need design with sufficient board edge Carriers non rectangular boards, panels, lack of board edges Page 17

18 SMT and Test Process Considerations Island strategy vs. in-line strategy Moving within the same strategy will be more straight forward. Change in strategy increases complexity - # of testers, tester leverage level, etc. Island strategy usually runs more models and requires more considerations such fixture exchange time. Inline Automatic Inline Manual Island Automatic Island Manual ICT ICT Production Testing Production Line in-line manual strategy Island strategy Page 18

19 SMT and Test Process Considerations Extra equipment needed: Cooling for capacitors testing Buffer conveyors Barcode, auto barcode readers and MES shopfloor Paperless repair station It will be Product Models going automation. Not single product model. Page 19

20 Benefits from Automation Page 20 Quality Improvements Production Management Cost Reduction

Benefits from Automation Quality Improvements Reduce Human Interaction with Your Product Human interaction is a quality concern - Boards can get damaged during handling ESD protection and board

21 Benefits from Automation Quality Improvements Reduce Human Interaction with Your Product Human interaction is a quality concern - Boards can get damaged during handling ESD protection and board damage? Too many fixture engagements caused damage? - Un-tested boards can flow to customers Testing only one board and pass all the other boards? Unauthorized test program and fixture changes? - Process improvement opportunities bypassed by operators People touching the board! Page 21

22 Benefits from Automation Quality Improvements Unified process between lines and factories It is common for the same product to be produced in different countries. It is even more common for one model to run on multiple lines in the same factory With automation, you can achieve one test program runs on multiple lines in different countries. Brazil US China Same configuration Hungary Same configuration 4 Page 22

23 Benefits from Automation Quality Improvements Quality improvements link to corrective actions and activities are traceable Quality changes can be reflected in ICT yield almost immediately. Environmental factors (such as human interventions) affecting quality can be greatly reduced Probe change Page 23

24 Benefits from Automation Production Management Output Volume stable and predictable shipments - No more baskets of un-tested boards Remove labor variations cost and experience - Temporary operators, shift changes More output per line better efficiency Two shifts Two shifts Page 24

25 Benefits of Automation Production Efficiency and Handling Time Manual handling Test Time Handling time Automated inline Test Time Improved efficiency Improved handling efficiency - 10~15% depending on actual test time. Will automation inject line down time and eats up the benefits from handling time? Page 25

26 Benefits of Automation Down Time is Crucial to Production Efficiency Production Time Line down time After implementing automation, you don t expect a higher down time. Line down time New product introduction (NPI) debugging Production test program fine tuning Maintenance System break down NPI Debugging Occupies time from production line Production Fine Tuning making first pass yield improvements System Maintenance and Repair Page 26

equipment costs Fixture conversion investment Annual maintenance cost

27 Cost of Automation Does it really save money? Reduction: operator cost Addition: Board handler and accessories Additional equipment costs Fixture conversion investment Annual maintenance cost Engineering expertise on automation Intangible Benefits: Better quality products Improved brand image and value Page 27

Benefits of Automation Example of Automation Savings Operator cost : $25K per year per person Automation hardware cost : $90K Fixture conversion cost : $30K Annual maintenance cost : $5K Cost

28 Benefits of Automation Example of Automation Savings Operator cost : $25K per year per person Automation hardware cost : $90K Fixture conversion cost : $30K Annual maintenance cost : $5K Cost of automation pays back in the 6 th year. Actual savings in dollar amount may not be obvious in the initial years. But improvements in quality, brand image and value will be significant. Page 28

29 Benefits of Automation Summary ICT automation involves many departments and manufacturing processes. The right product characteristics and optimized process produce the best results. Benefits from ICT automation includes Quality improvements Production management Cost reduction Keysight has a long history and experience in ICT automation. We can help you with deeper insight to meet various ICT automation needs, from robotic arms, bridge handlers to fully integrated solutions. Page 29

30 Questions? Page 30

31 What s Coming Up Next? Keysight Automated Inline ICT Series Automated Inline ICT Powertrain and Hybrid August 19 at 10 a.m. PT Automated Inline ICT Body Electronics, Safety and Driver Assistance September 24 at 10 a.m. PT Automated Inline ICT Infotainment and Communication October 29 at 10 a.m. PT Automated Inline ICT Industrial and Home Appliances November 19 at 10 a.m. PT Automated Inline ICT and Functional Test December 10 at 10 a.m. PT Next session will focus on the Powertrain and Hybrid test application Please visit the event page to register now For more information about Keysight Automated ICT products, please visit our product page at Page 31

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Design for Testability Guidelines. Conventional and EC-1 In-Circuit Test Fixtures

Design for Testability Guidelines Conventional and EC-1 In-Circuit Test Fixtures Revision F August 20, 2001 1. All test targets are preferred to be on one side of the PCB. ECT is quite capable of equipping