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1
the testing challenges in the EMS industry
towards our end customersKris Meeusmanager
test inspection engineering
2
overview

• intro tbp electronics
• who are we
• 3 paradoxes
• area of tension between
• suppliers ourselves - customers
• conclusion

3
introduction
tbp Dirksland (NL)
tbp Den Bosch (NL)
tbp Geel (BE)
cabinet assembly
headquarters PCBA activitiesfull lifecyclelow
medium volumeshigh tech
PCBA activitiescabinet assemblyfull
lifecyclelow up to high volumeshigh tech

• Over 30 years of experience
• 125 million euros in sales
• 500 employees
• active in the Netherlands and Belgium
• strong customer focus

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market position
tbp electronics
diversity complexity
technology
volume
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introduction tbp electronics Belgium

• capacity flexibility
• 400 Employees (incl. flexible workforce)
• 6 SMD lines ? 1 billion SMD/year ? 15 000
  PBA/week
• 500 000 products / year
• 820 different codes / year
• 4 400 Batches / year
• 250 New Product Releases / year
• 1 500 ECO / year (Engineering Change Orders)

defects per million opportunities ? 10 !
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overview

• intro tbp electronics
• who are we
• 3 paradoxes
• area of tension between
• suppliers ourselves - customers
• conclusion

7
first paradox

• own production control
• high quality, standard production
• in a
• flexible production environment

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our production mix

• high mix
• every day a new product
• high complexity
• 30 000 defect opportunities, and more
• low medium volume
• 50 50 000 boards / product / year

• no tuned line per product

• requires extensive process control

• production floor flexibility

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our production mix
/- 13.000 DOs
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our production mix
/- 28.000 DOs
components
solder joints
1 PCB
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our internal testing needs
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available test methods

• automatic optical inspection
• automatic X-ray inspection
• flying probe
• in circuit test
• boundary scan
• functional test
• burn-in / system test

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effect on our business
?
?
?
?

• specialism
• partner ship with customer
• product knowledge
• functional test development

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our internal testing needs
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summarized

• complexity of products and diversity of
  production orders requires total test strategy
  analysis
• for each product this must be investigated from
  in process control, over structural test till
  functional test and burn-in

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second paradox

• the customer needs how to fill this in
• customer expects 100 perfect products,
• at minimum cost

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customer requests

• 100 working products
• minimum testing cost(0 preferred)
• howevergood assembly ? working boards
• component deviation
• complex design
• environmental influences
• payback of investments and ownership dependency

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inputs to define the right test strategy

• knowledge on the testability of the product
• get product test knowledge from RD
• get involved in design phase to support with DfT
  to maximise testing features
• understand the product requirements to test
  against
• production test ltgt design verification test
• test stability gt delivery reliability
• test speed gt capacity
• fault indication accuracy gt reducing test cost

mostly, gathering and understanding these
inputs requires a lot of engineering effort
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finding the right strategy

• costs can be reduced by minimizing the number of
  test steps
• functional approach is important to meet customer
  requirements
• functional coverage is strongly related to
  product testing features
• total test strategy must be taken into account to
  define total coverage

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we support customers

• DfT review services
• testability features in the firmware
• review of available firmware
• own platform Basic Handler
• testability features HW design
• communication interfaces
• test mode
• testability features on lay-out
• access review
• test pad size / spacing

modular approach reduces NRE cost
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our observed customer groups

• 3 groups
• only interested in good boards _at_ minimal
  costoften decided to not invest in test
  knowledge
• aware of test requirements and willing to take
  them into accountfocus on cost efficient
  solutions
• aware of test requirements and high test
  knowledgefocus on end product quality

each group requires other services
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we support testability firmware

• add modular functional test access by us of a SW
  test platform embedded in the products
• BASIC HANDLER platform
• product independent, with specific test functions
• no influence to firmware or application SW
• full life cycle support of the product

product support/ maintenance
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we support coverage DfT

• with knowledge of all test processes, we can give
  a most complete view on total test coverage
• feedback on design optimization
• test access missing nets
• proposal for optimization
• proposal for test concept
• coverage optimization
• dig-jump techniques
• test point optimization gt spend effort on the
  right spot
• control proposals on BoundaryScan chain
• coverage review report

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we support e2e realization

• knowledge of all available test tools enables us
  to propose the best fit for the test project
• investment motivation generic equipment gt risk
  sharing specific equipment gt best offer
• ownership
• modular vs generic gt dependency
• end to end solution
• development
• realisation
• support
• data capturing and analysis

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summarized

• following the right steps will result in most
  economic solution
• DfT
• product knowledge
• project knowledge
• realization

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third paradox

• our needs suppliers offer
• modular solutions
• total solutions

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test measurement segment
structural test methods_at_ production
functional test methods _at_ production
much more diverse product dependent high
investment risk
responsibility of EMS generic product
independent limited tooling cost

• 2 big challenges
• functional test solution
• report total test solution

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a functional test setup

• a view on the different items in the total chain

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we need

• build and support end to end solutionswith
  modular or generic blocks.
• success of modular blocks depends on the
  availability usability of every item on the
  market
• too much parties to serve the complete chain
  results in expensive solutions
• infinite upgrading of generic solutions to serve
  diverse products success depends on available
  upgrades
• generic solutions require investment strategy gt
  risk sharing and dependency

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most diverse item in the chain

• interconnection to the UUT is typically most
  critical
• conform the product volume
• minimize the number of contact changeovers
• signal integrity
• each changeover represents a cost
• custom solution

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reporting tools

• realistic coverage presentation is key to
  motivate test solutions
• we fully support this on structural test level
• manufacturing defects
• functional coverage is not covered by an
  automated tool

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DfT reporting structure
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summarized

• complexity of total functional test chain
• specialism on UUT interconnection
• reporting of full test strategy is crucial to
  justify full test strategy

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overview

• intro tbp electronics
• who are we
• 3 paradoxes
• area of tension between
• suppliers ourselves - customers
• conclusion

35
conclusion
product controlassembly component
to obtain the best and most economic test
solution,specific engineering skills are
required(product, project and also test machine
development) these engineers have to co-engineer
with the customers in an early stageand they
need to be enriched with experience from a
manufacturing organization tbp can do this
minimum cost
appropriate solutions tools