How Engineering Supports Manufacturing Larry E. Hand Peavey Electronics March 28, 2000

Introduction n Senior Design n Larry E. Hand, MEE PE MCSE u Master Electrical Engineering, Auburn University 1977 u Harris Corporation, Melbourne Fl u Peavey Electronics, 1983-Present

Proof of Concept..

After Proof of Concept, What Next? n Vacation n Big Bonus n Two Attaboys n Another Project n Physical Design and Transition to Manufacturing

Life After Prototyping n Physical Design and PC Layout n Parts Procurement n Costing n Agency Approvals n Documentation, Literature and Manuals

More things to consider n Mechanical Design and Packaging n Manufacturing Deliverables n Murphy’s Law- ECN’s and rework n It’s Always yours..

Printed Circuit Board Design n Component Placement u Input/Output locations u Mounting Considerations u Technology Selection u Restricted areas u Minimize crossing count u Thermal Management

Printed Circuit Board Design n Electrical Considerations u High Impedance Nodes u Differential signal pairing u Shielding for Magnetic and Capacitive Coupling u Transmission Line Effects- OverShoot and Ringing u EMI/EMC u Ground is NOT Ground......

Printed Circuit Board Design n Manufacturing Considerations u Component Spacing u Orientations u Hole Sizes u Insertion Tooling Restrictions u Tooling Holes u Panelization

Parts Approval and Procurement n Standard Parts u Multiple Sourced F Cost Effective F Minimal Specifications required F Improved response to demand changes F Note: Not all parts are created equal.... u Single Sourced F Unique or Patented Technical Advantage F An Act of Nature could shut you down! F Know Who You’re Dealing With

Parts Approval and Procurement n Custom Parts u Product Differentiation u Protect Trade Secrets and Intellectual Property u Extensive Specifications/Documentation u If you change your mind, They’re still yours u Requires Accurate Forecasting

Parts Approval and Procurement n Approved Vendor List (AVL) n Lead Times n Minimum Quantities n Packaging/Delivery Options u Bulk u Tape and Reel u Tape and Ammo u Trays or Tubes

How is Cost Determined n Material Cost n Labor Cost n Manufacturing Burden n SG&A

How Much does it Cost n Material Cost---52% of Total Cost u Unit Price * Quantity for all BOM items n Labor Cost --- 8% of Total Cost u Direct labor or value added labor required to manufacture the product

How Much Does it Cost n Manufacturing Burden % of Cost u Indirect Labor u Utilities u Facilities u Employee Benefits u Depreciation, rent, etc..

How Much Does it Cost n Sales/General and Administrative -- 23% u Cost of Selling the Product u Sales commission u Advertising u Service and Warranty u Corporate Management u Research and Development u IS, Bad Debt, etc..

Agency Approvals n UL n CSA n FCC n NOM n CE n NEMKO n DEMKO n VDE n IRAM n SASO n SANZ n SAA n JIS n and more.....

Documentation n User Manual n Technical Specifications n Service Manual n Assembly Directions n Marketing Support n Advertising Copy

Packaging n Protect Unit During Shipment n Attractive at Point of Sale n Advertising n OEM or Consumer packaging

PCB Manufacturing Flow n Top Side SMT n DIP IC’s and Sockets n Axial leaded components n Bottom side SMT n Radial leaded components n Hand Assembly n Wave Solder n Touchup and Inspect n Precheck

Manufacturing Deliverables n Programs for Automated Assembly Equipment u Axial Sequencer and Insertion u Radial Insertion u DIP Socket and IC insertion u Surface Mount Chips, IC’s, Odd Shaped Components u GenRad Automated Test

Manufacturing Deliverables n PCB Assembly Drawings n Gerber Files n Mechanical Fabrication Drawings n Functional Test Procedure n Technical Specifications n Trouble Shooting procedures n Your Experience and Knowledge

Oops.... n Tolerances n Incomplete Beta Testing n Parts Availability n Poor Manufacturing Yield n Poor Reliability n Marketing Redirection/Feature Addition

Engineering Change Orders n ECO’s document a change that manufacturing will implement n Disposition of existing inventory n Disposition of Work In Process n Reason for Change n Cost/Performance/Schedule Impacts

Engineering Change Orders n Safety - Liability n Recall, Disposition of units already sold n Obsolete inventory

Sustaining Engineering n If you birth it, It’s always your baby n Customer complaints n Obsolete Parts n Unique Parts n Warranty claims and Field Failures n Specification changes in standard components