1. Subcontracting of electronics modules
TE-MPE-EM
Subcontracting of electronics modules
Betty Magnin /
13th ILO meeting

2. Summary Mandate Structure and ressources Volume of activity
Outsourcing and quality management
How can you help?

3. Mandate To provide a CERN-wide support for
The layout
The production
The assembly
In the domain of Printed Board Assemblies

4. Structure Final user Design Components suppliers PCB procurement
Planning
Coordination
Design
PCB procurement
Components suppliers
Subcontracting
team
Mechanical subcontractors via EN-MME
Harness subcontractors
Outsourced assembly of electronics modules

5. Ressources The team: 19 persons Uptodate equipments 26.10.2016
1 team leader
8 technicians for the design of std and special PCBs
2 technicians specialized in CAD libraries
3 technicians specialized in production processes, dedicated to design reviews, subcontractors validation and follow-up
3 technicians specialized in PCB assembly and special repair
2 technical assistants for ordering components and assembly
Uptodate equipments
CAD stations (CADENCE and Altium)
CAD to CAM software (Aegis)
Solder paste printing (Mydata)
Automatic SMD placement (Mydata)
Reflow soldering (vapor phase)
Cleaning
SMD component repair and replacement
Inspection

6. Typical examples of layout and production
Batch of 70 boards
230*220mm
2-sided, PTH, BGA, QFN, 0402
1325 components
5500 solder joints

7. Typical examples of layout and production
Crate with
2 PCB
cables, mechanical parts

8. Volume of activity A yearly average of Forecasts show an increase
800 new designs or design changes
400 PCB manufacturing batches (250 outsourced)
400 PCB assembly batches (250 outsourced)
Forecasts show an increase

9. A CERN-wide service

10. Outsourcing Internal facilities are dedicated to prototypes
The rest is outsourced
Volumes generally from 15 to 250 pcs, some up to 1500 pcs
Single shot, no repetitive production
Each project is split into PCB procurement, components kitting, assembly subcontracting in order to
Keep control
Reduce lead time
Components purchased through official distributors
3-year contracts with 2 PCB manufacturers
Limited number of contractors for PCB assembly

11. PCB procurement From 01.01.2016 to 31.12.2016 DAI issued: 247
Total cost:
624’835.- CHF
DAI < 5'000.-CHF:
229
DAI > 5'000.- and <10'000.-CHF: 11
DAI > 10'000.-CHF: 7
Most expensive DAI:
33'000.- CHF
Average cost per DAI:
2'530.- CHF

12. Assembly procurement From 01.01.2016 to 31.12.2016 DAI issued: 242
Total cost:
786'114.- CHF
DAI < 5'000.-CHF:
216
DAI > 5'000.-<10'000.-CHF: 19
DAI > 10'000.-CHF: 7
Most expensive DAI:
77'346.- CHF
Average cost per DAI:
3'248.- CHF

13. PCB manufacturing One of the most expensive parts of an assembly
A defective PCB may jeopardize a whole assembly
Defects in PCB may be hidden and involve reliability problems
The PCB must withstand the assembly process (RoHS) and CERN safety rules (halogen-free)
As compared to components from the shelf, each PCB is a new product made in a small quantity!

14. Purchasing of PCB
It is important to have trusty suppliers who have the whole process under control.
2 suppliers give some flexibility and help for load balancing
The cost of a PCB can easily be determined with a pricing model, based on batch size, lead time and technical parameters: size, layout count, holes, track width,..

15. How do we select a PCB manufacturer
General requirements
ISO 9001:2015 certified company
Production shall be done in CERN Member States
All process steps shall be done in-house, no subcontracting allowed
Halogen free base material shall be used  IS41, CERN standard
Acceptance of the PCB shall be compliant with IPC-A-600 standards
Controlled impedances
Finished holes diameter: down to 0.2 mm, aspect ratio to 8:1
Blind and buried via holes according to IPC-DR-572
Surface finishing: electroplated Au, Ni/Au electroless
Raphaël Berberat

16. 2 contracts with PCB suppliers
Purchasing of PCB
2 contracts with PCB suppliers
MS sent early 2014 to 89 firms, 23 replied
17 selected on the basis of their replies to the questionnaire
7 short listed after a technical audit (with the support of EP-DT, Rui de Oliveira)
IT sent to 7 firms
based on a representative panel of PCB
a pricing table was part of the deliverable (to garantee that the costs of the future orders will comply with those announced for the IT).
2 contracts established in July 2014 for 3 years and 370k€ each, extended to 750kCHF in 2016.
A new MS is in progress to set up new contracts by early 2018

17. And for electronic assemblies?

18. Electronic assembly procurement strategy
3 categories of assemblies
Simple: through hole components, low density
Intermediate: Through hole and simple SMD components
Complex: BGA, QFN, LGA
Each category has its assembly requirements, leading to different installed processes
A firm equipped for complex boards will not be competitive for simple ones
Urgent projects often require proximity with the firm
An open contract requires a pricing model to guarantee the best cost at any time for any project. For assembly, a price model is not easy to establish

19. Purchasing of assemblies
A survey of the market is regularly done with inputs from ILO’s, previous professional experience, other CERN groups, Purchasing Office, exhibitions at CERN or in dedicated fairs, adverts in specialised newspapers and websites
Firms looking as adapted to our requirements are highlighted
A first quote is requested to verify if their price is acceptable as compared to those from usual suppliers
The firm is then audited to verify on-site their technical capabilities
A limited panel of firms is qualified to fulfill our purchasing planning.
All large orders are discussed with Purchasing Office before inititiating the DO

20. Purchasing of assemblies
9 firms audited in 2016:
5 validated for series: 2 in UK, 2 in NO, 1 in PT
1 in PT to be further examined
3 did not have the required competences

21. Purchasing of assemblies
Selection Matrix

22. Purchasing of assemblies
The objective is to place large orders to unbalanced countries
PO by member state over the period 2013 – 2016

23. How do we select a supplier
General requirements
ISO 9001:2015 certified company
Production shall be done in CERN member states
All steps of process shall be done in-house, no subcontracting allowed
Acceptance of the electronic assemblies shall be compliant with IPC-A-610 standard, class 3
Class 1 -- General Electronic Products
Includes products suitable for applications where the major requirement is function of the completed assembly.
Class 2 -- Dedicated Service Electronic Products
Includes products where continued performance and extended life is required, and for which uninterrupted service is desired but not critical. Typically the end-use environment would not cause failures.
Class 3 -- High Performance Electronic Products
Includes products where continued high performance or performance-on-demand is critical, equipment downtime cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must function when required, such as life support or other critical systems.
Industrial cleaning equipment in house
Vapor phase oven may be an advantage

24. How can you help?

25. How can you help?
The world of electronics production, both PCB and assembly, is moving fast.
Word of mouth is not the most efficient way to survey the market, even if usefull.
We cannot only count on our previous professional experience, or Purchasing Office information or adverts in specialised newspapers and websites
We need your support

26. How can you help? When you organize exhibitions at CERN
With your input about firms able to fit to our requirements.
When you organize for us visits to such firms.

27. How can you help? A 30’ presentation cannot go into all details
We are open to receive you at our lab to deeper discuss all technical constraints of our activities.

28. Questions?