Introduction of Quality Procedures in the Electronics Design Office TS-DEM Introduction of Quality Procedures in the Electronics Design Office Betty Magnin CERN

TS/DEM mission From schematics to mounted PCBs 1 to 200 pieces/project, largest 2000 pieces Project cost: CHF 150.- to CHF 20’000.- Around 800 projects / year (500 new designs, 150 modifications, 150 production only)

Introduction 2002: two Design Offices from EST and PS merged. Both had their own tools and methods 2003: we provided additional services with small series production of electronics 2004: FSU contract requires change of methods 2004: volume of projects drastically increased

TS-DEM Planning office (DEM-BE) Request Circuit or module Design office DEM-BE Planning office (DEM-BE) ‘commercial’ contact Ordering Tracking Invoicing Circuit manufacturing DEM-PMT Assembly DEM-WS Sub-contracting (overflow of CERN capacity) Prototypes, fast turn-around local industry Sub-contracting Large quantities member states

Plan and follow-up the project Process Chart Order components from stores Deliver and Invoice Design librairies Design layout Order PCB’s Order Assembly Order mechanical parts Receive order Advise for DFM Plan and follow-up the project

Why quality procedures ? Understand and satisfy the customer’s needs Standardise working methods Design layout suited for manufacturing and assembly Have a reliable management of the activity, inhouse and subcontracted

The sources of non-quality Can be determined through Ishikawa Diagram (4P’s) People Plant Design Office Procedures Policies

People Determination of designers’ versatility Training through visits to assembly site Technical training to increase versatility and competencies (Cadence, High-Speed Design,…) Regrouping of the two design offices in one building

Plant 5S Process The five S stand for the five first letters of Japanese words meaning: Sorting out (Seiri), Systematic arrangement (Seiton), Spic and span (Seiso), Standardizing (Seiketsu), Self-discipline (Shitsuke) Eliminate what is useless Organise archiving of paper document and files Organise storing of components and documents for orders

Procedures Specify input data (together with DUG) Promote Design Review (together with DUG) Elaborate input data verification check-list Define a common procedure to produce documentation of mechanics drawn with Autocad Review generic PCB layout (panelisation, fiducials,…) Specify format of board and assembly part-lists Elaborate output data validation check-list EDMS archiving

Document management via EDMS Schematics Specification PCB Layout Manufacturing Assembly Mechanics Pictures Supplier info Items: EDA-xxxxx We send only the EDA number to subcontractors!

Policies Standardise design rules Standardise librairies                                 Policies Standardise design rules Standardise librairies Review available standards: JEDEC, NF, IPC, … Define IPC as the standard: covers all aspects from design to manufacturing, assembly and repair IPC: Institute for Printed Circuits

Prototype electronics production multi-layer PCB, standard priority Planification Prototype electronics production multi-layer PCB, standard priority Layout (and queue) 4 weeks PCB fabrication 3 weeks Queue 2-3 weeks Layout 1-2 weeks Assembly 2 weeks Margin 1 week Control of the turn-around time means: - tight planning and follow-up - companies you can rely on

Planification Until 2004, several tools JMT2 project for DEM one Filemaker database, 3 Excel files JMT2 project for DEM released for invoicing of multisection jobs Under test for the invoicing of specific PMT and WS jobs In work for the planning aspects The Design Office needs a single centralised activity management tool until the JMT2 project of TS/CSE is fully released

Activity management tool Centralised entry of all needs Simultaneously accessible by all section members Issues queries of orders to be launched by a supplier (internal or external) Issues queries of ongoing or late orders Issues the global invoice, for a one time entry in JMT2 when the job is delivered Simple MS-Access Data Base requiring no special knowledge to be maintained

Outil de gestion-planification

Next steps Continue with the planned actions Training (visits of PMT and WS workshop, EMC, …) Document in EDMS the procedures defined in 2004 Finalise the input and output controls for designs Finalise the implementation of JMT2

Conclusions Quality is important There is a lot to improve will give cheaper and better producible electronics will give higher quality designs (more reliable, less noise...) I have the ideas on how to improve using standards, technical training, improving procedures We have started the process, but it is not easy long history high workload for LHC no resources for a “bureau de méthodes”