1. Product Life Cycles and Sustainability
34%
34% 2% 2%
14%
14%
-3s
-2s
-1s m
+1s
+2s
+3s

2. Product Life Cycles
Concept
Design
Manufacture
Shipment and Installation
Warranty Period
Useful Life
Failure and Repair
Disposal

3. Shipment and Installation Warranty Period Useful Life
Product Life Cycles
Concept
Design
Manufacture
Shipment and Installation
Warranty Period
Useful Life
Failure, Service & Repair
Disposal
Traditional Design Eng Focus
Traditional Mfg Eng Focus

4. Shipment and Installation Warranty Period Useful Life
Product Life Cycles
Concept
Design
Manufacture
Shipment and Installation
Warranty Period
Useful Life
Failure, Service & Repair
Disposal
Traditional Design Eng Focus
Traditional Mfg Eng Focus
Life Cycle Product Focus

5. Customer Labeling: User Manual
Product Specifications
List Product Level Capabilities (Requirements)
Standard Requirements
Performance Requirements
Environmental incl Temperature, Humidity, etc
Mechanical Dimensions, Mass, Shock, etc
Control Inputs
Outputs including Displays
Interfaces including precise definition of connectors, signals
Complete Description of Operating Modes
Button or Menu Sequences for Clarity

6. Safety and Regulatory Certifications
User Manual
Safety and Regulatory Certifications
UL Safety Standards
IEC and CISPR EMC Standards
User Warnings
Limitations of Product by Demographics, Geographics
Cautions and Warnings
Compatibilities or Incompatibilities
Specific Label Applications or Misapplications
Safety Rules

7. Operation …..How do you use the product?
User Manual
Operation …..How do you use the product?
Step Method (used for simple products)
Step 1, Step 2, …. etc
Menu Method
Show how to move to any given mode
When in mode, show all user screens or displays
Show/Describe all Possible User Inputs
Describe all Possible Outputs/Displays user may see

8. User Manual Maintenance
Specified for a period of calander time, operational time or number cyclic operations
Describes what is to be calibrated, checked, replaced, etc
Test Procedures, Calibration Procedures, Replacement Procedures
Typical Replacements Include
Batteries
Sensors
Filters
Mechanical Wearout Components such as drive belts, pulleys, etc
Manual Section should show pictoral and textual replacment steps
Manual should indicate who should perform the maintenance (authorization, training level, etc)
Relationship to product warranty

9. User Manual
Service
Specified for repairs above and beyond normal maintenance
Service Strategies Include (Select 1 or more)
Field Repair by User
Requires service manual and replacement part depictions
Requires a concise list of replacement parts and procurement
Specialized Service Center
Requires specific replacement parts list
Specific testing equipment and skills
Factory Repair or Replacement
Still Requires replacement parts list documentation
Requires repair process chart (mimics mfg test processes)
Assembly/Dissassembly
Default-Disposal
Requires disposal strategy, No repair strategy
Must identify specific disposal procedures for ALL batteries

10. User Manual Warranty (From Previous Lab)
Specified for a period of time or number of operations
Must specify how to exercise the warranty
Teams should show (in ppt slide) relationship between warranty period and reliability calculations
Reliability analysis yields F(1 warranty period) = % of population that will fail within 1 warranty period. Assign Cost/Failure.
Warranty Costs = $ Cost of Failures << 1% of total sales
MTBF under simplified conditions indicates when ~63% of population has failed. In general, Warranty Period << MTBF

11. Other Sections/Elements
User Manual
Other Sections/Elements
Digital Pictures
Ideal for Describing User Controls
Assembly/Dissassembly, Exploded Views
Correct operational waveforms
Common Troubleshooting
Problem/Symptom
Cause
Corrective Action

12. Sustainability Aspects: Obsolescence
Standardized Industry Life Cycle Definition
Standardized Statistical Prediction Tool
Component Life Parameters, u, s
For any given part you must consider;
Part Type and Functionality
Manufacturer(s) and number of sources
Part Technology and Process
Part Package

13. Sustainability 6 Std Component Production Life Phases
Rate of Production
= Mean (Max) Sales of Unit Components per Unit Time
s = One Standard Deviation in Production/Time or Sales/Time

14. Production Life Cycle of a Component
Special Histogram of Production as Measure by Component Sales/Time (# shipped/time)
Concept Assumes Component Sales follow monotonically increasing to peak, then monotonically decreasing to obsolescence
Life Cycle is Measured Relative to Peak of Sales
+/- 1s from Peak = Mature Product
-1s to –2s from Peak = Growth Product
-2s to –3s from Peak = Introductory Product
+1s to +2s from Peak = Declining Product
+2s to +3s from Peak = Phase Out Product
+3s and higher from Peak = Obsolete Product

15. Statistics Application: Production Life Cycle of a Component
Recall Area under curve = Percent Probability
34%
34% 2% 2%
14%
14%
-3s
-2s
-1s m
+1s
+2s
+3s
Characterized by Two Parameters
m and s2
Normal Distribution = N( m,s2 )

16. Sustainability Life Cycle of Common Analog IC’s

17. Sustainability Life Cycles of Digital/Analog IC Processes

18. Sustainability Life Cycles of IC Process Voltages
1980
1990
2000
2010
2020

19. Sustainability Life Cycle Phases of IC Packages

20. Sustainability Discrete RC, SMT Package Outlook
Decreasing Power Rating
Dominant Package by Year

21. Sustainability Aspects: Obsolescence
For each applicable component in your block BOM, perform a variance analysis
1st Consider the part type: Find the u+(2.5)s, u+(3.5)s dates
2nd Consider any applicable attributes
3rd For each attribute find the u+(2.5)s, u+(3.5)s dates
Find the worst case u+(2.5)s, u+(3.5)s dates
Use u, s in years
+2s to +3s from Peak = Phase Out Product
+3s and higher from Peak = Obsolete Product
Create a separate BOM table of obsolescence analysis with above data
ID all parts above the 2.5s, Separately ID all above 3.5s
Formulate Corrective Actions or Risk Mitigations
Note: If you have a component that does not fit any category, ignore it for this analysis

22. Sustainability Aspects: Appendix
Component Life Cycle Data Table
Component Type u s
Applicable Attributes
Notes
Amplifier
2004.5
8.3
Technology, Package
Comparator
2003.0
11.1
Technology, Package, Voltage
Voltage Regulator or Reference
2004.0
6.5
A/D or D/A Converter
2001.5
7.8
Interface
2002
8.1
Specialty, Consumer
8 Bit Microprocessor
1990.5
9.2
16/32 Bit Microprocessor
1994.5
7.0
Memory
X+4
5.0
X = DOI
PLD
X+6
6.0
Carbon Resistor
1980
8.5
None
Metal Film Resistor
1990
12.0
Ceramic Capacitor
14.0
Other R, L, C’s
1985
10.0
Battery, Power Plug (AC-DC) or Transformer
Speaker, Mic, Display, Camera, or Sensor
DOI = Date of First Introduction to Market
Note: Based on actual data but ALL numbers may not be realistic

23. Sustainability Aspects: Appendix
Component Life Cycle Attribute Data Table
Process Technology u s
Comments
Bipolar
1975.0
12.5
NMOS
1986.0
8.0
PMOS
1968.0
8.5
CMOS
2010.0
BiCMOS
1997.0
4.0
Package
DIP – Dual Inline Package
1987.0
7.8
Thru Hole
SOP – Small Outline Package
1995.0
6.5
1st Gen SMT
CC – Leadless Chip Carrier
1996.5
4.5
2nd Gen SMT
PGA – Pin Grid Array
1997.1
QFP – Quad Flat Pack
1998.5
4.2
MCM – Multichip Module, All Other
1999.0
5.6
Process Voltage
5V and Above
1992.5
5.3
3.6V
3.0V, 3.3V
2.5V
2004.0
3.6
1.8V
2007.0
3.2

24. Will impact global electronics industry (incl USA)
Waste Electrical and Electronic Equipment (WEEE) Restrictions on Hazardous Substances (RoHS)
European Community Directives 2002/95/EC & 2002/96/EC
Will impact global electronics industry (incl USA)

25. Labeling Must Include the WEEE Symbol and Guidance Info
Directive 2002/96/EC “on Waste Electrical and Electronic Equipment“
Producers must take back waste electronic equipment from collection points
Financing:
Producers/Importers are responsible for financing and treatment of waste equipment from private households (which includes most small businesses)
Product sales can show a visible fee for up to 10 years
Producers and users others than private households may conclude agreements stipulating other financing methods
Products have to be marked with the brand of the producer, recycling symbol & date
Producers must provide specific disassembly information for treatment facilities
Targets are set in the directive for reuse, recovery and recycling (ex. Medical)
Producers/Importers have to be registered with local systems
Member states have to report on the targets; so record keeping required
*There will be a pre-registration phase that will start 18 months before each of these deadlines. The goal of pre-registration is to facilitate the formation of consortium and to force the sharing of data.
Labeling Must Include the WEEE Symbol and Guidance Info
“This symbol indicates that the waste of electrical and electronic
equipment must not be disposed as unsorted municipal waste and must be
he manufacturer or other authorized
disposal company to decommission your equipment.”
collected separately. Please contact t
Date of manufacture: month / year
Typical Guidance Statement for Industrial Equipment

26. WEEE Regulated Materials and Devices
1) Polychlorinated biphenyls (PCB) containing capacitors in accordance with Council Directive 96/59/EC of 16 September 1996 on the disposal of polychlorinated biphenyls and polychlorinated terphenyls (PCB/PCT) (1).
2) Mercury containing components, such as switches or backlighting lamps,
3) Batteries Including,
Lithium batteries
Alkali-Manganese batteries
Dry cell batteries
Nickel-cadmium rechargeable batteries
Lead rechargeable batteries
Silver round cell batteries
4) Printed circuit boards of mobile phones generally, and of other devices if the surface of the printed circuit board is greater than 10 square centimeters.
5) Toner cartridges, liquid and pasty, as well as color toner.
6) Plastic containing brominated flame retardants.
7) Asbestos waste and components which contain asbestos.

27. WEEE Regulated Materials and Devices
8) Cathode ray tubes
9) Refrigerant including chlorofluorocarbons, hydrochlorofluorocarbons, hydrofluorocarbons & hydrocarbons
10) Gas discharge lamps such as halogen, neon, xenon, etc
11) Liquid crystal displays (together with their casing where appropriate) of a surface greater than 100 square centimeters and all those back-lighted with gas discharge lamps
12) External electric cables
13) Components containing refractory ceramic fibers as described in Commission Directive 97/69/EC of 5 December 1997 adapting to technical progress Council Directive 67/548/EEC relating to the classification, packaging and labeling of dangerous substances (2).
14) Components containing radioactive substances (except components below exemption thresholds set in Art. 3 of and Annex I to Directive 96/29/Euratom of 13 May 1996 laying down basic safety standards for the protection of the health of workers and the general public against the dangers arising from ionizing radiation (3)) .
15) Electrolytic capacitors containing substances of concern (height > 25 mm, diameter > 25 mm or proportionately similar volume) .

28. WEEE Implementation Difficulties
Member States can expand the equipment list
Producers will be accountable for records of annual mass of each restricted substance shipped into each EC country
But conflicts among accounting firms on how to reserve for WEEE obligations, some countries may charge up-front
Firms may have to pay into a deposit system;
and reserve for a contingent liability
Some European wide associations being formed to manage WEEE
But member states have strong incentive to keep all waste in their system to maximize fee income
Definition of “producer” is problematic
What happens if distributors ship equipment from one member state to another? Who is responsible as the “producer”?

29. Recycling Passport
Master Recycling Passport
Edition: 1
03/2003
Model Type xxx
Editor / Department
Page
of 4 (
/ FAX:
File:
_rp neu.doc 8 5 4 11 7 10 12 13 9 3 2 6
1. General view of the device
Type Number
WEEE requires special identification of waste for recycling or special handling
Example: Agfa Copier
(Operator Manual)

30. RHS
Directive 2002/95/EC “on the Restriction of certain Hazardous Substances in Electrical and Electronic Equipment“ (ROHS)
Requirements:
Covered Equipment put on the market after July 1, 2006 is not allowed to contain (0.1% mass or less in homogenious materials, 0.01% or less for Hg):
Lead
Mercury
Cadmium
Hexavalent Chromium (used mostly for corrosion protection)
Polybrominated Biphenyls (PBB) or
Polybrominated Diphenyl ethers (PBDE) (flame retardants)
Limited, but critical exemptions (medical devices for example)

31. 2006 – Products/Industries
2008 – Med Devices
Large household appliances
Small household appliance
IT and telecommunications equipment
Consumer equipment
Lighting equipment
Electrical and electronic tools
Toys, leisure and sports equipment
Automatic dispensers
DI Products (X-Ray, MR, CT, etc.)
Patient Monitoring
EKG, Lab Eq, Dialysis
Category Device Exemptions Expected to End Jul 1 ’08

32. Pb Free Replacement Solder Properties
Alloy Composition
Liquidus Temp. (ºC)
Reflow Temp. (ºC)
Melting Range# (ºC)
Sn-37Pb (63% Tin, 37% Lead)
Sn-3.5Ag
221
240 – 250
Sn-0.7Cu
227
245 – 255
Sn-3.0Ag-0.5Cu*
220**
238 – 248
Sn-3.2Ag-0.5Cu
218
Sn-3.5Ag-0.75Cu*
Sn-3.8Ag-0.7Cu
Sn-4.0Ag-0.5Cu
Sn-4.0Ag-1.0Cu*
Sn-4.7Ag-1.7Cu*
244**
237 – 247
Sn-5Sb
Sn-0.2Ag-2Cu-0.8Sb*
285** %
Sn-2.5Ag-0.8Cu-0.5Sb*
225
233 – 243
Sn-2Ag-7.5Bi*
216**
220 – 230
Sn-3Ag-3Bi*
218**
Sn-3Ag-5Bi*
230 – 240
Sn-3.4Ag-4.8Bi*
215**
225 – 235
Sn-3.5Ag-3Bi*
217**
Sn-3.2Ag-1.1Cu-3Bi*
240**
Sn-3.5Ag-3In-0.5Bi*
Sn-3Bi-8Zn
**V. Solberg, "No-Lead Solder for CSP: The Impact of Higher Temperature SMT Assembly Processing," Proc. NEPCON West 2000 Conf. (Feb Mar. 2, 2000) Anaheim, CA (Source: Indium Corp.) #N.-C. Lee, "Lead-Free Chip-Scale Soldering of Packages," Chip Scale Review, March-April 2000 *Many of the above are Patented compositions; may require licensing or royalty agreements before use.

35. Component Suppliers Timeline for Pb free Changeover
Component risk mitigation plans defined
80% suppliers compliant
90% suppliers compliant
100% suppliers compliant
Production quantities available
Purge non-green component stock
JUN 04
DEC 04
MAR 05
JUN 05
SEP 05
DEC 05
JUN 06
Impact
Tracking and distributing communications from suppliers on ROHS & EOL to all affected parties.
Tracking ROHS compliant and non-compliant parts separately in Mfg lines.
ECN volume increase as manufacturers migrate and obsolete parts in favor of ROHS parts.
Requests for last time buys.
Only ROHS components on new design, re-spins.
Impact
Phase-out accelerates, broker mkt demand for old parts will cause pricing pressure
Likely lead time/fulfillment issues as mfg focus shifts to ROHS compliant parts.
Obsolescence Risks,
Component Rollovers

36. Lead Free – Typical EMS Timeline
April 2005
Jan 2006
July 2006
Lead Free Process Defined
Training Complete and Process Qualified
Production Ramp
Nov 2004
July 2005
Mixed Technology
Qualification Plans Defined or Complete
Manufacturing Processes
Ability to monitor material compliance
Defined.
Mfg systems in place
Jan 2005
Supply chain notified
Capability to convert BOM , find alternates ( Offered by SCI , Jabil , Plexus ..)
Challenges
CM Pb-Free Process Defined – Celestica, Jabil, Plexus, Flextronix, etc working in sync
Most EMS will charge for service of Scrubbing BOM, converting design to Pb Free
Qualification / Validation responsibility ?
Pilot/Qualification samples.
Lead Free – Typical EMS Timeline

37. Categories of electrical and electronic equipment covered by
Covered Equipment
Categories of electrical and electronic equipment covered by
RoHS, Annex IA
Large household appliances
Small household appliances
IT and telecommunications equipment
Consumer equipment
Lighting equipment
Electrical and electronic tools (with the exception of large-scale stationary industrial tools)
Toys, leisure and sports equipment
Medical devices (with the exception of all implanted and infected products)
Monitoring and control instruments
Automatic dispensers

38. RoHS Definition of “Equipment“ falling into scope
Equipment, which:
Is dependent on electric current or electromagnetic fields in order to work properly (electric current or electromagnetic fields as primary energy), and equipment for the generation, transfer and measurement of such currents and fields, and
Is covered by the categories set out in annex I A, and
is listed in annex I B (examples for the categories), and
Is designed for use with a voltage rating not exceeding 1000 Volt for alternating current and 1500 Volt for direct current, and
Is not a product which is intended for specifically military purposes, and
Is not part of another type of equipment that does not fall under the scope of the directive

39. Appendices

40. Sustainability Aspects: Appendix Actual Study Data Example
Assume Microcontroller is Special Consumer
For Digital and other IC’s don’t use Type attributes
Add 5 years to correct

41. Obsolescence Table Example
Sample calculations for a few suspect IC’s (Present Date p = )
In this case, the present date was subtracted from the window points and any negative value means there is a potential issue