1. MPE-EM Workshop
Design Office
William Billereau

2. MPE-EM Design office Mission Resources Workload Quality management
Cost management
Service improvement

3. Mission Design of products Design of CAD libraries Standard PCB
2 to 16 layers, rigid, flex, flex-rigid
Related mechanical parts
front panels, boxes
Crates and racks
Readout for MPGD
Design of CAD libraries
Schematic symbols
PCB Footprints
3D models for Altium

4. Resources Personnel design of standard and special PCB
1 team leader (staff)
10 technicians (FSU) for the
design of standard and special PCB
design of CAD libraries
Equipment
CAD stations (Cadence, Altium)
AutoCAD
CAD to CAM software (Aegis)

5. Design exemple

6. Design exemple

7. Workload
Designs
Around 200 new jobs / year, ~400 including modifications
Statistics by year from JMT
2012
2013
2014
2015
2016
V1-0
220
201
189
211
105
total (all Versions)
448
486
423
424
241
all but V1-0
228
285
234
213
136

8. Workload Designs 20/40 jobs in progress
60 Jobs in the pipeline (has been 90 in August 2015)
Most of them are waiting for files/informations (some of them since 2015)
Around 10 of them ready and to be done per week
Since 2012, 2 sub-contractors to face overload

9. Quality management (Designs)
The quality of a design directly depends on the quality of the entering information from the engineer
Check list, NDI form, Design review,..
During the design, a constant link with the engineer for a mutual understanding of the constraints
Important changes asked by the engineer during the design are recorded
The design is done according to international standards (IPC, class3),
CAD software have internal controls (DRC) based on the same standards
Production can only be launched when documents are Released in EDMS
At the end, the design is controlled both by the engineer and another technician of the design office (crosschecks)
All issues met during prototype and series production are registered to be solved at the next design change or production request

10. Quality management (Designs)
Non Conformity (FNC)

11. Quality management (Designs)
Quality is part of the FSU contract indicators, analysed at the monthly meeting
FSU contract indicators (Cross-check report):

12. Non Conformité : problèmes détectés lors de la production.
Lancement d’une étude
26/03/2015

13. Statistiques Controle Croisé BE du:
Quality management (Designs)
FSU contract indicators (Cross-check/FNC analysis)
Statistiques Controle Croisé BE du:
17/04/2012 au
15/06/2016
2012
2013
2014
2015
2016
Total
Nombre de verif:
132
161
233
224
164
914
Erreur par version:
Retour PO (FNC)
Conception
Documentation
Esthétique
Dénomination
Stockage %
Number
verif V1 78 84
121
128 94
505 V1 87
203
117 21
14.85% 75
verif V2 34 48 69 59 39
249 V2 31 85 40 17 32
19.68% 49
verif V3 11 16 35 24 18
104 V3 8 22 12
33.65%
verif V4 4 5 10 V4 2
22.86%
verif V5 3 1 V5
18.18%
verif V6 V6
verif V7 V7
verif V8 V8
verif V9 V9
223
163
912
131
342
185 53
129
18.49%
169
58.48%
152.68%
82.59%
23.66%
57.59%
Erreur jobs/année: 41
Nombre total de job critiques
0.45% 72 36 89 73
(problemes détectés dans les 5 rubriques): 37
Nombre total de job "RAS"
353
38.62% 15 14
(aucun probleme détecté): 26
Retour PO 51
Altium/Cadence: A
A/C C
Dessinateur CA BC BR MJ MR AP
JMC
JMW PV WB NL DL
total
verifs faites/dess. 71
276
240
211 19 38 23
913
jerifiés faits/dess.
217
174
148 9 46
139 43
1-PCB
2PCB+MECA
3-MECA
4-CHASSIS
FNC 2012
FNC 2013
FNC 2014
FNC Total
verif par type de job
503
314 60 25 62

14. Cost management (Designs)
Preliminary pricing
A cost estimate can be established once a schematic and a few constraints (size, density) are available.
We use since 2008 an Excel form to calculate it

15. Cost management (Designs)
Cost follow-up
A JMT job is open, which will be used to invoice the FSU costs
The technician in charge of the design is aware of the preliminary pricing and must alert in case of overcost
A follow-up document is updated to record all extra work or overwork.
In case of overcost, MPE-EM management is informed and forwards the information to the final user
Invoicing
From FSU to CERN when the design is finished (JMT)
From MPE-EM to the final user when the job is finished (JMT)

16. CAD LIBRARIES
The library is the first requirement to make a design, either for the schematics or for the layout
CERN officially supports 2 CAD (Altium and Cadence)
2 independent libraries (no way to use the same for both)
Size of each library : Altium : ~6000 components, Cadence : more than components
Rule: to each component in the library corresponds only one physical component (no ambiguity)
The PART NUMBER of a component in the library is the one visible in the BOM, anyone (CERN user or external assembler) can buy the correct component
current thresholds: RQTD/F: <100 A: 2 V, 190 ms, 100 < I < 350 A: 100 mV, 190 ms, above to be reassessed
limit number of trips at 7 TeV  give Rainer all necessary freedom

17. Workload Altium/Cadence Libraries
Between 200/300 new symbols / year for Cadence
Only ICs, Connectors and special parts are taken in account, not the discrete parts (capa, res, diodes, self..)
The main work is the update of a more than 20 years old library.
Around 1000 new symbols / year for Altium
All parts are taken in account, including discrete parts.
Recent library (end of 2007)
2011
2012
2013
2014
2015
2016
Cadence
336
301
409
293
272
120
Altium
1099
1150
1010
1002
1129
645

18. Quality management (CAD Libraries)
A correct component is the key input to make a good layout
Layout proposed by manufacturer does not always fit with IPC class 3 rules
Both libraries are managed with the same design rules
Based on IPC standard, through a single tool.
current thresholds: RQTD/F: <100 A: 2 V, 190 ms, 100 < I < 350 A: 100 mV, 190 ms, above to be reassessed
limit number of trips at 7 TeV  give Rainer all necessary freedom

19. Cost management (CAD Libraries)
Library design is a service to all CAD users, not only for layout done by MPE-EM
No cost charged
Charged on MPE-EM budget (150k)
Annual ELEC contribution (30k)

20. Service improvement As suggested during the survey Design Libraries
Extra CAD software (KICAD?)
Expertise in EMC, HF, …
Recommendations about feasability
Libraries
Collaboration with external services
Information about component obsolescence and availability
Monthly/Weekly diffusion of new components list

21. Questions ?