1. PADS DFMA Jeff Kuester Field Application Engineer jeff@edadirect.com
From-Concept-to-Chip-to-Board

2. Your Design for Excellence Partner
Since 1997 EDA Direct has helped customers in the High Tech industry with design tools, training, and services

3. Executing PCB Fabrication Executing PCB Assembly
Presentation Title
DFMA
The NPI Business Process
Executing PCB Fabrication
Execute fabrication process
NPI
Optimize product for process
Prepare process instructions
PCB Design
Define the product
Executing PCB Assembly
Execute assembly process
In the Design through Manufacturing process, there are several steps – the PCB design stage where you are defining the product, the NPI stage and the manufacturing stage where both the bareboard fabrication and PCB assembly processes take place.
Within the NPI stage there are actually two unique aspects. One is where the product is optimized for the manufacturing processes. The other part is where the manufacturing processes instructions are created. We will show you how the Valor NPI solution addresses both of these aspects.
Design-through-Manufacturing

4. Cost of Manufacturing Related Design Change
DFMA
The NPI Business Process
Using prototyping and production to uncover DFM issues is time consuming and expensive
At each step, it costs 10 times more to fix a problem than the previous step
The most expensive failures are the ones that you find in the field
Shift Left $
Cost of Manufacturing Related Design Change
DFM shift left optimizes NPI success
Fastest time-to-market
Minimize expensive design-spins $ $
If you look at an electronic product’s lifecycle it could be defined in this manner – Design, New Product Introduction, Ramp-to-Volume, Volume Production and then Sustaining through End-of-Life.
Click
As you progress along this continuum it costs you an increasing amount to identify and then optimize your product for volume production and reliability.
With systematic DFM tools you have the ability to optimize your PCB designs for volume production and reliability much earlier in the lifecycle, thus saving your company substantial money and time. $
Design
NPI
Ramp to Volume
Volume
Sustain End-of-Life
Product Lifecycle

5. DFMA
Fabrication and assembly analysis built into PCB design environment
100 most common fabrication and assembly checks
Correct identified issues in PCB layout prior to sending to manufacturing
Reduce design cycle time by minimizing iterations between design and manufacturing
Design for Manufacturing Analysis (DFMA) With DFM analysis in the PADS flow, you can minimize production issues, achieve fewer revision spins per design, and save time in your release schedule.
Ensuring that your design is prepared correctly for manufacturing is critical because PCB manufacturers value fast throughput more than quality, meaning design changes made to expedite production may not be communicated back to you.
PADS' DFMA solution will enable your organization to achieve fewer revision spins per design, with fewer major production issues and save you time in your release schedule. All of this value is delivered in a solution that is intuitive and easy to use.

6. PCB Design Review and Release Process Today
Presentation Title
PCB Design Review and Release Process Today
When do you perform DFM today?
Leaving it to your external suppliers:
Is too late in the process to make any changes
Doesn’t represent your interests
Library Cell Generation
Component Placement
Route PCB
Generate Manufacturing BOM
Create/Review Manufacturing Outputs
Release to Manufacture
Fabrication Supplier Review
Assembly Supplier Review
Your Initials, Presentation Title, Month Year

7. PCB Design Review and Release Process Today
vSure Version 9.1 Highlights
PCB Design Review and Release Process Today
DFM Interests
Subject
Design Organization
External Manufacturer
Product costs
Minimize costs
Maximize profit
DFM trade-offs
Wants control of decisions
Form factor
Miniaturization
Maximum manufacturing yield
Design revision spins
Wants to minimize/eliminate
Makes money off of each spin
PCB design integrity
Wants PCB built as designed
Wants/needs to edit PCB design for manufacturing processes
Communication
Expects full disclosure of all edits
Will communicate as required
Component sourcing
Wants control for quality reasons
Wants control for costs/profit reasons
Product reliability
Of utmost concern
Of little concern
Virtually every company has their designs run through DFM today. Often times it is by their suppliers, be it the PCB fabricator or the PCB assembly house. The problem is the design company’s interests are different than their supplier’s.
(select only 2-3 of these to speak to for time sake)
For example, you know that minimizing the design costs is very important to your company and you might assume that discipline is respected by your suppliers. But that is not really the case. They are motivated to maximize their profit on your job to the extent the contract permits. This affects how they see your design and the actions they take on it.
I always tell people DFM doesn’t do anything for you. It doesn’t change your design or magically make it better. What it does is present to you potential manufacturability issues that may adversely affect the yield, cost or reliability of your product. Sometimes you have to accept the issue as the trade-off for making a design change could be worse. But it is the visibility and control of those trade-offs that designers want. Your supplier may only show you the DFM issues they want addressed, leaving you to wonder what other issues you may run into with another supplier. If you don’t have visibility to these potential issues during the design process you can’t control the trade-off decisions.
All products push toward miniaturization. You’re wanting to fit as much functionality into a form factor as possible. Yet this runs contrary to what your manufacturing supplier wants. The greater the spacing between circuits or the greater the spacing between components the easier it will be for them to get high yield, increasing their profitability of the job.
You would also think that your manufacturing partner shares your objective to get to volume production in as few revision spins as possible. But then you realize they make money off of each revision spin you send them, so why should they work so hard to reduce that motivation for themselves?
We also assume that our PCBs will be built as designed. And for the most part they are. However, all designs are modified some before being fabricated. The fabricator has to add global etch compensation depending on the copper weight and they will add a scaling factor to the layers in consideration of the lamination process. But depending on the explicit permissions you give them or don’t give them they may also choose to edits features of the design to improve yield. I’ve had many fabricators tell me they wouldn’t hesitate to shave an inner layer pad by 3 mils if it would help yield.
That leads to the next point regarding communication. You might be fine with the idea of a fabricator making edits to improve your design for manufacturability, but if you are not informed of those changes you assume your original design is good and submit that to another supplier, maybe this time for production build, only to find out you got different results from the second supplier because they did not make the same edits. You need a way of avoiding the need for a supplier to edit your design and you need a way of validating that they did not make any unauthorized edits.
Many EMS companies’ business models are based on them sourcing the components. In essence they act as a distributor and buy components in volume and there is nothing wrong with that. The question is how confident are you that every alternate part they propose will be acceptable to you from a form and fit perspective? Wouldn’t you want control of that?
Lastly, we speak of product quality. A gain we often assume our supply partner’s objectives are the same as ours, but they are not. Our company’s name is on the product and therefore at stake so product reliability is of utmost concern to us. The external supplier’s responsibility to reliability ends when he ships you the boards you ordered. His liability ends as soon as they pass your incoming inspection. So it behoves you, not your supplier, to analyze a design for reliability issues.
None of this is to say your suppliers are doing you a disservice – they are not. They are often our customers as well. It is just that their interests are not always the same as yours.

8. PCB Design Review and Release Process Today
Presentation Title
PCB Design Review and Release Process Today
Release to Manufacture
Library Cell Generation
Electrical Engineer
Component Engineer
Librarian
Mechanical Engineer
PCB Designer
Manufacturing Engineer
Library Cell Review
Component Placement
NPI Engineer
Test Engineer
Component Placement Review
Route PCB
Quality & Test Engineer
Product Manager
Supplier Quality Engineer
PCB Design Review
Generate Manufacturing BOM
Manufacturing BOM Review
Create/Review Manufacturing Outputs
Manufacturing Package Review
Fabrication Supplier Review
Assembly Supplier Review
Your Initials, Presentation Title, Month Year

9. Yield, cost & reliability Manufacturing violations
Presentation Title
DFMA Complements DRC
DFM enables you to optimize your design for volume manufacturing in the initial release
An issue can pass DRC but still impact yield, cost or reliability
Close spacing over an extended length affects yield and therefore costs
Yield, cost & reliability
opportunities
Manufacturing violations
Your Initials, Presentation Title, Month Year

10. PCB Design Review and Release Process with DFMA
Library Cell Generation
Component Placement Review
Component Placement
Lock in placement for manufacturability before you start routing copper
Validates placement against assembly processes
Route PCB
Component clearance requirements vary by type, orientation and placement machine
Toeprint too close to conveyed edge can be damaged by SMT gripper
Tall components too close to adjacent components make it difficult to access the short component for repair
Misplaced reference designator causes confusion at test, repair and for manually placed components
Generate Manufacturing BOM
Create/Review Manufacturing Outputs
Release to Manufacture

11. PCB Design Review and Release Process with DFMA
Presentation Title
PCB Design Review and Release Process with DFMA
Library Cell Generation
PCB Design Review
Component Placement
Running DFM concurrent with PCB design accelerates the release process
Common fabrication issues are identified and addressed immediately by the Designer
Route PCB
Slivers can cause repeat defects due to photo-resist flaking
Starved thermals prevent proper heat containment, affecting quality of via solder connection
Manufacturing process tolerances can cause a same net short, potentially affecting circuit behavior
Circuits close to a pad must be fully covered by mask to avoid solder bridging during the assembly process
Generate Manufacturing BOM
Create/Review Manufacturing Outputs
These are all checks that can be done as part of Valor DFF.
DRC does not report same net spacing.
Release to Manufacture
Your Initials, Presentation Title, Month Year

12. PCB Design Review and Release Process with DFMA
Graphically synchronize views between DMFA tool and PADS to resolve issues immediately
Library Cell Generation
PCB Design Review
Component Placement
Route PCB
Generate Manufacturing BOM
Create/Review Manufacturing Outputs
Release to Manufacture
Designer gets the benefit of Valor DFM during the layout process

13. DFM Analysis

14. DFM Analysis - Activation
Presentation Title
DFM Analysis - Activation
There are two modes of activation.
Start Analysis is for when the analysis is completely configured and can simply be run.
Setup is for configuring a limited set of analysis requirements. In most cases, this will only need to be done during initial setup.
PADS Export Menu Pick
Your Initials, Presentation Title, Month Year

15. Setup

16. DFM Analysis - Setup Presentation Title PADS Export Menu Pick
Your Initials, Presentation Title, Month Year

17. DFM Analysis - Setup Open Attribute Assignment Editor
Activates advanced attribute assignment functionality
Preview Analysis Constraints:
Configures the automated procedure to expose the constraint information used by the analysis
Open Constraints Editor
Opens the analysis constraint interface
Specify display units?
Indicates the display units to be used by the application

18. Constraints Editor Used to setup analysis values
Values are stored as templates and can be later recalled
Values used on a design are stored with the design
Once stored in a design, the values are reloaded for each analysis run

19. Constraints Editor Save Inch/Micron Expand/Collapse Constraint Name
Constraint Value

20. Constraints Editor
Load… - Reads a previously saved set of analysis constraint values
Save – Save the current constraint values overriding the existing set
Save As… - Save the current constrain values using a different name
Close – Close the Constraints Editor.

21. DFM Analysis - Setup
Save – Save the existing flow configuration under a different name for later reuse.
Stop – Stop the configuration process. The “Next” button will change to “Start” to restart the process.
Next – Continue to save the configuration for use by the DFM Analysis automated process.

22. Start Analysis

23. DFM Analysis - Activation
Presentation Title
DFM Analysis - Activation
PADS Export Menu Pick
Your Initials, Presentation Title, Month Year

24. DFM Analysis - Constraints Editor
Presentation Title
DFM Analysis - Constraints Editor
Preview Analysis Constraints may appear.
This is dependent upon the configuration stored during the setup process.
Once you are satisfied with the analysis constraints, select “Continue” to start the manufacturing analysis process.
PADS Export Menu Pick
Your Initials, Presentation Title, Month Year

25. Result Viewer Toolbar Results Tree Click layer to display Display Area
Overview Area

26. Spacebar will also advance
Presentation Title
Result Viewer
First
Back
Forward
Last
Spacebar will also advance
Location
Your Initials, Presentation Title, Month Year

27. Result Viewer All Locations Displayed Presentation Title
Toggle Viewed Status
Toggle Units
All Locations Displayed
Display All
Description
Your Initials, Presentation Title, Month Year

28. Contact Info
EDA Direct Inc.
(408)
(888) 669-9EDA
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