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

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

3. 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

4. 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

5. 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

6. 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

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

8. 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

9. 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

10. 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

11. 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!

12. 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

13. 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

14. 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

15. 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

16. Outil de gestion-planification

20. 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

21. 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”