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Network Communications The generation, transmittal, and storage of process information is critical for real-time control of a circuit board assembly process, whether that process is for building consumer electronics in high volume or involves a low-volume assembly line for high-reliability military, space, or satellite electronics. The information that is generated by operators or automated machines on the shop floor typically includes commodity usage (i.e., circuit boards, components, etc.) as well as defects and machine malfunctions. Commodity usage information can then be made available to inventory control in the plant stockroom or even to the bill-of-material (BOM) suppliers across town and around the world, identifying the need for additional components, flux, and such at that particular site. Process information is also accessed by the manufacturing engineer, who is monitoring the overall assembly flow, as well as by the process engineers or technicians who are directly responsible for equipment operations (e.g., furnace zone temperatures, flux levels, etc.). In addition, information may be shared between the different machines on an assembly line to prevent slowdowns in process flow due to equipment outage. Such slowdowns and stoppages can impact upstream steps. For example, there can be shelf-life issues with solder paste that is left out in a printer too long due to a stoppage created at a subsequent component placement machine or reflow oven. It is often necessary to archive process-related information. Archived data are used to track defects as a means of process control. These data can assist in quickly determining the root cause of an out-of-control process. Process information can also be used to monitor long-term equipment performance, indicating the need for periodic preventive maintenance or machine replacement. Easy access to historical process information can also facilitate the reintroduction of a particular product line with a minimum investment in process development efforts.

Finally, archived process data are useful in an investigation of field failures The traceability of the troubled product to the exact process parameters used on the assembly line at that time, material lots, operators, and so on can be accessed; these data are invaluable for the follow-up root-cause analysis, particularly in the case of high-valued, high-consequence electronics systems (eg, military equipment, space and satellite hardware, as well as medical and automotive electronics) Understanding the circumstances under which the defective product was made can also provide insight into implications regarding long-term reliability and specifically warranty costs versus liability and the need to implement a product recall The need to access information quickly as part of assembly operations extends beyond process and inventory control Peripheral information such as equipment software and operations manuals must also be quickly accessible.

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The ready availability of boot-up software and instructions minimizes the downtime required to reestablish a product line or effect repairs on a malfunctioning machine Once the need for a network has been determined, the locations of terminals, servers, and information storage equipment must be established Local area networks (LANs) and the worldwide web (WWW, or Internet) can link access points located in adjacent rooms or halfway around the world However, it is critical that the network uses consistent computer and data transmittal protocols in order to provide uninterrupted, information handling in an efficient manner For example, serial communication via an RS-232 port is relatively common, but too slow for most machine applications Ethernet communication via transmission control protocol/Internet protocol (TCP/IP) is a preferred method because most equipment suppliers offer this network option.

The TCP/IP method allows computers to share resources, no matter whether the operating system is for an Apple , a version of the Microsoft operating system for PCs, or the UNIX operating system Also, the Semiconductor Equipment Communication Standard (SECS)/Generic Equipment Model (GEM) is widely used as the interface between the host computer and assembly machines Lastly, the need for efficient network communications is particularly acute with the advent of Pb-free solders In the case where OEMs as well as contract manufacturing service (CMS) companies are assembling both Sn-Pb and Pb-free technologies, it is essential to control all aspects of the assembly process with precision In fact, process control extends beyond simply certifying that the reflow, wave, or soldering iron correctly reflect the higher soldering temperatures.

c c Av = a b 1 a b 2 2 Av = 775 12 1 775 12 2 Av = 535 in 345 10 3 m2

It must also make certain that components and circuit boards have been delivered to the appropriate process line having the correct surface finishes and/or MSLs Also, process control must establish that other factors, such as flux type and cleaning procedures that may be unique to the Pb-free process, are being used on the appropriate product line..

The selection of assembly process equipment is an extensive undertaking for the manufacturing engineer. The three principle variables are equipment utilization, costs, and physical plant requirements. These three areas are listed in order of consideration, not in the order of importance. The analysis behind equipment selection can be very complex, given the wide variety of product designs, potential automation options, and access to worldwide labor markets. Unfortunately, the failure to consider thoroughly the details underlying any one of these three factors can result in a significant financial burden, lost time to market, and poor product quality/reliability for the OEM or CMS. The following sections provide relatively general discussions of these three areas. The reader is referred to many excellent texts on the topic of manufacturing engineering, as well as source books that specifically address assembly process equipment for electronics manufacturing.

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