MANUFACTURING INFORMATION, DOCUMENTATION in Software

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MANUFACTURING INFORMATION, DOCUMENTATION
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DESIGN ANALYSIS AND REVIEW
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Design analysis and review is a refinement of the initial design review performed earlier but is the first step in the CAM (soft-tooling) process.This step focuses on the actual design data submitted for fabrication and assembly. The design analysis and review step consists of the following tasks:
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Design rule checking Manufacturability analysis Single-image edits DFM enhancements Panelization Fabrication parameters extraction
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These tasks provide the final checking of the PCB design requirements against the capabilities of the PCB manufacturer and preparation of the design for manufacturing. Most fabrication problems occur or are discovered during the initial tooling (CAM) phase. The following are among the causes of such problems:
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Poorly documented designs Improperly formatted drill files Use of 274-D Gerber with separate aperture tables Lack of proper clearance on solder mask openings Inadequate drill-to-copper clearance Misaligned layers Inadequate manufacturing clearances Lack of an IPC-D-356 netlist Use of positive plane layers instead of negative ones Minimal communication between the designer and the fabricator
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The best advice for these problems is to fix them during the design phase. Consider the following precautions and considerations:
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Try not to use 274-D with separate aperture tables. Because there are no standards for aperture tables, the fabricator must do extra work to accommodate the tables, with increased opportunity for error. Use 274-X whenever possible. The apertures are embedded and files are easier for the fabricator to work with. This provides better support for special aperture shapes. Better yet, if possible, use intelligent formats like GenCAM, DirectCAM, or ODB++. These formats should enable the fabricator to better understand your design.Also, such formats have the netlist information embedded. Design rules can be embedded in some formats.
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THE CAM-TOOLING PROCESS
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The CAM-tooling process consists of six or more distinct manufacturing engineering activities. These include the following:
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PRINTED CIRCUITS HANDBOOK
Design rule checking (DRC) Manufacturing review Single-image edits DFM enhancements Panelization Fabrication and assembly parameters extraction
Design Rule Checking Design systems lay out circuits to defined rules; however, these systems may fail to adhere to these rules, because of either system failure or manual intervention. The purpose of reviewing the data package, in addition to reviewing the documented design constraints, is to confirm that the product can be produced at the manufacturing site and to the expected manufacturing yields. The analysis of the data describing the circuitry of the PCB to the manufacturing facility s production capabilities is critical to the success of the product. Table 20.4 defines typical design rule checking that is performed, the reasons for checking, and the method of checking.
Manufacturability Review The design rule checking results are reviewed against the PCB manufacturing capability matrix, with dispositions being made to the acceptability of violations.The PCB customer may be contacted regarding design violations, to correct and retransmit the design or to permit design changes to be performed by the PCB manufacturer. Additionally, the factors reviewed during the initial design review are revisited to confirm the results based on design actuals. If differences are noted, product yields and/or cost predictions may need to be altered. During this step of tooling, several concerns are uppermost in the fabricator s mind: Does the board meet the intent of the design Can it be built Will it function as planned Does it pass a master rule set Can it be improved, that is, be made cheaper or better Is there component interconnectivity Does the IPC-D-356 netlist show any shorted nets or broken nets Were any multiple plane ties not happening Did a design work-around fool the system or allow intentional errors to slip through 20.6.2.1 Bare-Board Analysis. Several physical artwork problems are not discovered by design rule checking and are not strictly speaking the result of design rule violations. Nonetheless, these problems can affect the manufacturability of a board and its yield. Table 20.5 describes some of these issues. Figure 20.14 shows examples of many of these problems. Most modern CAM-tooling systems can correct these manufacturability issues. Thus the manufacturing notes on the fabrication drawings should acknowledge this and allow for the fabricator to implement corrections. Other, less frequent, artwork errors discovered include:
Signal integrity and performance issues Verification of last-minute changes [life savers and engineering change orders (ECO)] Made in XX and revision controls
20.6.2.2 Printed Circuit Assembly. In a similar situation, assembly tooling requires the checks and analysis of supplied BOM, machine files, and artwork for the assembly process. These actions are specifically designed to locate potential manufacturability problems during
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