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FIGURE 38.21 Fully automatic verification system and CAR station. (Courtesy of Everett Charles Technologies.)
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described for verification purposes is used to highlight the proposed repair site to the operator, who performs the appropriate cuts or welds.
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38.6 TEST DEPARTMENT PLANNING AND MANAGEMENT
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In most cases, a new manager inherits a selection of existing equipment, processes, and personnel. Nonetheless, over a period of time, the manager has the same opportunity to shape the test floor operation as does the unlikely individual starting from a clean sheet of paper. To the extent that the past suggests the future, the new manager may expect increased density, finer pitch, higher total test-point counts, decreased tolerance for test escapes, shorter product delivery times, shorter product lifetimes, and larger numbers of smaller batches of boards for just-in-time delivery. 38.6.1 Equipment Selection Most equipment being purchased for general bare board testing consists of universal grids and flying probers. The increased capabilities of flying probers and increased demand for small lot and prototype testing have increased the number of probers selected. This trend seems likely to continue, but each shop must determine its appropriate solution individually. A first consideration in selecting equipment lies in recognition of the type of business you anticipate. For very-high-volume production of a variety of part numbers, the universal grid is a likely participant. For medium volumes, considerable savings may result from the elimination of test fixturing costs and delays that can be achieved by combining flying-probe test systems with throughput enhancement systems, as described in Sec. 38.4.3. For prototype or small lot
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production, a quantity of flying-probe systems may be the best alternative due to the elimination of fixture expense. Dedicated (wired) fixture type equipment is rarely demanded due to fixture cost, excepting very simple systems that remain devoted to an extremely high-volume run of a single product type for extended periods of time. A further important concern is the level of technology that you anticipate. Verify that it does not outrun the capabilities of the fixture or test system types that you plan to use. Plan for change, as the equipment that you purchase must last for several years. Also consider the level of support available from the equipment vendor, including ordinary maintenance service, emergency service, employee training support, and applications support. For high-volume operations, you can achieve substantial throughput and consistency of operation by adding automatic handling systems to a universal grid system configuration. For prototypes and moderate production volumes, the ability to place a stack of boards on a flying probe system and walk away for an hour or so, rather than wait for a board to come out every three minutes, can result in huge labor savings. Note that some very large, very thin, or very small product types may not be well suited to automatic handling without the use of special carriers or adapters. It may be best to size the automation equipment to handle the major portion of production and leave unusual product configurations on manually loaded equipment. An often overlooked but practical consideration is maintaining some degree of commonality in equipment and fixtures. It is not uncommon for fixture problems to lead a test engineer to change equipment types several times, resulting in a motley assortment of incompatible (but expensive) test systems but failing to resolve the fundamental underlying issue. With datadriven test processes and automated fault data management in the mainstream, the ability of equipment to share data, fixtures, and operating procedures will decrease cost, increase throughput, simplify training, and enhance opportunities for combinational test solutions. This is harder to achieve with a random mix of equipment. If this seems to state the obvious, try this experiment: Visit some shops, stopping in drill rooms and in the electrical testing area. Do you see a difference in the assortment of equipment Department planning should include not only new equipment, but also an exit strategy for old and inefficient equipment that you wish to retire.
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Fixtures: Build or Buy, and What Type If you plan to use fixtures, the selection of fixtures is probably more important than the choice of equipment on which you choose to run the fixtures. Certainly you must have equipment at least adequate to the fixture, and with sufficient test-point density for the product. This is where a careful evaluation of product technology is crucial. If the product includes even fairly simple SMT boards, then you should plan immediately for a dual-side capability. If the product includes fine-pitch SMT, dense BGA patterns, and such, then you must consider higher-density universal grids and modern tilt-pin fixtures consistent with the test-site density on these products. If you plan to build fixtures in-house, recognize that you are creating a complete manufacturing operation. Measurement of complete material, labor, inventory, and overhead costs as well as operating efficiency is critical to effective management of this operation. Don t just measure how fast you build a fixture, but include measurement of the time it takes to get it running. Consider whether you would be better served by outsourcing fixture fabrication. Avoid manufacturing multiple styles of fixtures. Ensure that you have an inventory management process that does not run out of pins at midnight, but does not have half a million dollars tied up in obsolete pin inventory. Consider outsourcing at least the more difficult fixtures to specialists. You may save time, plus gain a partner who provides exposure to alternative techniques and materials.
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