Towards Next-Generation Design-for-Manufacturability Frameworks for Electronics Product Realization Phase 1: Rule-based Manufacturability Verification of Circuit Board Designs

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Towards Next-Generation Design-for-Manufacturabil
ity Frameworks for Electronics Product
RealizationPhase 1 Rule-based Manufacturability
Verification of Circuit Board Designs
Semicon West 2003 SEMI Technology Symposium
International Electronics Manufacturing
Technology Session 210 Factory Simulation,
Automation and Integration SEMI and IEEE/CPMT?
San Jose, CA July 18th, 2003
Recipient of the Best Paper Award in Session
210, IEMT, Semicon West 2003

• Manas Bajaj, Dr. Russell Peak, Miyako Wilson,
  Injoong Kim
• Thomas Thurman, M.C.Jothishankar, Mike Benda
• Dr. Placid Ferreira, Dr. James Stori

Updated web version http//www.eislab.gatech.edu/
pubs/conferences/2003-ieee-iemt-bajaj/
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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Simulation for Flexible Manufacturing
(SFM)Project Vision

• Enable a collaborative environment for engineers
  (design, manufacturing, producibility, test etc.)
  to work together and negotiate for a robust
  product model

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Simulation for Flexible Manufacturing
(SFM)Project Timeline Teams

• Teams
• Rockwell Collins (RCI)
• Thomas Thurman, M.C.Jothishankar, Mike Benda
• Georgia Tech (GIT)
• Dr. Russell Peak, Manas Bajaj, Miyako Wilson,
  Injoong Kim
• University of Illinois at Urbana Champaign (UIUC)
• Dr. Placid Ferreria, Dr. James Stori, Dong Tang,
  Deepkishore Mukhopadhyay
• SFM Project Timeline
• Initiated in August 2002
• Completed Phase 1.1 in December 2002
• Completed Phase 1.2 in April 2003
• Developed Framework used for production at RCI in
  May 2003

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Simulation for Flexible Manufacturing
(SFM)Project Phase 1

• Develop a DFM Framework
• Enable designers, manufacturers, assembly and
  test engineers to work collaboratively
• Domain of Interest
• Printed Circuit Assembly design process
• Motto of the DFM Framework
• Develop a generic and modular architecture
• Core components customizable for specific
  enterprises

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Motivation for building a DFM frameworkSimulatio
n-based Design General Overview

• Systems Approach to product realization --
  organizing the smorgasbord
• Capturing mutual interaction amongst design,
  manufacturing, assembly, testing, packaging etc.
  related activities
• Building product and associated process models
• Creating smart configurations adaptable to
  changing technology and business needs
• Reduce cycle time and possibilities of redesign
• Capturing activity specific knowledge and utilize
  it for enhancing related activities and tasks
• Learning from todays experience to improve
  performance tomorrow Intelligent Systems

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Motivation for building a DFM frameworkSimulating
Process Emulating Knowledge

• Simulate Printed Circuit Design process
• Emulate expertise of manufacturers, test and
  producibility engineers for robust designs

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Core Ingredients of a DFM Framework1.
Electronics Product Design Model

• Need of an Integrated Design Model
• Ability to support different dimensions of
  product design
• Functional Model
• Part - Assembly Structure
• Configuration Management
• Requirements Specification
• Formal data specification for higher fidelity
  across engineering domains
• Semantically rich in content and coverage
  ability to expand to the ever rising complication
  in product and process data structure

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Core Ingredients of a DFM FrameworkChallenges
towards an Integrated Design Model
Existing Tools
Tool A1
Tool An
...
Legend
Content Coverage Gaps
dumb information capture (only
human-sensible, I.e., not computer-sensible)

• Smart Product Model
• Building Blocks
• Models meta-models
• International standards
• Industry specs
• Corporate standards
• Local customizations
• Modeling technologies
• Express, UML, XML, COBs,

Example dumb figures
Content Semantic Gaps
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Core Ingredients of a DFM Framework2.
Manufacturing Expertise

• Need to capture the expertise of manufacturers
• To be able to gather manufacturing knowledge
• To be able to represent this genre of knowledge
• To be able to use these knowledge sets to guide
  design decisions
• To be able to share this knowledge across
  enterprise specific manufacturing facilities

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Core Ingredients of a DFM Framework Challenges
towards capturing manufacturing knowledge

• Fuzzy nature of manufacturability knowledge

• Design Parameters
• geometrical dimensions
• -- gd_1
• -- gd_2
• -- .
• material properties
• -- mp_1
• -- mp_2
• --

?2

• weak
• gttensile
• gt 10 MPa

Manufacturability Knowledge
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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Functional Foundation of DFM Framework1.
Answering integrated design model challenge

• Use of STEP AP210 standard specifications to
  build the semantically richer and higher fidelity
  integrated design model

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STEP AP 210 (ISO 10303-210) Domain Electronics
Design(ap210.org)
800 standardized concepts (many applicable to
other domains) Development investment O(100
man-years) over 10 years
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Functional Foundation of DFM Framework2.
Answering knowledge capture challenge

• Use of Expert Systems Technology
• Expert Systems are computer programs to emulate
  human expertise and take decisions to the best of
  current knowledge.
• Used for problems / scenarios that are complex
  (abstract, deeply branched decision tree etc.)
  enough to require human expertise.
• Facility to add knowledge
• Explanation facility to track the chain of logic
  serves as a conformance test

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Core Advantages of Expert Systems

• Separation of knowledge from control
• Better foundational architecture
• Ease of maintenance
• Ability to add new knowledge and refine
  functionality
• Ability to handle abstraction
• Support decision making in the design process in
  the absence of knowledge to the best use of
  as-available information
• Trace the tree of design decisions
• Ability to track the logical steps in process
• Serves as an explanation facility
• Used for conformance testing

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Conceptualizing the DFM ArchitectureFundamental
Framework Pulling it all together
End User View Manufacturability Feedback ij of a
given design i
Design Integrator
Results Manager
Design View j Generator
Rule-based Expert System
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Building the SDF (SFM DFM Framework)
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Integrated Design Model STEP AP210Example view
in STEP Book AP210 Browser (LKSoft)
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SDF Rule-based Expert SystemRule authoring
tool Rule checking tool
DFM document j (human sensible)
Rule Description Facility (RDF)
rules in RDF (computer sensible)
Design View ij
Manufacturability Knowledge Base j
Rule Execution Facility (REF)
Results ij
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SDF Results ManagerViewing DFM violations in the
Results Browser
Results Log (from SFM Rule-based Expert System)
Results Viewer (highlighted features have DFM
violations)
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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Future Architecture Standards-based Framework
Machine Simulator
Rules Repository
Rules Engine
AP 210
LKSoft
AP 210 3D Viewer
Exceptions
ECAD Design
CIM Package Library
Visula Package Library
Simulation for Flexible Manufacturing
Converter
AP 203
AP 203 3D Viewer
CAM Application
MCAD Part Design
MCAD Assembly Design
Inspection Application
PDF 2D Viewer
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Future ArchitectureExpanding the scope of the
current architecture

• Enhancing the scope of the DFM Framework to a
  generic DFX Framework
• DFX Design for X
• where X Manufacturing, Testing, Assembly etc.
• Expanding the downstream application of the 210
  design model
• Rule-based Manufacturability analysis
• Finite Element based PWB Warpage analysis
• Engineering economy based analysis
  (Design-to-Cost)

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Conclusion

• Achievements of the SDF SFM DFM Framework
• Demonstrated the ability to build an integrated
  design model to support manufacturability
  constraint check
• Use of STEP AP210 standard
• to support product life cycle related tasks
• foundation for building semantically richer and
  higher fidelity product models
• Demonstrated the ability to capture and utilize
  manufacturing expertise
• Integrating core functionalities for developing a
  collaborative environment for designers and
  manufacturers

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Acknowledgements

• Rockwell Collins
• Kevin Fischer, Floyd Fischer, Wayne Foss, Dick
  Postma, Jennifer Waskow, Ian Wicke, Jim Lorenz,
  Jack Harris
• LKSoft (lksoft.com intercax.com)
• Lothar Klein, Viktoras Kovaliovas, Giedrius
  Liutkus, Kasparas Rudokas
• PDES Inc. Electromechanical Team
  (pdesinc.aticorp.org)
• Greg Smith (Boeing), Mike Keenan (Boeing), Craig
  Lanning (Northrop Grumman)
• Arizona State University
• Prof. Teresa Wu
• Georgia Tech
• Prof. Robert Fulton, Prof. Nelson Baker

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Contents

• Introduction -- Simulation for Flexible
  Manufacturing
• Design-for-Manufacturability (DFM) Framework
• Motivation
• Core Ingredients
• Functional Foundation
• Building the SDF (SFM DFM Framework)
• Future Architecture
• Conclusion
• Acknowledgements
• Questions?

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Questions?