How Engineering Supports Manufacturing

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How Engineering Supports Manufacturing

• Larry E. Hand

Peavey Electronics March 28, 2000
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Introduction

• Senior Design
• Larry E. Hand, MEE PE MCSE
• Master Electrical Engineering, Auburn University
  1977
• Harris Corporation, Melbourne Fl. 1977-83
• Peavey Electronics, 1983-Present

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Proof of Concept..
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After Proof of Concept, What Next?

• Vacation
• Big Bonus
• Two Attaboys
• Another Project
• Physical Design and Transition to Manufacturing

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Life After Prototyping

• Physical Design and PC Layout
• Parts Procurement
• Costing
• Agency Approvals
• Documentation, Literature and Manuals

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More things to consider

• Mechanical Design and Packaging
• Manufacturing Deliverables
• Murphys Law- ECNs and rework
• Its Always yours..

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Printed Circuit Board Design

• Component Placement
• Input/Output locations
• Mounting Considerations
• Technology Selection
• Restricted areas
• Minimize crossing count
• Thermal Management

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Printed Circuit Board Design

• Electrical Considerations
• High Impedance Nodes
• Differential signal pairing
• Shielding for Magnetic and Capacitive Coupling
• Transmission Line Effects- OverShoot and Ringing
• EMI/EMC
• Ground is NOT Ground......

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Printed Circuit Board Design

• Manufacturing Considerations
• Component Spacing
• Orientations
• Hole Sizes
• Insertion Tooling Restrictions
• Tooling Holes
• Panelization

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Parts Approval and Procurement

• Standard Parts
• Multiple Sourced
• Cost Effective
• Minimal Specifications required
• Improved response to demand changes
• Note Not all parts are created equal....
• Single Sourced
• Unique or Patented Technical Advantage
• An Act of Nature could shut you down!
• Know Who Youre Dealing With

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Parts Approval and Procurement

• Custom Parts
• Product Differentiation
• Protect Trade Secrets and Intellectual Property
• Extensive Specifications/Documentation
• If you change your mind, Theyre still yours
• Requires Accurate Forecasting

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Parts Approval and Procurement

• Approved Vendor List (AVL)
• Lead Times
• Minimum Quantities
• Packaging/Delivery Options
• Bulk
• Tape and Reel
• Tape and Ammo
• Trays or Tubes

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How is Cost Determined

• Material Cost
• Labor Cost
• Manufacturing Burden
• SGA

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How Much does it Cost

• Material Cost---52 of Total Cost
• Unit Price Quantity for all BOM items
• Labor Cost --- 8 of Total Cost
• Direct labor or value added labor required to
  manufacture the product

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How Much Does it Cost

• Manufacturing Burden --- 17 of Cost
• Indirect Labor
• Utilities
• Facilities
• Employee Benefits
• Depreciation, rent, etc..

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How Much Does it Cost

• Sales/General and Administrative -- 23
• Cost of Selling the Product
• Sales commission
• Advertising
• Service and Warranty
• Corporate Management
• Research and Development
• IS, Bad Debt, etc..

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Agency Approvals

• UL
• CSA
• FCC
• NOM
• CE
• NEMKO
• DEMKO

• VDE
• IRAM
• SASO
• SANZ
• SAA
• JIS
• and more.....

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Documentation

• User Manual
• Technical Specifications
• Service Manual
• Assembly Directions
• Marketing Support
• Advertising Copy

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Packaging

• Protect Unit During Shipment
• Attractive at Point of Sale
• Advertising
• OEM or Consumer packaging

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PCB Manufacturing Flow

• Top Side SMT
• DIP ICs and Sockets
• Axial leaded components
• Bottom side SMT
• Radial leaded components

• Hand Assembly
• Wave Solder
• Touchup and Inspect
• Precheck

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Manufacturing Deliverables

• Programs for Automated Assembly Equipment
• Axial Sequencer and Insertion
• Radial Insertion
• DIP Socket and IC insertion
• Surface Mount Chips, ICs, Odd Shaped Components
• GenRad Automated Test

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Manufacturing Deliverables

• PCB Assembly Drawings
• Gerber Files
• Mechanical Fabrication Drawings
• Functional Test Procedure
• Technical Specifications
• Trouble Shooting procedures
• Your Experience and Knowledge

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Oops....

• Tolerances
• Incomplete Beta Testing
• Parts Availability
• Poor Manufacturing Yield
• Poor Reliability
• Marketing Redirection/Feature Addition

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Engineering Change Orders

• ECOs document a change that manufacturing will
  implement
• Disposition of existing inventory
• Disposition of Work In Process
• Reason for Change
• Cost/Performance/Schedule Impacts

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Engineering Change Orders

• Safety - Liability
• Recall, Disposition of units already sold
• Obsolete inventory

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Sustaining Engineering

• If you birth it, Its always your baby
• Customer complaints
• Obsolete Parts
• Unique Parts
• Warranty claims and Field Failures
• Specification changes in standard components