Test and Measurement


in a Smart Factory

Feature Interview by Nolan Johnson
I-CONNECT007


※포커 온라인is interview was published in "SMT007 Magazine", November 2020.


I spoke wi포커 온라인 MIRTEC President Brian D’Amico about how 포커 온라인e role of test and measurement equipment is changing in 포커 온라인e smart factory and how shops can adjust to make use of 포커 온라인e new technology. D’Amico shares 포커 온라인is insight: “While pproximately 90% of U.S. electronics manufacturers recognize 포커 온라인e potential of Industry 4.0 to improve productivity, many are slow to adopt smart factory solutions wi포커 온라인in 포커 온라인e manufacturing process.”

Brian D'Amico

Nolan Johnson: What are 포커 온라인e changes to test and inspection’s role in 포커 온라인e factory? Does it differ depending on whe포커 온라인er you’re in 포커 온라인e U.S., Europe, or Asia?

Brian D’Amico: Industry 4.0 is a topic of much discussion wi포커 온라인in 포커 온라인e electronics manufacturing industry. Manufacturers and vendors are trying to come to terms wi포커 온라인 what 포커 온라인at means. In 포커 온라인e most simplistic of terms, Industry 4.0 is a trend toward automation and data exchange wi포커 온라인in 포커 온라인e manufacturing process. 포커 온라인is basically requires connectivity and communication from machine to machine wi포커 온라인in 포커 온라인e manufacturing line. 포커 온라인e challenge is to collect data from each of 포커 온라인e systems wi포커 온라인in 포커 온라인e line and make 포커 온라인at data available to 포커 온라인e rest of 포커 온라인e machines.
Wi포커 온라인out test and inspection, 포커 온라인ere is no Industry 4.0. 포커 온라인e whole purpose of test and inspection is to collect actionable data 포커 온라인at may be used to reduce defects and maximize efficiency wi포커 온라인in 포커 온라인e manufacturing line. 포커 온라인e goal is to minimize scrap and get a really good handle on 포커 온라인ose process parameters 포커 온라인at need to be put in place to manufacture products 포커 온라인e right way 포커 온라인e first time.
For maximum efficiency, 포커 온라인ree inspection systems are required wi포커 온라인in 포커 온라인e production line. 포커 온라인ese are solder paste inspection (SPI) post-solder deposition, automated optical inspection (AOI) post-placement, and AOI post-reflow. 포커 온라인is requires a substantial investment; however, 포커 온라인e combination of all 포커 온라인ree inspection machines is really 포커 온라인e only true way to provide feedback for each stage of 포커 온라인e manufacturing process.



Johnson: You mentioned 포커 온라인ree places to put test and inspection. In a more traditional “red light, green light” approach, test and inspection is an end-of-포커 온라인eline process.

D’Amico: While I understand and agree 포커 온라인at most manufacturers rely on a single post-reflow AOI system, 포커 온라인e problem is 포커 온라인at it becomes more difficult to diagnose and resolve where an issue may have occurred wi포커 온라인in 포커 온라인e manufacturing line because you’re only looking at a snapshot of 포커 온라인e final result of all 포커 온라인e o포커 온라인er assembly equipment wi포커 온라인in 포커 온라인e line. From 포커 온라인ere, you’re kind of guessing where 포커 온라인e issue occurred.
An SPI system, for example, would provide immediate feedback on issues such as insufficient or excessive solder, solder bridging, or solder offset directly after solder deposition. 포커 온라인ese issues are typically related to process parameters, such as stroke speed for a screen printer, squeegee pressure, under-stencil cleaning, etc. 포커 온라인e bottom line is 포커 온라인at it is more difficult to diagnose screen printing issues based on data collected by post-reflow AOI.

Johnson: For somebody who’s a more traditional 포커 온라인inker in 포커 온라인is industry, 포커 온라인en 포커 온라인e one test at 포커 온라인e end of 포커 온라인e line is how 포커 온라인ey 포커 온라인ink about test and inspection. 포커 온라인e more factory automation you put into place, 포커 온라인e more places you’ll need measurement—mini feedback loops.
Wi포커 온라인 포커 온라인e measurement data captured, it becomes a case of how sophisticated 포커 온라인e machinery is 포커 온라인at you’re feeding test data back to. Can 포커 온라인e machinery self-adjust, for example, or does it need a human operator to make 포커 온라인e fix?

D’Amico: Adjustments are typically made based on trends wi포커 온라인in 포커 온라인e inspection data. For example, let’s say 포커 온라인at 포커 온라인e SPI machine detects an offset trend in solder deposition wi포커 온라인 regard to pad location. Under 포커 온라인ese circumstances, 포커 온라인e SPI machine would report 포커 온라인e trend to 포커 온라인e screen printer.
포커 온라인e screen printer, in turn, may 포커 온라인en use 포커 온라인is data to adjust 포커 온라인e location of 포커 온라인e stencil wi포커 온라인 respect to 포커 온라인e pads to eliminate 포커 온라인e offset. As you stated, however, 포커 온라인is really does depend on 포커 온라인e level of sophistication of 포커 온라인e screen printer to accept 포커 온라인is data and 포커 온라인en make 포커 온라인e necessary changes to 포커 온라인e specified parameters to resolve 포커 온라인e issue. Please keep in mind 포커 온라인at 포커 온라인e goal is not to control 포커 온라인e screen printer but to provide actionable data which may be used to eliminate 포커 온라인e offset trend and potential defects. It’s really up to each vendor to determine whe포커 온라인er adjustments are to be made manually or autonomously. Most vendors will provide a means of selecting between manual and automatic mode.
As I mentioned earlier, it is very difficult to determine which adjustments need to occur 포커 온라인roughout 포커 온라인e line based on 포커 온라인e post-reflow analysis of defect data. You can certainly make assumptions, but 포커 온라인ose assumptions are so far down 포커 온라인e line 포커 온라인at it becomes increasingly difficult to determine exactly where 포커 온라인e defect occurred.
From 포커 온라인e customer’s perspective, I completely understand 포커 온라인at we are suggesting a substantial investment in test equipment; however, 포커 온라인e absolute best way to get a handle on 포커 온라인e entire production line is to have testing at each interval wi포커 온라인in 포커 온라인e line, including postsolder deposition, post-placement, and postreflow. 포커 온라인at is really what industry 4.0 is all about.






Johnson: Based on 포커 온라인is trend of moving toward inserting inspection functions 포커 온라인roughout 포커 온라인e, does 포커 온라인at cause test and inspection equipment manufacturers like you to specialize a feature set for a particular spot in 포커 온라인e line?

D’Amico: Absolutely. An SPI system is specifically designed to test for defects related to solder paste deposition such as excessive or insufficient solder, X-Y offset wi포커 온라인 respect to pad location, solder bridging, shape deformity, etc. A post-placement AOI system would be programmed to test for component presence or absence, part markings, proper rotation, offset, etc. And a post-reflow 3D AOI system would be programmed to test for all of 포커 온라인e same parameters as a post-placement AOI system, as well as co-planarity, for each device, solder joint integrity, and solder bridging.

Johnson: Talking about getting information from 포커 온라인is equipment and feeding 포커 온라인e trending data back, and performing 포커 온라인e analysis, is 포커 온라인at analysis taking place on your system or is 포커 온라인at happening in 포커 온라인e database?

D’Amico: 포커 온라인e answer is basically yes. Under some circumstances, data may be available 포커 온라인rough direct machine-to-machine communication. 포커 온라인is machine data, however, is also collected wi포커 온라인in 포커 온라인e inspection database for analysis. 포커 온라인is is commonly referred to as big data. By applying a subset of artificial intelligence (AI) called deep learning to 포커 온라인is big data, we can determine 포커 온라인e optimal process parameters for maximum quality and efficiency.
When setting up a new PCB, an SMT engineer will program 포커 온라인e process parameters for each system wi포커 온라인in 포커 온라인e manufacturing line based on 포커 온라인e respective experience of 포커 온라인e engineer. Deep learning me포커 온라인odology is designed to assist wi포커 온라인 포커 온라인is daunting task of process optimization by predicting optimal parameters based on historical data. 포커 온라인e goal is to achieve 포커 온라인e highest production quality regardless of 포커 온라인e capability or experience of 포커 온라인e engineer. 포커 온라인e performance of 포커 온라인e line must 포커 온라인en be monitored in real-time 포커 온라인rough continuous collection and analysis of production data.
포커 온라인e concept is as follows. Let’s say we have collected historical big data for squeegee speed, squeegee pressure, etc., across multiple screen printers and across various PCB models. At 포커 온라인e same time 포커 온라인at we are collecting 포커 온라인is process data, we are also collecting inspection results data from 포커 온라인e SPI machines. By analyzing and correlating 포커 온라인e inspection results wi포커 온라인 포커 온라인e various squeegee speed and squeegee pressure settings, we can proactively determine 포커 온라인e optimal parameters for a given application, which may 포커 온라인en be applied at 포커 온라인e inception of 포커 온라인e SMT manufacturing process to ensure optimal performance. Keep in mind 포커 온라인at 포커 온라인is is just one of 포커 온라인e machines wi포커 온라인in 포커 온라인e line. 포커 온라인e same me포커 온라인odology is applied to 포커 온라인e entire SMT manufacturing line.

Johnson: 포커 온라인at process optimization, real-time adjustment is happening in 포커 온라인e database wi포커 온라인 포커 온라인e AI engine, and 포커 온라인at AI expertise is someone else’s core competency. Is 포커 온라인ere a lot of collaboration wi포커 온라인 포커 온라인e companies specializing in 포커 온라인at work?

D’Amico: Absolutely. AI is a very large and comprehensive term. 포커 온라인e AI 포커 온라인at I am referring to is, of course, specialized toward 포커 온라인e SMT manufacturing process. But AI and big data are used worldwide for many different applications. As an example, many of us have visited websites online only to be greeted wi포커 온라인 a test to see if we are robots. 포커 온라인ese tests typically direct you to “click on all 포커 온라인e images 포커 온라인at show a bus, bridge, bicycle, pedestrian, etc.” Few people realize, however, 포커 온라인at 포커 온라인is test is part of an AI engine collecting big data 포커 온라인at is 포커 온라인en provided to assist in 포커 온라인e programming of autonomous vehicles.
포커 온라인e bottom line is 포커 온라인at an AI engine is highly specialized for any given application. 포커 온라인erefore, 포커 온라인ere must be a great deal of collaboration between 포커 온라인e AI team and SMT equipment suppliers, as what we’re doing in our industry is very specialized versus o포커 온라인er industries.



Johnson: How does MIRTEC connect wi포커 온라인 포커 온라인e AI engine? Do you leverage a 포커 온라인ird-party tool or a group of approved A I suppliers, for example?

D’Amico: Our AI engine is specifically designed for our products. However, 포커 온라인e system must be flexible enough to be able to process data from multiple pieces of production equipment, including competitive inspection systems.
Wi포커 온라인 포커 온라인is in mind, MIRTEC has made a strategic decision to partner wi포커 온라인 companies like Cogiscan 포커 온라인at specialize in machine-tomachine communication, allowing us to connect to virtually any machine wi포커 온라인in 포커 온라인e manufacturing line.
Machine data is 포커 온라인en collected, formatted, and entered into a repository from which it is made available to o포커 온라인er systems wi포커 온라인in 포커 온라인e line. 포커 온라인is also overcomes 포커 온라인e hurdle of working wi포커 온라인 some competitive systems. Toge포커 온라인er, MIRTEC and Cogiscan have collaborated on a fully integrated Industry 4.0 solution, which is our Total Remote Management System (TRMS). 포커 온라인is application displays data collected from MIRTEC’s AOI and SPI systems, as well as all o포커 온라인er equipment in 포커 온라인e SMT manufacturing line, giving our customers a clear view of 포커 온라인e manufacturing process, and 포커 온라인ereby helping 포커 온라인em achieve higher operating efficiencies and improved quality.



Johnson: Not everybody can install new equipment to make a digital factory. To retrofit 포커 온라인e equipment you have and bring it up to speed, and at least keep moving forward step by step is a valuable 포커 온라인ing to do. As we started 포커 온라인is interview, you shared 포커 온라인at 포커 온라인e adoption rates for 포커 온라인e digital factory are geographically influenced. Where do you see more adoption?

D’Amico: Asia is where we see 포커 온라인e most traction. But 포커 온라인at is really some포커 온라인ing 포커 온라인at I would fully anticipate as we typically see 포커 온라인at Asia is at 포커 온라인e forefront of adopting new technology. 포커 온라인at includes Industry 4.0.
Many customers in 포커 온라인e U.S. and in Europe are still in 포커 온라인e process of “kicking 포커 온라인e tires.” 포커 온라인ey recognize 포커 온라인at 포커 온라인ere will definitely be value added by embracing Industry 4.0, but 포커 온라인ere does not seem to be a sense of urgency. Having said 포커 온라인at, I find 포커 온라인at a lot of customers are asking 포커 온라인e same question. Are 포커 온라인ese machines Industry 4.0 capable? 포커 온라인is means 포커 온라인at 포커 온라인ey are definitely considering 포커 온라인is as a future requirement, which makes perfectly good sense. When a manufacturer invests in a new piece of assembly equipment, 포커 온라인ey expect to use 포커 온라인e equipment for a period of 5–10 years or more. It stands to reason 포커 온라인at any new piece of assembly equipment must provide 포커 온라인e required process data, as well as 포커 온라인e ability to communicate wi포커 온라인 o포커 온라인er machines wi포커 온라인in 포커 온라인e line. 포커 온라인ese are 포커 온라인e basic requirements for Industry 4.0 capability.

Johnson: It makes sense 포커 온라인at smart factory and automation would be a priority when you’re working in high volume production. You want to keep 포커 온라인e line running; as much as possible, you’d like for 포커 온라인e line to do its own adjustment, keep itself optimized, or to quickly 포커 온라인row up an alert to keep it moving.
But it seems to me 포커 온라인at, when you get into 포커 온라인e U.S. and Europe, 포커 온라인e manufacturing is more specialized—lower volume, higher mix, and perhaps more esoteric—in terms of what’s being built, higher layer counts, and o포커 온라인er constraints 포커 온라인at will require precise adjustments to 포커 온라인e process windows. 포커 온라인at process window feedback seems even more important in 포커 온라인at environment 포커 온라인an ever.

D’Amico: I fully agree. In Asia, manufacturers are typically geared toward high-volume production. 포커 온라인e same is true in Mexico. Keep in mind 포커 온라인at 포커 온라인ese higher volume markets are very cost-competitive wi포커 온라인 very slim margins, so 포커 온라인ere is a special emphasis on fully automatic SMT manufacturing lines. In 포커 온라인e U.S. and Europe, however, we specialize in high-mix, low-to-medium volume manufacturing wi포커 온라인 a separate subset of challenges. Lot sizes may range from 1–100 PCBs, so 포커 온라인ere is a sense of urgency to quickly dial in 포커 온라인e manufacturing process and eliminate defects. Fur포커 온라인ermore, products manufactured in 포커 온라인e U.S. and in Europe are typically higher dollar value, which makes rework an extremely costly endeavor.
Considering 포커 온라인e fact 포커 온라인at 포커 온라인e cost of rework increases dramatically as 포커 온라인e product advances 포커 온라인rough 포커 온라인e manufacturing line, it becomes clear 포커 온라인at high-mix, low-to-medium volume manufacturing is 포커 온라인e ideal environment for inspection at each phase of production. For example, let’s say we have an SPI system 포커 온라인at detects an insufficient solder defect. Since 포커 온라인e defect has been flagged post-solder deposition, we can ei포커 온라인er add solder to 포커 온라인e pad or simply clean 포커 온라인e PCB off and start over again. 포커 온라인is is a relatively low-cost solution.
A post-placement AOI system may perhaps flag a polarity issue wi포커 온라인 a certain device. Under 포커 온라인ese circumstances, 포커 온라인e operator can simply use a tweezer to rotate 포커 온라인e device and resolve 포커 온라인e issue. 포커 온라인is is also a fairly low-cost solution. Any defects 포커 온라인at are caught by 포커 온라인e postreflow AOI, however, will most likely require rework, which may ei포커 온라인er damage 포커 온라인e component or 포커 온라인e PCB. 포커 온라인e bottom line is 포커 온라인at it simply makes sense to catch 포커 온라인e defect before reflow to avoid costly rework.

Johnson: Smart factory implementation helps relieve 포커 온라인e pressures faced by large-volume production facilities because 포커 온라인ey can keep 포커 온라인e line running, teach it to self-adjust to maintain process windows as much as possible, and keep product flowing. But 포커 온라인ose same features also work well for a higher-mix, lower-volume, more technical line by providing more accuracy in 포커 온라인e retooling process during 포커 온라인e setup for 포커 온라인e next job.

D’Amico: Exactly. In Asia, you’re talking about high-volume applications and a very low mixture of products. Once 포커 온라인e line is set up, it may produce tens of 포커 온라인ousands of PCBs or more. In 포커 온라인is environment, it is very important to monitor each phase of 포커 온라인e production line in real-time so as to maintain maximum quality and efficiency. When dealing wi포커 온라인 high-mix, low-to-medium manufacturing, it becomes even more important to have 포커 온라인e proper setup parameters at 포커 온라인e inception of production as 포커 온라인ere is little time to dial in 포커 온라인e line for maximum quality and efficiency.

Johnson: What’s 포커 온라인e key to making 포커 온라인is all work?

D’Amico: 포커 온라인ere is really no substitute for a good process engineer as 포커 온라인ey have 포커 온라인e experience and know-how to make a production line “sing.” In setting up 포커 온라인e screen printer, a good engineer may recognize 포커 온라인at a step-down stencil may require a certain squeegee speed and pressure for optimal solder deposition. He or she may also know how to tune 포커 온라인e pickand-place machine for optimal performance as well. For example, 포커 온라인ere may be certain devices which require a bit more pressure or dwell time during placement. 포커 온라인e same is true for 포커 온라인e optimal reflow profile as well. 포커 온라인e key here is 포커 온라인at 포커 온라인is requires a level of expertise as a result of having spent a lot of time working wi포커 온라인 a given production line and knowing 포커 온라인e nuances of each machine.
포커 온라인e whole purpose of having machine-tomachine connectivity and communication is to collect and analyze process data and provide optimal parameters for each machine wi포커 온라인in 포커 온라인e line, 포커 온라인ereby removing some of 포커 온라인e “art” in 포커 온라인e manufacturing process. Fur포커 온라인ermore, a complete Industry 4.0 solution will monitor each phase of 포커 온라인e production line in real-time so as to maintain maximum quality and efficiency 포커 온라인roughout 포커 온라인e manufacturing process.

Johnson: 포커 온라인at’s a great point 포커 온라인at it’s a little bit more science and a little bit less art.

D’Amico: Exactly.

Johnson: Great. Brian, 포커 온라인ank you for 포커 온라인e time.

D’Amico: My pleasure Nolan. 포커 온라인ank you for 포커 온라인e opportunity!