DDi Europe 2002 1 Time for DDi DDi Corporate. DDi Europe 2002 2 DDi Group Strengths DDi Corp. is a leading provider of time-critical PCB manufacturing.

DDi Europe 2002 2

DDi Group Strengths

DDi Corp. is a leading provider of time-critical PCB manufacturing and assembly services to OEMs and EMS providers

Strategically positioned at the front-end of customer product development and innovation

Multiple production facilities based both in North America and Europe positioned to respond to customer demands

Technological leadership in manufacturing. 2,200 employees worldwide

Comprehensive and flexible product and service capabilities. Over 2,500 customers worldwide

DDi Europe 2002 3

OEMs EMS Providers

EMS Providers

CustomersCompetitors

=

DDi Group Diversified, Blue Chip Customer Base

Strong Customer Relationships– Approximately 90% of quarterly revenue

from existing customers

End-Market Diversity

Limited Customer Concentration Risk– No customer >10%– Top 10 customers represent 34% of revenues versus 50-

60% for EMS companies

3%

18% 57%

22%

Communications

Other: Defense, Industrial, Aerospace

Medical

Computer,Peripheral

End Markets

DDi Europe 2002 4

DDi Group Established International Platforms

Europe

• Established presence in 1997

• Europe currently accounts for 30% of Group business

• Adding customers and expanding end-markets

• Recently completed add-on acquisition in the UK to expand international platform and range of services

Canada

• Established Northeastern footprint

• Penetration of new markets

DDi Europe 2002 5

Ddi Group

Global Locations

French Sales OfficesFrench Sales Offices

United KingdomUnited Kingdom

North AmericaNorth America

DDi Europe 2002 6

Time for DDi

DDi EuropeDDi Europe

DDi Europe 2002 7

DDi Europe

DDi Europe 2002 8

Customer

DDi Tewkesbury

DDi Precision

DDi USA

DDi Marlow

International

DDi Technologies

Customer

Where we sit within the groupWhere we sit within the group

DDi

DDi Europe 2002 9

Time for DDi

DDi TechnologiesDDi Technologies

DDi Europe 2002 10

Manufacturing Capability

7,000 m² facility

SMT and Conventional assembly

Low to medium volume production

On site inspection and test

Dedicated Fastrack facility(Prototype, time critical service)

Project management

Complete turnkey engineering design

Design to assembly in 3 - 10 days

QFP & µBGA placement to 0.3mm pitch

X-Ray & Environmental stress screening facility on site

Approvals including ‘List X’

Standard practice to manage sensitive information

DDi Europe 2002 11

• DDi Technologies is a well established, full capability, low volume, high value added contract manufacturer

• The company operates from a new 7,000 m² purpose built facility in Calne and employs 190 people (115 direct)

• Dedicated in-house Fastrack facility enables quick turn prototype production

• Historically, the company has focused on the aerospace, military and industrial markets

Technical StrengthsTechnical Strengths

DDi Europe 2002 12

• The company's reputation and new facilities now allow it to broaden its customer base whilst retaining its focus on low volume, value added business

• DDi Technologies offers design and procurement through to the delivery of engineering prototypes, pre-production and low volume assembly including final equipment build and full functional test.

• This unique group capability enables DDi Technologies to become a true partner with its customers

Technical StrengthsTechnical Strengths

DDi Europe 2002 13

Reputation

DDi Europe 2002 14

Procurement Procurement

• Project procurement (buy it – make it) - Fastrack

• Project procurement to cost targets

• Repeat Product procurement i.e lowest cost, contracted procurement

• Full project procurement

• Consignment Stock and Management

• Specialised procurement

• Full estimating – Project costing

• Component sourcing and obsolescence

• Dedicated resource (customer specific)

• Project resource – Project based

• Estimating resource

DDi Europe 2002 15

Materials and Inventory ManagementMaterials and Inventory Management

• Sage CS3 ERP System

• Tetra 2000 MRP

• Secure Stock Holding and Rotation (automation)

• Bonded Stores

• Dedicated Kitting Area’s

• Consignment Stock

• Kan-Ban capability

• Partnerships with Key Distributors

• Leverage Buying from Multi-customers

• Supported Factory Buys

DDi Europe 2002 16

Project ManagementProject Management

• NPI Process

• Transfer strategy

• Focus on key processes

• DDi resources at Customer site

• Last-off & First off checks to validate processes and

ongoing control of key parameters

• Disciplined Project management (MSProject) and Review

mechanism

• Utilise existing experts to minimise risks through transfer

and settling in period

• Risk management and contingency plans

DDi Europe 2002 17

Services availableServices available

Floor 2 ServicesFloor 1 Services

Box Build Assembly

Final Assembly

Front End Engineering Fastrack

SMT Assembly

TestT/H Assembly

DDi Europe 2002 18

Manufacturing Process

DDi Europe 2002 19

• Configured Line

•Dek 265 Fully Auto Printer, High volume (50K/hr) - Siemens Is-place HS50/F5 + 10 Zone BTU Pyramax Oven

• Configured Line

•EKRA E5 Fully Auto Printer, Medium - high volume (20K/hr) - Mydata MY15+ 10 Zone BTU Pyramax Oven

• Configured Line

•Dek 248 + Vision, Medium volume (15K/hr) – 2 x Tenryu + 5 Zone Sirocco Oven

• Configured Cell

•Dek 248 + Vision, Low - medium volume (6K/hr) - 4 x Mydata TP9 2 x 6 Zone Surf

PCB Assembly CapabilitiesPCB Assembly Capabilities

DDi Europe 2002 20

PCB CapabilityPCB Capability

• To 0.4mm BGA placement and rework capability (advanced @ 0.25mm)

• QFP placements to 0.3mm pitch

• Full off-line machine set-up using Valor

• Water soluble, no-clean, lead free and HMP chemistries

• 4 x Flow line conventional assembly (PAF)

• 2 wave solder machines

• Ultrasonic Co-Solvent Cleaning System

• Full ESS on site (with Nitrogen)

• Conformal Coating on site (Spray & Dip)

DDi Europe 2002 21

Technology statement

• In the last 12 months DDi have placed:

• over 3 million 0402 components

• Over 45,000 BGA’s – 20,000 less then 0.8mm pitch

DDi Europe 2002 22

• Automated Optical Inspection (AOI) x 2

• Optical inspection

• 3D X-ray (BGA) Inspection

Quality Inspection ProcessesQuality Inspection Processes

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Fastrack (Prototype Service)

DEK249 Paste PrinterDEK249 Paste Printer

Stencils available in a 4-48 hour turn round from

receipt of PCB data

BTU Vip 98 Reflow OvenBTU Vip 98 Reflow Oven

Single and Double sided

Precision zone control (5 chambers)

InspectionInspection

Fully Automated Optical Inspection (AOI)

3D XRAY inspection for BGA devices

Ersascope (Under BGA inspection)

Visual InspectionVisual Inspection

Vision VS7 smt inspection system

JVC Digital colour 12.7mm colour video camera

Fixtureless TesterFixtureless Tester

2 x Takaya 9400 Flying Probes

Off line programming

0.3mm and BGA

Dedicated ResourcesDedicated Resources

Process Engineers

Pick & Place Operators

Leaded Assemblers

Inspectors

AOI / X-ray Engineers

Flying Probe Test Engineers

Continual training with IPC approved schemes

Mydata 12 Pick & PlaceMydata 12 Pick & Place

20,000 placements per hour

Min case 0201

Min placement 0.3mm

DDi Europe 2002 24

2 x Mydata 12 Pick & Place

20,000 placements per hour Min case 0201

Min placement 0.012" (300 m)

Diagnosis AOI m/c

3D X-ray (BGA) Inspection

2 x DEK249 Paste Printer

Vision Alignment

Reflow Oven

BTU VIP 98 7 zone

Fastrack CapabilityFastrack Capability

DDi Europe 2002 25

2 Day PCB Manufacture 2 Day PCB Assembly

Data received & verifiedPrint innersEtchBond

DrillCopper plateSoldermaskIdent

TestFinal inspection Despatch

Data ReceivedPick and Place Program createdAOI program createdFlying Probe program createdSMT Stencil ordered

PCBs ReceivedKit received and checkedStencil deliveredKit loaded to Pick and Place machineTest and Despatch

Day 1

Day 2

Day 3

Day 4

Day 3

Fastrack TurnaroundFastrack Turnaround

DDi Europe 2002 26

Our DFM/NPI StrategyOur DFM/NPI Strategy

To be able to provide our customers:-

• A Virtual Prototyping system for zero defects, first time, every time

• A Reduction in pre-production (CAM) engineering cycle time by 50-60% (Reduction in cost passed to our customer)

• Full job reverse engineering and manufacturability analysis

• Automated DFFabrication, DFManufacture and DFTest on every board, every time

• Automated creation of all machines programs Print, P&P, AOI, Test) and accurate assembly DWG's (Assy Aids, Hand Assy, No fit)

• Pre and Post manufacture First article reports

• Enhanced responsiveness to customer needs in Product Quality, Manufacturability and Testability.

• Fully engineer job for manufacture inc job pack

DDi Europe 2002 27

Solutions in Place at TechnologiesSolutions in Place at Technologies

Valor TRILOGY 5000 s/wValor TRILOGY 5000 s/wDFx AnalysisAutomated ProgrammingComp LibraryOptimisationOutputs

Aiges Circuitcam s/wAiges Circuitcam s/wOff line m/c programming MydataAssembly aids and documentationOff-line access to m/c libraries

Aiges Equinox Optimisation s/wAiges Equinox Optimisation s/wM/c line balancingM/c placement optimisationCommon Loading plans

Siemens Si-Place Pro in Q1 2002Siemens Si-Place Pro in Q1 2002Off line m/c programming SiemensAssembly aids and documentationOff-line access to librariesM/c data collectionSPC

Myriad Engineering ViewerMyriad Engineering ViewerView all documentation viewer 

Tetra CS3 ERP SystemTetra CS3 ERP SystemFactory wide integrated Erp system

DDi Europe 2002 28

Single Data FormatSingle Data Format

Genesis 2000FABRICATION CAM

Trilogy 5000ASSEMBLY CAM

Genesis 2000 & Enterprise 3000CAD/DFM TOOL

DDi USADDi USA

DDi Europe AssemblyDDi Europe Assembly

DDi Europe DDi Europe FabricationFabrication

Valor Universal

Viewer

DDi Europe 2002 29

Technical Capability (Test)

General20 dedicated test engineersTotal test experience 380 yearsRF or RF/Digital solutionsProgramming for ATE and FICT platformsFunctional test covering:Precision analogue measurement, Programmable synthesis, Programmable loads, Multi-channel digital sampling, Static, Simulation, Dynamic, Diagnostic, Boundary Scan, Go/Nogo, IEEE compatible, CommunicationsICT programsManufacturing defect analysis18 off ICT / FICT capital equipmentOffline programmingSoftware conversion packagesTest strategy / solution definitionDFT reviews

The RF factor30 years combined RF experience between 5 employees across several projects

Create test solutions for low / medium volume RF or RF / Digital products

Partnered with clients for complex Digital / RF products up to 3.6 GHz

Working closely with RF vendors, specifically Anritsu to provide low to medium volume test solutions

Partnered with IFR to provide Radio Test Sets to replace current test equipment reducing test overheads

DDi Europe 2002 30

DDI Programming Capability

Dedicated and Experienced Programming staff for: WK 900 & 3900 ATE test platforms. Takaya 8400 and 9400 Programming bureau. Midata 511 Programming facility. Design for ATE Test Consultancy. Programming Debug ATE facility. Off-line Programming bureau facility. Fabmaster CAD file conversion software.

DDi Europe 2002 31

Board test Sub Assembly test Assembly test Equipment test Fixture proving

1. Manufacturing Defect Analysis (MDA) 2. Continuity programs with board label identification. 3. In-circuit test verification for passive components. 4. Test-jet SMT component placement verification. 5. Fixtureless test MDA with opens test using the latest generation Tester 6. Functional test programs to suit: -

Static Go/Nogo IEEE compatible Simulation Dynamic Diagnostic Boundary scan Communications Precision analogue measurement: Programmable synthesis: Programmable loads: Multi-channel digital sampling. 7. 2nd Line sub-assembly testing. 8. 3rd Line Equipment testing.

ATE TEST PROGRAM CAPABILITIES

DDi Europe 2002 32

ATE TEST PROGRAM BENEFITS: -

1. Speed and reliability of throughput. 2. Effective deployment of skills, targeting relatively unskilled operators for ATE test,

technicians for repairs, etc. 3. Flexibility of test due to extensive range of modules available, no requirement to purchase or

rent most types of test bench equipment. 4. Return on investment by reducing dependence upon manual inspection and test personnel. 5. Fault printouts automatically generated with Data-logging as an option. 6. Comprehensive range of testing available. 7. Test coverage for up to 2000 nets on WK 3900 providing extensive coverage. 8. Prototype build and verification (important aid for design to market time-scales). 9. Fine pitch components coverage to 12 thou with the Takaya allowing test for the latest

generation of printed circuit boards.

DDi Europe 2002 33

W K 3900 Combinational ATE

Programming Debug ATE facility. 1 off WK 900 ATE test platforms. 3 off WK 3900 ATE test platforms. Off-line Programming bureau facility. Fabmaster CAD file conversion software.

Customers include: WK Test. Radio Detection (Dean Spencer 01179 767776) Group 4 (Stuart White 01684 277103) Moog (Don Murphy 0035 321 4378933) Vitalograph (Shane O’Donnell 00353 6864100) Malvern, Tellabs(Finland), Versus, National Air Traffic Control (NATS), BNFL, Joy Mining, Kidde Fire, Menvier.

DDi Europe 2002 34

PTS Minimum Requirements Recommendation

Minimum information requirement for the production of ATE test solutions. The following components are required by PTS before commencing any work with program design or fixture specification: 1. 1 Fully tested and approved bare board 2. 1 Fully tested and approved loaded board, at the correct build state for the time of test, or at it’s most populated board state, whichever applies. 3. Current circuit diagram, in legible format, any circuit diagrams supplied should be preferably backed up with a soft format either in HPCL format or as a DXF file. 4. Gerber files. This should include as much information as is available from the CAD software the diagram is produced on. Any test point or node name reports, which can be generated, should also be included. 5. Full and current parts list, including build variations, and the different variants required to be included within the test, This would also be, preferably, backed up with a soft copy. 6. A fully detailed test specification should be included for all test requirements, Additional test enhancements may be included by PTS within the development period, however, only specified tests can be guaranteed to be included.

DDi Europe 2002 35

PTS Minimum Requirements Recommendation

The following requirements only apply to special cases, specifically functional tests.

1. Previous PAS for adaptation by PTS 2. All details of previous test software/hardware, including any embedded

software. 3. The loan of required software / hardware for the implementation of and

embedded software / enhancements. 4. A general introduction to the board, common faults not currently picked

up by ATE, current test solution procedure etc. An experienced test engineer should compile this.

The following are required during the commissioning period.

1. A quantity of working and faulty boards for test, as specified by the ATE engineer.

2. Commissioning period for approval by design engineer.

DDi Europe 2002 36

Takaya 9400 FICT ATE

Programming Debug ATE facility. Off-line Programming bureau facility. Fabmaster CAD file conversion software.

Customers include:

BAE, Malvern, Sun Micro, Marconi

DDi Europe 2002 37

Takaya Technician

Nebeel SulaimanTakaya Programmer

PTS – Programming and Test SolutionsPTS – Programming and Test Solutions

Mary Stanley Marina ThomasFabmaster Engineer

David SladeWK 900/3900 Programmer

Mark JohnsonATE Programming Manager

Special Project EngineersNPI

Charles Phiri Special Projects Snr Engineer

Repair Staff

Bill NavaretteSnr Engineer

Mark HortonRepairs Manager

Peter StonehamDirector of PTS

ATE Programmers