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OPTIMUM DESIGN’S 100 WAYS TO REDUCE · PDF file1 100 ways to reduce cost cost saving tips for pcb assembly optimum design’s 100 ways to reduce cost

Mar 07, 2018

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  • 1 100 Ways to Reduce Cost

    COST SAVING TIPS FOR PCB ASSEMBLY

    OPTIMUM DESIGNS

    100 WAYS TO REDUCE COST

  • Ideas For Engineers

    Things Buyers Can Do Now16

    Ways MFG Can Cut Cost32

    57

    SUMMARY

  • Design ........................................................................................................................ 4Resistor Nets, Cost Philosophy, Product Design, Mil Spec Job, End of Life, Over Design, DDR3, High Volume Design, Limited Automation, Rework, Manufacturability, Spec Components, Legacy,ENIG vs HASL, Smaller is Better, Mating, Standardizing, Blind & Buried, Layer Count, Special Cuts, Materials, Sourcing

    Library ........................................................................................................................7Providers Rates, Using a Virtual Library Provider, Library Cost Savings, Scripting/Automating Footprints, Valor Library Check

    Layout ........................................................................................................................ 8Layout Providers, IPC Library, Reliable Provider, Placement Review, 24 Hour Service, Buy Direct, Multiple Designers, Mentor Expedition, Faster Design Work, Valor Layout Check, Avoiding Cheap Tools

    DFM, DFA, and DFT ................................................................................................11Defect Opportunities, Design for Manufacturing (DFM), Design for Assembly (DFA), Design for Test (DFT), BOM Scrubbing

    Purchasing ............................................................................................................. 12Negotiating, Review, Component Pricing, Material Cost, Forecast, Component Descriptions, Min. for Max, Blanket Orders

    Manufacturing ....................................................................................................... 13SMT, X-Ray, SPI, Reels, Packaging, Revision Control, SMT vs Through Hole, Avoid Through Hole, Shipping Method, Packaging, First Article, Solder Samples, One Stop Shop, Maintenance Program, Feeders Cost, Effective Shipping

    Test ............................................................................................................................ 15Complimentary Inspection, Network, Pre-Assembly, Final Testing, KGB, Concurrent Testing, Design Qualification, Sampling, Standardization, Firmware, Flying Probe

    Quality ..................................................................................................................... 17Non-conformance, Appraising, Requirements, Unipoint, New Product Review, Quality Planning, Capability Evaluations, Buy Direct, AOI, Continuous Improvement, Cost of Quality (COQ), Reworking, Retesting, Rebuild, Training, Attrition

    CONTENTS

  • 4 100 Ways to Reduce Cost

    Resistor Nets - Use resistor nets where possible to reduce part count and PCB real estate to drive down cost.

    Cost Philosophy - Effective product cost management requires a design to cost philosophy as its basis, since 90% of the product cost is dictated by decisions made in the design process.

    Layer Count - Keep the layer count as low as possible. Less layers = less cost incurred.

    Mil Spec Job - Never design in mil spec components when a commercial part can do the job. Commercial components are less expensive and more readily available.

    End of Life - When designing in components always look at end of life. Having to redesign in another component in a production mode is very costly.

    Over Design - Designers tend to over design creating added cost and complexity.

    DDR3 - Using DDR3 memory is cheaper to design in than DDR2. It is much easier to layout so it takes less time and is more readily available.

    Design

    90% of Product Cost is Dictated By Decisions Made in the Design Process.

  • 5 100 Ways to Reduce Cost

    Limited Automation - Common mistakes made in design are choices that limit automation for production.

    Rework - Keep rework in mind when designing. The part fits, but can it be reworked if needed? Better to rework than to scrap.

    Spec Components - Always try to spec in components that have a form, fit and function cross available. This is not always possible but a good thing to do if one is available.

    Legacy - Re-design of legacy products may lower your cost.

    ENIG vs HASL - PCB surface finish can add cost. You might want to use ENIG for prototypes and move to HASL for production to save cost.

    Smaller is Better? - Component selection and package options can be cost drivers. Smaller semiconductor package sizes will optimize PCB space but may be more expensive and more difficult to manufacture.

    Mating - Components with gold plated pins can be expensive. If you only mate one time choose the gold flash option. The more mating cycles the more gold is needed.

    High Volume - Designing in high volume commercially available components used in the networking, cellular and PC industries is always a cost saver.

  • 6 100 Ways to Reduce Cost

    Standardize - Standardizing package sizes to lower your placements always results in a cost savings.

    Blind & Buried - Careful when designing in blind & buried technology as it can add 20% to your PCB costs.

    Special Cuts - Think twice before adding special cut outs to your board as this is a cost driver.

    Materials - Do your homework when doing PCB material selection. You might think you need to use Rogers when you can use a higher end FR4 that will get the job done.

    Sourcing - Try to never design in a single sourced part. Multiple sources are key to a cost effective design.

    Product Design - In the absence of a structured product design and qualification test process, unnecessary costs are added to the product. Most often the added costs take the form of rework, scrap and warranty cost.

  • 7 100 Ways to Reduce Cost

    Library

    Providers Rates - A virtual library providers rates are 15%-25% cheaper than layout rates.

    Using a Virtual Library Provider - A virtual library provider can have the benefit of sharing cost for footprints that already exist in their library.

    Library Cost Savings - A virtual library service provider is a cost saving in itself. Youre not paying for tools and expertise you might not need every day.

    Scripting / Automating Footprints - Scripting / Automating footprints saves time and is more consistent when you do a make from using an existing footprint. It also makes checking the new footprint easier.

    Valor Check - Using Valor to check your library is key to zero package footprint defects. You cant make a mistake when using Valor.

    A Virtual Library Providers Rates are 15%-25% Cheaper Than Layout Rates.

  • 8 100 Ways to Reduce Cost

    One Stop - A PCB layout provider who also provides manufacturing services is more likely to consider and incorporate design for manufacturability.

    Layout Provider - Time to market is reduced when using a proven design PCB layout provider. No need to budget revisions of your design, it should be done right the first time.

    Reliable Provider - Most companies have one or two designers that do other things besides PCB layout, and might only do layout a few times a year. A service provider who uses these tools everyday can most likely do it faster and more efficiently, saving time and money.

    Use Best-in-Class Design Rules - Using a service provider who designs every day, designs for different markets, and keeps up on best-in-class design rules can provide creative solutions to your design challenge including a more manufacturable product, resulting in cost savings.

    24 Hour Service - After hours resources available? A good design service provider with a global presence can keep things going 24 hours a day, saving you time & money.

    Layout

    Utilize Best-in-Class Design Rules for a More Manufacturable Product.

  • 9 100 Ways to Reduce Cost

    Buy Direct - Buy from the manufacturer when possible. Gets rid of the middle man and their markup.

    Multiple Designers - If a company has one designer and he gets sick, what do you do then? Using a PCB layout service with multiple designers keeps things up and running.

    Mentor Expedition - Customers design tool of choice is often PADS, but it is a low end tool that takes a considerable amount of time. A good design service can use a higher end tool such as Mentor Expedition and then convert to PADS, saving time and most likely providing a better design.

    Faster Design Work - A design service provider who has multiple designers can complete a design sooner. They can have several designers work on the same project and save time.

    Valor - Utilizing Mentor Graphicss Valor to check layout designs is key to saving money. Everything is caught up front before the design is released to manufacturing.

    Avoid Cheap Tools - Cheaper / low end tools dont necessarily save you money, and in the long run they are less efficient. They might lend well to smaller designs but it will take you longer to finish your layout.

    ODB++ - The ODB++ file format is best for front end engineering/manufacturing use. No time or money spent converting files.

  • 10 100 Ways to Reduce Cost

    Fiducial Location is Key - There should be a minimum of 8 per board. Some put them on the borders but for best in class registration and best quality throughput they should be 200mls in from the edge of the board. Perfect registration and quality saves time and money in the form of rejects.