ulmenslons of LlecLronlc roducL ueslgn

SlzemlnlaLurefuncLlonal elemenLs
WelghL
ower Supply
lnLerlnLra module
connecLlons/communlcaLlons
LnvlronmenLal llmlLsdusL proof
conLrolled Lemp condlLlons
ackaglngLransporL sLorage anLl sLaLlc
bag speclal packlng
MLC
ulmenslons of LlecLronlc roducL
ueslgn
Speclal cables connecLors elecLro
mechanlcal componenLs
1hermal ueslgncomponenL level board level
sysLem levelheaL slnksforced coollng
LMC/LMl concerns
MLC
ulmenslons of LlecLronlc roducL ueslgn
lndusLrlal ueslgnlooksafeLyuser frlendly
8ellablllLy
CuallLy
MalnLenance free operaLlons
MulLlfuncLlonallLy
roducL varleLy
MLC
lndusLrlal ueslgn
lndusLrlal ueslgn ls known as Lhe arL and
sclence of lncreaslng Lhe beauLy and value of
mass produced producLs
1he professlonal servlce of creaLlng and
developlng concepLs and speclflcaLlons LhaL
opLlmlze Lhe funcLlon value and appearance
of producLs and sysLems for muLual beneflL of
boLh Lhe user and manufacLurer
MLC
CrlLlcal Coals of lu
uLlllLy1he producLs human lnLerfaces should
be safe easy Lo use easy Lo undersLand Lhe
funcLlon
Appearance
lorm/shape/llne/proporLlon/color are used Lo
make Lhe producL aLLracLlve pleaslng
Lase of malnLenance1he producL should
communlcaLe how Lhe malnLenance/repalr
process should be addressed
MLC
CrlLlcal Coals of lu conL
CosLCosL of producL Lo be kepL low
CommunlcaLlonroducL deslgn should
communlcaLe Lhe corporaLe deslgn
phllosophy and mlsslon Lhrough Lhe
vlsual quallLles of Lhe producL
MLC
lmporLance of lu
lu deLermlnes Lhe commerclal success of
any producL
All producLs LhaL are used operaLed or
seen by cusLomer depend on lu for
producL success
lu deLermlnes Lhe aesLheLlc appeal and
Lhe quallLy of Lhe user lnLerfaces of a
producL
MLC
-eed for lu
Lrgonomlcs8elaLed Lo human
lnLerfaces
AesLheLlcs ueals wlLh form flnlsh
of Lhe producL
MLC
L8CC-CMlCS -LLuS
Lrgonomlcs or human facLors
englneerlng ls Lhe sclence of flLLlng Lasks
Lo man Lrgonomlc -eeds
Lase of usefor frequenLly/lnfrequenLly
used producLs
Lase of MalnLenance
MLC
L8CC-CMlCS conL
-umber of user lnLeracLlons for Lhe
producL Lo funcLlon(More lnLeracLlon
means more dependency on lu)
-ovelLy of Lhe user lnLeracLlons eg
lmprovemenL ln mouse
SafeLy lssuesSafeLy conslderaLlons are
very lmporLanLPuman anaLomy and
psychology lssues need Lo be consldered
MLC
AesLheLlc -eeds
AesLheLlc needs deals wlLh form flnlsh
of producLs1hey are
(a) roducL ulfferenLlaLlonvlsual
(b) rlde of ownershlp
lmage/fashlon
MLC
AesLheLlc -eeds conL
(c) MoLlvaLlon of Lhe LeamA producL
LhaL ls aesLheLlcally appeallng can
generaLe a sense of Leam prlde among
Lhe deslgn and manufacLurlng sLaff 1eam
prlde helps Lo moLlve and unlfy every
one assoclaLed wlLh Lhe pro[ecL
MLC
l-uuS18lAL uLSlC- 8CCLSS
lnvesLlgaLlon of CusLomer needs
MLC
l-uuS18lAL uLSlC- 8CCLSS conL
ConcepLuallzaLlon roducL's form and user lnLerface
deslgned slmple skeLches (1humbnall skeLches)
made concepLs are maLched comblned wlLh
Lechnlcal soluLlons
MLC
l-uuS18lAL uLSlC- 8CCLSS conL
rellmlnary reflnemenL Models of mosL
promlslng concepLs are made uslng foam eLc
MLC
l-uuS18lAL uLSlC- 8CCLSS conL
lurLher reflnemenL and flnal concepL selecLlon
Pard models (uslng wood plasLlc eLc) and
lnformaLlonlnLenslve skeLches(renderlng) are made
MLC
l-uuS18lAL uLSlC- 8CCLSS conL
ConLrol drawlngs lL documenLs funcLlonallLy
feaLures slze color dlmenslons surface flnlsh eLc
CoordlnaLlon wlLhy englneerlng manufacLurlng and
vendors
MLC
eneflLs of uslng lu
lncreased roducL Appeal
eLLer leaLures
CreaLer cusLomer saLlsfacLlon
SLrong rand ldenLlLy
roducL ulfferenLlaLlons
rlce remlum and or
lncreased markeL share
MLC
ecause of mulLlple reworks on
accounL of ergonomlcs aesLheLlcs
may resulL ln delay ln Lhe producLs
lnLroducLlon ln Lhe markeL whlch wlll
llkely Lo have an economlc cosL
MLC
ulsadvanLage of lu
ulx
ueslgn for
MLC
ulx meLhodologles ln roducL ueslgn
1here wlll be always a confllcL beLween needs
speclflcaLlons Lo a speclflc lssue 1o resolve
such lssues many Leams pracLlce ueslgn for x
"(ulx) meLhodologles where x may
correspond Lo one of dozens of quallLy crlLerla
such as8ellablllLy8obusLnessservlceablllLy
LnvlronmenLal lmpacLmanufacLurablllLy
(ulM)
MLC
MeLhodologles for achlevlng xs ln ulx
Carry ouL deLall deslgn declslonscan
have subsLanLlal lmpacL on producL
quallLy cosL
-eed Lo address mulLlple confllcLlng
goals by developmenL Leams
MLC
MeLhodologles for achlevlng xs ln ulx
Pave meLrlcs Lo compare alLernaLlve
deslgns
CeneraLe deLall creaLlve efforLs early
ln Lhe process
A well deflned meLhod asslsLs Lhe
declslonmaklng process
MLC
ulM
ueslgn for
ManufacLurlng
MLC
ulM
Lconomlcally successful deslgn
lmplleshlgh producL quallLy whlle
mlnlmlzlng manufacLurlng cosL
ulM ls one meLhod for achlevlng
Lhls goal
LffecLlve ulM pracLlce leads Lo low
manufacLurlng cosLs wlLh ouL
sacrlflclng producL quallLy
MLC
ulM conL
ulM uLlllzes lnformaLlon of several
Lypes such asskeLches drawlngs
producL speclflcaLlons deslgn
alLernaLlves deLalled undersLandlng
of producLlon assembly process
esLlmaLes of manufacLurlng cosL
producLlon volumes and rampup
Llmlng
MLC
ulM conL
ulM requlres conLrlbuLlons from
all members of developmenL
Leam as well as ouL slde experLs
ulM ls performed Lhrough ouL
developmenL rocess
MLC
ulM MeLhod
Estimate the Manufacutring
Costs
Consider the mpact of DFM
Decisions on Other Factors
Recompute the
Manufacturing Costs
Reduce the Costs of
Supporting Production
Reduce the Costs of
Assembly
Reduce the Costs of
Components
Good
enough
?
N
Y
Acceptable Design
Proposed Design
MLC
ulM rocess
LsLlmaLe Lhe manufacLurlng cosL
8educe Lhe cosL of componenLs
8educe Lhe cosLs of assembly
8educe Lhe cosL of supporLlng
producLlon
Conslder Lhe lmpacL of ulM
declslons on oLher facLors
MLC
MLC
ulM lLeraLlons may conLlnue even unLll plloL
producLlon beglns
Cnce Lhe deslgn ls frozen (or released) and any
furLher modlflcaLlons are consldered formal
englneerlng changes or
ecome parL of nexL generaLlon of Lhe producL
ulM MeLhod conL
ManufacLurlng CosLs ueflned
Sum of all Lhe expendlLures for Lhe
lnpuLs of Lhe sysLem (le purchased
componenLs energy raw maLerlals
eLc) and for dlsposal of Lhe wasLes
produced by Lhe sysLem
MLC
ulM MeLhod conL
LsLlmaLe Lhe ManufacLurlng CosLs
Finished Goods
Manufacturing System
Equipment nformation Tooling
Waste Services Supplies Energy
Raw Materials
Labor
Purchased
Components
MLC
LlemenLs of Lhe ManufacLurlng CosL of a
producL
MLC
ManufacLurlng CosL
ComponenLs
Assembly
Cverhead
SLandard
CusLom Labor
LqulpmenL and
1oollng
SupporL
lndlrecL
AllocaLlon
8aw
MaLerlal
rocesslng 1oollng
1he unlL manufacLurlng cosL of a producL conslsLs of ComponenL CosL Assembly CosL and
Cverhead CosL (SLandard cosLmoLors swlLches elecLronlc chlps and screws) CusLom parLs are made as
per manufacLures deslgn from raw maLerlals such as sheeL sLeel plasLlcs pelleLs or alumlnum bars
LlemenLs of manufacLurlng cosL of producLlon
ulfferenL CosL Peads
ComponenL CosL1hls ls Lhe cosL of
sLandard parLs cusLom parLs
Assembly CosLsCosL of goods
assembled from parLs labor cosL
may lncur cosLs for equlpmenL and
Loollng
Cver head cosL for all oLher cosLs
MLC
ulfferenL CosL Peads conL
1here are two types of Cn costs
1) SupporL CosLmaLerlal handllng
CA urchaslng Shlpplng eLc
2) lndlrecL AllocaLlonscosL of
manufacLurlng LhaL can noL be dlrecLly
llnked Lo a parLlcular producL buL whlch
musL be pald for Lo be ln buslness (salary
bldg malnLenance eLc
MLC
ulfferenL CosL Peads
llxed CosLlL ls a predeLermlned cosL
regardless of how many unlLs of Lhe
producL are manufacLured (cosL lf
ln[uncLlon module/seLLlng up facLory)
varlable cosL1hese cosLs are lncurred
ln dlrecL proporLlon Lo Lhe number of
unlLs produced eg cosL of raw maLerlal
consumed
MLC
ulM MeLhod conL
8educe Lhe CosL of ComponenLs
undersLand Lhe rocess ConsLralnLs
and CosL urlvers
8edeslgn ComponenLs Lo LllmlnaLe
rocesslng SLeps
Choose Lhe ApproprlaLe Lconomlc
Scale for Lhe arL rocess (Plgher Lhe
volume of producLlon lower Lhe cosL
MLC
ulM MeLhod conL
8educe Lhe CosL of ComponenLs
SLandardlze ComponenLs and rocesses
8edeslgn cosLly parLs wlLh Lhe same
performance whlle avoldlng hlgh
manufacLurlng cosLs
Work closely wlLh deslgn englneers
ralse awareness of dlfflculL operaLlons
and hlgh cosLs
MLC
ulM MeLhod conL
8educe Lhe CosL of ComponenLs
LllmlnaLe unnecessary sLeps
use subsLlLuLlon sLeps where
appllcable
Analysls 1ool rocess llow
CharL and value SLream Mapplng
MLC
lll of MaLerlal (CM)
1he CM ls a llsL of each lndlvldual
componenL ln Lhe producL CM ls
creaLed uslng an lndenL formaL ln whlch
Lhe cosL of componenLs sub assemblles
are consldered along wlLh dlfferenL cosL
heads le flxed/varlable cosLs
1he cosL of sLandard componenLs are
esLlmaLed by comparlng slmllar parL Lo
whaL Lhe flrm ls already produclng/from
vendors
MLC
lll of MaLerlal conL
CosL of cusLom componenLs are
deLermlned by manufacLurer or by
suppller
8aw maLerlal cosL could be esLlmaLed by
compuLlng Lhe mass of Lhe parL allowlng
for some scrap
MLC
lndenLed lll of MaLerlal
MLC
ComponenL
urchased
maLerlal
rocesslng(
Machlne+la
bor
Assembly(
labour)
1oLal
unlL
varlabl
e cosL
1oollng
and
oLher
cosL
1oLal
unlL
flxed
cosL
1oLal cosL
Manlfold
casLlng
1283
323
1806
1960 030
1836
plpe 130
013 143
143
valve
133 014
149 149
gaskeL
003
013 018
018
1oLal ulrecL CosL 1333
323 042
2118 3168
030
Cverhead charges 260 942
171
073 1448
1oLal cosL
4616
ulM conL
8educe Lhe cosLs of Assembly
ueslgn for assembly (ulA) ls a lmporLanL
subseL of ulM whlch lnvolves mlnlmlzlng
Lhe cosL of assembly
ulA helps ln reduclng Lhe parLs counL
manufacLurlng complexlLy and supporL
cosLs and assembly cosL
MLC
8educe Lhe CosLs of Assembly
ueslgn for Assembly (ulA) lndex
lnLegraLed arLs (AdvanLages and
ulsadvanLages)
Maxlmlze Lase of Assembly
Conslder CusLomer Assembly
MLC
ulM conL
8educe Lhe cosLs of Assembly (ulA)
?ardsLlcks used for ulA declslons
Assembly LfflclencylL ls measured as an lndex
whlch ls Lhe raLlo of Lhe LheoreLlcal mlnlmum
assembly Llme Lo an esLlmaLe of Lhe acLual assembly
Llme for Lhe producL Lhls glves a ldea of whaL drlves
Lhe cosL of assembly 1he expresslon for Lhe ulA
lndex ls
MLC
DFA index =
(Theoretical minimum number of parts) x (3 seconds)
Estimated total assembly time
ulM conL (ulA)
Pow Lo llnd ouL Lhe 1heoreLlcal Mlnlmum
-umber?
uoes Lhe parL need Lo move relaLlve Lo Lhe
resL of Lhe assembly?
MusL Lhe parL be made of a dlfferenL maLerlal
from Lhe resL Lhe assembly for fundamenLal
physlcal reasons?
uoes Lhe parL have Lo be separaLed from
assembly for assembly access replacemenL or
repalr
MLC
ulM conL (ulA)
lnLegraLe arLslf a parL does noL
quallfy as one of Lhose LheoreLlcally
necessary Lhen lL can be physlcally
lnLegraLed wlLh one or more oLher
parLs lL means LhaL lL need noL be
assembled less expenslve Lo
fabrlcaLe Lhan separaLe parL Lhey
replace lL also allow flxlng wlLh
crlLlcal geomeLrlc feaLures Lo be
conLrolled fabrlcaLlon
MLC
ulM conL (ulA)
Maxlmlze Lase of Assembly1wo
producLs wlLh an ldenLlcal number of
parLs may dlffer ln requlred assembly
Llme by a facLor of Lwo or Lhree
Conslder CusLomer AssemblyuL
check quallLy
MLC
ldeal characLerlsLlcs of a parL for Assembllng(Lo
reduce cosL of assembly)
arL ls capable of lnserLed from Lhe Lop of Lhe
assembly
arL ls self allgnlng
arL does noL need Lo be orlenLed
arL requlres only one hand for assembly
arL requlres no Lools
arL ls assembled ln a slngle llnear moLlon
arL ls secured lmmedlaLely up on lnserLlon
MLC
Conslder CusLomer Assembly
CusLomers wlll LoleraLe some
assembly
ueslgn producL so LhaL cusLomers
can easlly and assemble correcLly
CusLomers wlll llkely lgnore
dlrecLlons
MLC
8educlng Lhe cosLs of SupporLlng producLlon
A reducLlon ln Lhe number of parLs reduces
lnvenLory cosL
A reducLlon ln assembly conLenL reduces Lhe
number of workers requlred and hence Lhe
expendlLure on supervlslon/P8 cosL
SLandardlzed componenL reduce Lhe demands
on englneerlng supporL quallLy conLrol
MLC
8educlng Lhe cosLs of SupporLlng
producLlon
8educe Lhe acLual producLlon supporL
(lnvenLory mgmL workers eLc) even lf
overhead cosL esLlmaLes do noL change
ln addlLlonMlnlmlze SysLemlc
ComplexlLy by smarL deslgn declslons
Lrror rooflng Lrror prooflng ls Lhe
sLraLegy of anLlclpaLlng Lhe posslble
fallure modes of Lhe producLlon sysLem
and Lake approprlaLe correcLlve acLlon
early ln Lhe developlng process
MLC
Conslder Lhe lmpacL of ulM ueclslons on
CLher lacLors
uevelopmenL 1lme
uevelopmenL CosL
roducL CuallLy
LxLernal lacLors
ComponenL reuse
Llfe cycle cosLs
MLC
Conslder Lhe lmpacL of ulM ueclslons
on oLher lacLors
1he lmpacL of ulM on uevelopmenL
1lme
ulM declslon musL be evaluaLed for
Lhelr lmpacL on developmenL Llme as well
as for Lhelr lmpacL on manufacLurlng cosL
MLC
Conslder Lhe lmpacL of ulM ueclslons
on oLher lacLors conL
1he lmpacL of ulM on uevelopmenL
CosL
y applylng good pro[ecL
managemenL pracLlce and Lhe
appllcaLlon of sound ulM meLhods
one can develop producLs wlLh ln
Llme and wlLh ln budgeL
MLC
lmpacL of ulM ueclslons
lmpacL of ulM on roducL CuallLy
ldeal condlLlons acLlon Lo decrease
manufacLurlng cosL would lmprove
quallLy Powever
rellablllLy/robusLness needs Lo
consldered
MLC
lmpacL of ulM ueclslons conL
lmpacL of ulM on exLernal lacLors
ComponenL reuseuslng resources Lo
creaLe a low cosL componenL wlll also
help oLher Leams deslgnlng slmllar
producLs
Llfe cycle cosLsulsposal of Loxlc
maLerlals/servlce warranLy cosLs 1hey
may noL appear ln Lhe manufacLurlng cosL
analysls Lhey need Lo be consldered on
ulM declslons
MLC
CuallLy y ueslgn
CuallLy ls deflned as 'Lhe LoLallLy of feaLures
and characLerlsLlcs of a producL or servlce
LhaL bears on lLs ablllLy Lo saLlsfy sLaLed or
lmplled needs'
CuallLy feaLures can be classlfled lnLo Lwo
ma[or caLegorles
11he conformance of Lhe feaLures
deslgned ln Lhe producL Lo Lhe speclflcaLlons
(process dependenL)
21he deslgned feaLures lL self (deslgn
dependenL)
MLC
CuallLy y ueslgn conL
roducL 8aLlng for CuallLy of lu
1) CuallLy of user lnLerface
2) LmoLlonal Appeal
3) AblllLy Lo MalnLaln and 8epalr Lhe roducL
4) ApproprlaLe use of 8esources
MLC
CuallLy y ueslgn conL
3) roducL ulfferenLlaLlon1hls dlfferenLlaLlon
arlses predomlnanLly from appearancewlll a
cusLomer can slngle ouL Lhe producL ln Lhe
sLore from lLs appearance? wlll a cusLomer
can recollecL Lhe producL from an ad? Wlll lL
be recognlzed when seen on Lhe sLreeL? uoes
Lhe producL flL wlLh or enhance Lhe corporaLe
ldenLlLy
MLC
CuallLy y ueslgn conL
CuallLy Assurance
CA ls broadly Lhe prevenLlon of quallLy
problems Lhrough planned and sysLemlc
acLlvlLles (lncludlng documenLaLlon)
Ma[or CA sLandards are
MLC
CuallLy y ueslgn conL
1) lso9001
ensures conformance Lo requlremenLs
durlng deslgn and developmenL producLlon
lnsLallaLlon and servlclng 1herefore
englneerlng and manufacLurlng flrms who
deslgn develop produce lnsLall and servlce
Lhelr producLs are covered under Lhls
sLandard
MLC
CuallLy y ueslgn conL
2) lSC9002speclfles a model for CA when only
producLlon and lnsLallaLlon conformance ls requlred
3) lSC9003speclfles a model for CA ln flnal lnspecLlon
and LesLlng
4) lSC9004conLalns guldance on Lechnlcal
admlnlsLraLlve and human facLors affecLlng Lhe
quallLy of Lhe producLs and servlces
MLC
SkeLches Lnglneerlng urawlng of LlecLronlc
roducLs
SkeLches are usually llne drawlngs showlng Lhe
producL ln perspecLlve wlLh annoLaLlons of key
feaLures
Where as englneerlng drawlng ls Lhe prlnclpal
medlum used by manufacLurlng as crlLerla for
produclng Lhe producL
1hese drawlngs are reflecLlons of deslgn
englneerlng drawlngs buL formaLLed and
organlzed Lo enhance produclblllLy and proLecLed
from mass or blankeL change
1he drawlngs are generaLed uslng a sequenLlal
process of checklng approval
MLC
SkeLches Lnglneerlng urawlng of
LlecLronlc roducLs
1he drawlngs are LesLed durlng pre producLlon
bulld phase and Lhe proLo Lype bulld phase
arLs and maLerlals are purchased based on
Lhe drawlngs
Cn recelpL of parLs and maLerlals Lhe same ls
checked and compared wlLh Lhe drawlngs
1he manufacLurlng drawlngs reflecL Lhe
producL exacLly
MLC
urawlng 8elease
A key acLlon ln lnLroduclng a producL lnLo
manufacLurlng ls Lhe offlclal drawlng release phase
lrom an englneerlng deslgn polnL of vlew Lhere ls no
Lurnlng back Cfflclal drawlng release may be
consldered Lhe momenL when deslgn ls frozen 1he
CM ls prepared based on Lhls 1herefore changes
ln any of Lhls documenLaLlon afLer Lhe offlclal
drawlng release wlll requlre processlng Lhrough Lhe
esLabllshed change noLlce procedure
MLC
lnpuLs ConLrol ulsplay lnLerface
lnLerfaceLhe means by whlch we can
connecL/lnLeracL wlLh Lhe funcLlonallLy of a devlce
user
lnLerface ueslgn 1heoryPuman cmpLr
a ueslgn Lo make easler lnsLrucLlon for human
/compLr lnLeracLlons
b ueslgn Lo dlscover Lhe mosL efflclenL way for
undersLandable elecLronlc messages
c roper dlagram of menus lcons forms as well
as daLa dlsplay and enLry norms
MLC
8ules for lnLerface ueslgn
SLrlve for conslsLency eg ulalogue box ln CAu
or ln oLher appllcaLlons
ldenLlcal Lermlnology should be used ln
prompLs menus and help screens
c conslsLenL color layouL fonLs eLc should be
employed LhroughouL
MLC
8ules for lnLerface ueslgn
Lnable frequenL users Lo use shorLcuLsLo
lncrease Lhe pace of lnLeracLlon use
abbrevlaLlon speclal keys hldden
command eLc
Cffers lnformaLlon feed backfor every
user acLlon Lhe s/w should respond ln
Lhe same way eg do you wanL save Lhe
flle?
MLC
8ules lor lnLerface deslgn
ermlL easy reversal of acLlonback undo
8educe shorL Lerm memory loadby deslgnlng
screens where opLlons are clearly vlslble eg
maxlmum mlnlmum close all clearly vlslble
ueslgn user frlendly s/w acLlons avold
Ledlous sequences of daLa enLry
MLC
uocumenLs
MarkeL 8esearch 8ef for deslgn Leam
ueslgn uocumenLs 8ef for Lngg Leam
Lngg ueslgn uocumenL8ef for
purchase/producLlon
1esLlng MalnL documenLuseful for deslgn
Leam whlle deslgnlng new verslon of Lhe
producL
MLC
ueslgn uocumenLs of LlecLronlc roducLs
lock ulagram
SLrucLure ulagram
roducL SkeLches
ClrculL ulagram
C rouLlng gulde llnes
MLC
Lnglneerlng uocumenLs of LlecLronlc
roducLs
CMlll of maLerlalup daLed every week
C Lay ouL
C/CAu flle for manufacLurlng
Mechanlcal drawlngs of enclosures and any
oLher mechanlcal parLs lnvolved
Assembly lnsLrucLlons
1esL lan documenLs
MLC
1esL uocumenLs
useful for englneerlng Leam Lo flnallze Lhe
deslgn before producLlon
Checks conflrm Lhe producLlon process
Pelps deslgn englneers Lo change any deslgn
Lo meeL producLlon requlremenL
Pelps ln valldaLlng Lhe deslgn speclflcaLlons
1esL documenLsLnvlronmenLal 1esLlng
LMl/LMC Compllance LesLlng
MLC
LnvlronmenLal/LMlLMC 1esLlng
1emperaLure Cycllng
PumldlLy 1esL
vlbraLlon 1esL
ump LesL
ConducLed LMl 1esL
8adlaLed LMl LesL
MLC
LlecLronlc ackaglng
LlecLronlc ackaglng ls Lhe means by whlch
sysLem componenLs are lnLerconnecLed and
lnLegraLed Lo creaLe a producL wlLh a deslred
funcLlonallLy
provldlng a sulLable envlronmenL Lo Lhe
elecLronlc producL as a whole Lo perform
rellably over a perlod of Llme
MLC
LlecLronlc ackaglng
LlecLronlc packaglng musL provlde for
elecLrlcal connecLlons beLween
componenLs physlcal supporL of each
componenL Lhermal managemenL for Lhe
heaL dlsslpaLed by each componenL
roLecLlon(Mech/Chem/LlecLromagneLlc)
and connecLlon of Lhe sysLem Lo Lhe ouL
slde world
MLC
ComponenLs of LlecLronlc ackaglng
1he mosL common form of elecLronlc
packaglng ls Lhe prlnLed clrculL assembly
(CA) 1he CA conslsLs of Lhe rlnLed ClrculL
oard (C) and Lhe varlous elecLronlc
componenLs LhaL are aLLached Lo lL lncludlng
lnLegraLed clrculLs (lCs) dlscreLe componenLs
connecLors and modules
MLC
Common ueflnlLlons
looL rlnLlL ls Lhe subsLraLe area occupled by Lhe
package componenLs
lLchls Lhe perlodlc dlmenslon LhaL characLerlzes Lhe
spaclng beLween repeaLlng elemenLs of a perlpheral
or array paLLerns
SubsLraLe1he subsLraLe of an elecLronlc assembly ls
Lhe sysLem elemenL Lo whlch elecLronlc componenLs
are aLLached and Lhelr respecLlve l/C are connecLed
LogeLher (lL Lherefore conslsLs of Lhe bulk subsLraLe
maLerlal and one or more layers of conducLlve
rouLlng for Lhe dlsLrlbuLlon of elecLrlc slgnals or
power)
MLC
ConL
ModuleA subsLraLe whlch aLLaches Lo a larger
sysLem subsLraLe ls called a module lL ls a smaller
CA LhaL ls connecLed Lo a larger CA (moLher oard)
CArlnLed clrculL assembly ls Lhe mosL common
form of elecLronlc packaglng CA conslsLs of Lhe
prlnLed clrculL board (C) and Lhe varlous elecLronlc
componenLs LhaL are aLLached Lo lL such as lCs
dlscreLe componenLs connecLors and modules
MLC
ConL
CrlnLed ClrculL oard provldes elecLrlcal
lnLerconnecLlons as Lhln meLal Lracks on
dlelecLrlc subsLraLe whlch also supporLs Lhe
componenLs
ulscreLe ComponenLslL conslsLs of reslsLors
capaclLors lnducLors
dlodesLranslsLorsosclllaLorsand swlLches
MLC
MLC
chlp
chlp
SubsLraLe
for chlp
Second level card
assembly
llrsL level package
connecLor
ack panel or
MoLher oard
1hlrd Level Assembly
Levels of LlecLronlc ackaglng
module
luncLlons of ackaglng
1o provlde elecLrlcal connecLlons beLween
varlous devlces
1o provlde mechanlcal supporL Lo Lhe producL
1o faclllLaLe assembly operaLlons
1o dlsLrlbuLe power Lo all componenL and chlp
clrculLs
1o proLecL Lhe clrculL from envlronmenLal
mechanlcal damage
MLC
ConL
Shleldlng from exLernal elecLromagneLlc
radlaLlon and lnLerference
revenLlng harmful radlaLlon golng ouL of box
1o remove heaL generaLed from lCs and oLher
componenLs
1o allow removal and replacemenL of falled
componenLs
1o faclllLaLe elecLrlcal and funcLlonal LesLlng of
Lhe clrculL
MLC
Levels of packaglng
MLC
Leve/s of Pockoqinq
Leve/ 0 Pockoqinq
lnLerconnecLlons wlLhln semlconducLor lC
lnLerconnecLlons on a monollLhlc slllcon dle
MLC
Chlp (lC) Level ackaglng (Level 1)
Chlp level ackaglng ls flrsL level packaglng 1he
chlp ls connecLed Lo lLs carrler ln many dlfferenL
ways
a Leaded ackage(slngle dual quad
eLc lnllne)
b 1A/1C ackage (1apeauLomaLed
bondlng/1ape carrler package)
c CC( chlponboard)
d lllpchlp
e CA (all grld Array)
f CS (chlp scale packages)
MLC
MLC
MLC
lllpChlp ackaglng
lllpChlp packaglng provldes Lhe hlghesL lnLerconnecLlon
denslLy for a glven area and a very hlgh level of
mlnlaLurlzaLlon
1he bare dle ls mounLed dlrecLly Lo Lhe subsLraLe
ellmlnaLlng Lhe need for an lnLermedlaLe lC package
lllpchlp can be cosLeffecLlve ln very hlgh volume
appllcaLlons
1he elecLrlcal characLerlsLlcs of a fllpchlp connecLlon are
generally beLLer Lhan a wlrebonded devlce due Lo Lhe
ellmlnaLlon of performancesapplng conducLance and
capaclLance ln leads and wlre bonds
MLC
lllpChlp ackaglng
lllpchlps ls dlfflculL Lo LesL hlgh mechanlcal sLress
due Lo Lhermal mlsmaLch 1hermal sLress lssues are
handled by underfllllng Lhe assembly wlLh an epoxy
lllpChlps ls used where a hlgh manufacLurlng yleld ls
requlred exLreme mlnlaLurlzaLlon ls of uLmosL
lmporLance
Assembly Lhlckness of less Lhan03 mm can be
achleved wlLh fllpflop
MLC
aslc lllpchlp consLrucLlon
MLC
SuS18A1L
MeLal ump
underflll
lC ule
Solder or conducLlve
adheslve bond
CrosssecLlon
all Crld Array (CA)
MLC
SuS18A1L
SCLuL8 ALLS
lC ulL
lllpChlp lC
LncapsulaLlon
CA packages uLlllze a small prlnLed clrculL carrler as an lnLerposer beLween lC and Lhe
prlnLed clrculL subsLraLe 1he lC ls wlrebonded or fllpchlpped Lo Lhe prlnLed clrculL carrler
and ls encapsulaLed ln a manner slmllar Lo a leaded package 1he prlnLed clrculL carrler rouLes
Lhe perlpheral wlrebonds Lo an array paLLern on Lhe underslde of Lhe carrler 1he array
paLLern ls populaLed wlLh solder balls LhaL funcLlon as leads for surface mounL aLLachmenL Lo
Lhe prlnLed clrculL subsLraLe'
CS ackage
CS ackage ls slmllar Lo CA package buL
wlLh smaller fooLprlnLs Lhan CA
rovlde Lhe mlnlaLurlzaLlon and performance
as LhaL of a fllpchlp package
Pave beLLer LesLablllLy reduced mechanlcal
sLress
1he lnLerposer layer ln a CS can be used Lo
Lransform Lhe l/C paLLern of Lhe devlce from
perlpheral Lo array
MLC
ulscreLe ComponenLs
All dlscreLe componenLs are deslgned Lo be soldered
on Lo a C subsLraLe (surface mounL varleLy)
ulscreLe componenLs form a large parL of any
porLable elecLronlc equlpmenL
luncLlonallLy performance and cosL are deLermlned
by Lhe selecLlon of dlscreLe componenLs
ulscreLe componenLs normally have a hlgh Lolerance
levels
Powever ln cerLaln sysLems hlgh Lolerance levels are
avolded by havlng a ad[usLable dlscreLe componenLs
MLC
level 2 packaglng
MLC
MLC
C Assembly (Level 3)
C assembly wlLh slnglechlp packages
mulLlchlp modules and dlscreLe componenLs
forms Lhe basls of carrler level packaglng
alLernaLlvely known as Lhlrd level packaglng
1he oLher componenLs are connecLors
sockeLs power devlces mlnl Lransformers
cables eLc
MLC
ConL
1he ma[or parLs of Lhlrd level package are
1rlnLed clrculL carrler( rlgld and flexlble)
2ConnecLors (slgnal power sockeLs)
3Slngle Chlp and mulLl chlp packages
4ulscreLe componenLs
3ower devlces such as Lransformers
baLLerles
6Speclal componenLs such as crysLal
CsclllaLors reseL swlLches speakers
MLC
ConnecLors
ConnecLors are an essenLlal parL of elecLronlcs
packlng A connecLor serves Lwo purposes
a Mechanlcal connecLlon Lo hold Lhe Lwo
clrculLs LogeLher
b LlecLrlcal connecLlon Lo provlde slgnal
and power Lransmlsslon from one clrculL Lo
oLher
MLC
ConnecLors conL
MLC
ConnecLors conL
Some examples of many uses of connecLors are
1lnserLlon of adapLer cards on a moLher board
uslng a card edge connecLor
2Memory lnsLallaLlon ln SlMM sockeLs
3ConnecLlng power supply Lo varlous l/C devlce
4Puuluu and Cu_8CM connecLlons Lo Lhe
moLher board uslng cable connecLors and pln
headers
3key board and mouse connecLlon Lo C
6oardLo oard connecLlon uslng flaL cable
connecLor
MLC
MLC
MLC
ConnecLor ConLacLs
ColdplaLed conLacLs are used for hlgh rellablllLy
appllcaLlons such as mlllLary Lele communlcaLlons
medlcal hlgh end compuLers
alladlum ls a low cosL alLernaLlve Lo Lhe gold
-onnoble meLals such as Llnlead plaLlng ls used for
low end compuLers auLomoblle appllcaLlons
consumer producLs because of lLs low cosL
MLC
ConnecLors
1he hlgh speed clrculLs requlre slgnal propagaLlon
paLhs LhaL are free of crossLalk and resulLlng
elecLrlcal nolse
lncreased lnLerconnecL denslLy means more cross
Lalk
Pence need for proper selecLlon of connecLors
1he conLacL maLerlal for connecLors depends on
many facLors such as
1connecLlon denslLy
2componenL proflle
3operaLlng envlronmenL rellablllLy
MLC
ueslgn 8equlremenL of ConnecLors
ConLacL force
ConLacL reslsLance
1emperaLure rlse
CurrenL uenslLy
SLress relaxaLlon under LemperaLure
Lase of use
erformance Plgh performance connecLors for
achlevlng necessary slgnal fldellLy
ueslgn based on expecLed maLe/demaLe cycles
ConnecLor lnLended only Lo faclllLaLe Lhe orlglnal
sysLem assembly need Lo be raLed only for a small
number of lnserLlons
MLC
ConnecLors/wlres used ln orLable
LlecLronlcs
SM1 1ype Lhey are surface mounLed Lo Lhe
C (boardLo oard connecLlon) known as
Lll/Zll connecLor uslng polylmlde/polyesLer
flex
PeaL Seal connecLorsused Lo achleve very
flne plLch (polylmlde flex) or very low cosL
(polyesLer flex) used for connecLlng sysLem
C Lo LCu
MLC
ConnecLors/wlres used ln orLable
LlecLronlcs
SockeL ConnecLorsused for mlcroprocessor and mulLlchlp modules
Lo lnLerface lnLo a sysLemsockeLs are cosLly and used where Lhe
sysLem ls sub[ecL Lo revlslon/upgrade/posLponemenL (flLLlng Lhe
expenslve componenL [usL before shlpplng)
Wlre cables/flex clrculLs are ofLen employed for elecLrlcal connecLlon
when boardLo board connecLlon ls noL posslble
llex clrculLs enable a very hlgh denslLy of elecLrlcal connecLlons Lo be
rouLed ln a compacL volume Lhey allow dlsLrlbuLed" elecLronlcs for
spaceconsLralned appllcaLlons allow conLrolled elecLrlcal
characLerlsLlcs and physlcal geomeLry
MLC
asslgnmenL
ll-u -AMLS Cl A-? 10 1?LS Cl
CC--LC1C8S l1S ALlCA1lC-
SPC81 -C1L C- CALLS (CCAxlAL
u1S18lC- ClC eLc
MLC
MLC
LlecLronlc ackaglng MeLrlcs
-umber of connecLlonsLoLal number of lnLer
connecL lnLroduced on accounL of solder [olnLs
adheslve lnnerconnecL or counLer Lermlnal
lnLerfaces
CpporLunlLy counLLoLal number of parLs plus LoLal
number of connecLlons Lhe same lndlcaLe LhaL each
of Lhese elemenLs represenL an opporLunlLy for
fallure A hlgh counL means complex rlskler
elecLronlc assembly
Average ln counL (AC)
MLC
ConL
Average ln CounLraLlo of LoLal number of componenL
Lermlnals Lo LoLal number of parLs aL sysLem level Clves a
ldea of lnLegraLlon level and/or 'dlglLalness' of Lhe overall
producL Low ACs reflecL a hlgh number of dlscreLes or oLher
lowpln counL devlces ofLen characLerlsLlcs of analog clrculLs
Plgh ACs means a dlglLal clrculLhlgh pln counLs
ConnecLlon denslLyLhls meLrlc ls a raLlo of LoLal number of
connecLlons Lo LoLal prlnLed clrculL board assembly area ln
unlLs of connecLlons per cm
MLC
ConL
arL uenslLy1hls meLrlc ls a raLlo of Lhe LoLal number of parLs
Lo LoLal prlnLed clrculL board assembly area ln unlLs of
componenLs per cm Plgh parL denslLy reflecL challenges ln
surface mounL assembly ln Lerms of preclslon of placemenL
number of placemenL and englneerlng of parL clearances
8ouLlng uenslLy3x(average pln counL) x (parL denslLy)1/2
parL denslLy formula ls parLlcularly useful for deslgner Lo
deLermlne Lhe requlred wlrlng resources needed ln a
subsLraLe based on Lhe average pln counL and requlred pln
denslLy of Lhe producL
MLC
1
ulsplays
ln a porLable elecLronlc deslgn Lhe user lnLerface ls
mosL affecLed by Lhe selecLlon of dlsplays
lxel resoluLlon deLermlnes Lhe level of graphlc deLall
LhaL can be dlsplayed ln a slngle lmage frame
8esoluLlons varles from lowresoluLlon
monochrome segmenLed characLeronly dlsplay Lo
hlgh resoluLlon color dlsplays capable of dlsplaylng
mllllons of plxels
1he color range of dlsplay deLermlnes Lhe number of
varlaLlons of color LhaL can be dlsplayed
MLC
ulsplays
rlghLness lndlcaLes how much llghL ls emlLLed from
Lhe surface of Lhe dlsplay
8eflecLlve dlsplays have no brlghLness and rely on
reflecLed amblenL llghL Lo reveal Lhe conLrasL and
color creaLed on Lhe dlsplay surface
Lmlsslve dlsplays generaLe llghL aL each plxel 1hls
llghL creaLes Lhe color and conLrasLs Lo form Lhe
lnLended lmage
1ransmlsslve dlsplays use a backllghL whlch ls fllLered
by Lhe dlsplay surface Lo creaLe color and conLrasL
1ransflecLlve dlsplays reflecL amblenL llghL back
Lhrough Lhe fllLerlng dlsplay surface Lo creaLe an
lmage
MLC
MLC
ulsplay 1echnology
MosL porLable elecLronlc devlces LhaL have a dlsplay use a
flaL panel dlsplay (lu) and ln mosL cases Lhe lu ls based
on LCu Lechnology 1ypes of lu
Llquld CrysLal -emaLlc
SmecLlc
Chlral
Lmlsslve lleld Lmlsslon
ulsplays
LlecLrolumlnescenL
LlghL LmlLLlng polymers
Mlcrodlsplays Llquld CrysLal
MLMS
LlecLrolumlnescenL
MLC
asslgnmenL
ll-u Cu1 C lA8lCA1lC-
1LCP-lCuLS
MLC