New CEO Mitchell Breathing Life in IPC

The early feedback is that new IPC CEO John Mitchell has brought a much-needed breath of fresh air to an organization that had lost its drive and character after 11 years under the previous regime.

Among the early changes include a recognition that IPC has become out of touch with many segments of its membership. Designers were so disenchanted, a group of the Designers Council leaders were preparing to bolt the organization altogether. Fabricators’ antipathy toward IPC is well-documented and may even run deeper, as many smaller and private shops have long since labeled IPC as disinterested in their concerns. Even some assembly equipment suppliers have shared concerns over the standards process and perceived biases toward certain groups.

Much of that is turning around under Mitchell. He has moved quickly to make the rounds of various constituents, and in a departure from his predecessor, has not relied on staff to vet member opinions. He has begun to shed some of the entrenched “lifers” who had alienated too much of the membership to continue in their roles. And he has made clear, according to sources, that the staff focus going forward needs to be on the members, which is a long overdue switch from a decade of “Is It Good for the IPC?”*

Further, he is repositioning the organization to better reflect the way the industry is structured. One new division is simply called Member Success, which he describes as a group of functions (membership, member support, events and industry councils and market research) “focused on helping our members be more successful and taking an active role in helping them more fully benefit from their IPC membership.” Most of these areas had grown stagnant to the point of calcification. One of the problems many had identified with IPC is that it existed as much (or more) to ensure its own success but had lost its vision on how to improve members’ profitability. Recognizing that the onus needs to be on IPC to help its members (and not the other way around) is a long overdue and welcome shot in the arm.

Dave Torp, whom many feel is a talented but marginalized asset, is now clearly in charge of the technology and training programs, a role where his background in engineering at Rockwell Collins and sales and marketing at Kester will truly help him excel.

There is a renewed interest in Public Policy, which will in the future coordinate with Brussels and Beijing (and perhaps other key spots). IPC plans hire a new vice president for this space, a sign that it needs fresh input and energy if it plans on making a difference with the legislative branch.

Mitchell seems highly motivated to invest in IPC’s international operations, a space where the trade group’s board had been critical of the previous president for moving at a glacial pace. To that end, IPC is casting about for a president of its China organization, a smart move and a tacit nod that in Asia, titles mean something, and the approach of using a middle manager with no real authority was not working. It says here that if vice president Dave Bergman stays on, he should move to Shanghai, where his experience at IPC (30 years) could better be put to use.

One very smart move was to create a Special Projects function, which allows IPC to look at new or short-term initiatives without distracting staff from the core functions.” We see this as wise because new projects often either sap all the attention and resources from important but functioning efforts, thus potentially leaving those programs to wither, or vice versa, attending to existing programs can act as a excuse for letting new efforts simply dangle. Mitchell has brought on a former colleague named Ed Trackman to run this area.

IPC holds a critical place in the electronics supply chain, but that spot had slowly been eroding over the years. It’s early, and the proof will be in the results, but based on several conversations with IPC members who are much happier today than I’ve seen them in years, Mitchell appears the right person for the job.

*With apologies to Office Space.

Welcome, New Readers

Today we start welcoming readers from another blog we run called Laying It Out. We’ve imported the blog posts from the past several years to this site, and readers are able to sort all the old (and new) postings from Laying It Out by Pete Waddell, Judy Warner and myself by clicking on the Laying It Out category.

Why the switch? We’ve realized that many readers were using both blogs because some of the content on the Hot Wires blog overlapped quite a bit with the design and fabrication segment (Duane Benson, I’m looking at you!). Merging all the content into one space should save all of us some time each day.

Thanks for reading!

Another Tidal Wave Hits Japan

Old friend Dominque Numakura comes back from the annual JPCA Show with a stunning announcement: Japan’s PCB industry seems to be on life support.

From a series of dull presentations to the outsourcing of manufacturing to a general lack of optimism, the mood is dour, Numakura says. More ominous, some veterans are comparing the trend to the decimation of the US PCB industry in late 2001.

As late as 2000, the US and Japan were neck-and-neck in annual PCB sales, with the US dominating the large board space and Japan leading in HDI. Despite the problems experienced in the US, Japan continued to be the technology leader in PCBs, leading some to surmise that its vast investment and wise decisions on which technologies to focus on made Japan impervious to the cost pressures that sunk the North American industry. Numakura’s essay suggest that’s not the case, leaving one to wonder what this means for the circuit board industry for the coming decade.

Electrolytic Ambiguity

I’ve written about ambiguity a few times before, like this post about fiducials. But I’m not talking about the PCB today. I’m talking parts. More specifically, I’m talking about silkscreen markings for your parts on the PCB.

Diodes have a lot of opportunity for ambiguity, as you can read here. There are many ways to mark parts, but fewer ways to clearly mark them. Take a typical electrolytic capacitor. It can be through-hole, SMT metal can, tantalum, or a few other form factors. The capacitor manufacturers aren’t doing any of us any favors insofar as “markation” is concerned.

Check out the image at the right. Yikes! In all cases shown here, I’ve oriented positive on the left, which, according to IPC is pin 1. This is also the zero degree rotation for the centroid value. But, isn’t it nice of those component manufacturers to put the identification bar on the positive side for tantalum capacitors and on the negative side for metal can electrolytics? Not!

So, how should you mark this in the silkscreen on your PCB? For an electrolytic capacitor, the best approach is to mark the positive sided with a plus (+) sign. If you mark pin 1 with the number 1, it can easily be mistaken for the minus sign. If you mark the negative side with a minus sign, it can easily be mistaken for pin 1.

For a metal can capacitor, it is also acceptable to put the notched outline in silkscreen. We still recommend that you place the plus (+) sign on there too.

Duane Benson
I’m just positive I put the negative right on the left

http://blog.screamingcircuits.com/

Behind the Sigrity Deal

Cadence’s acquisition of Sigrity, announced yesterday, is a big deal for reasons beyond the technology being acquired.

Sure, it’s great for Cadence to gets its hands on Sigrity’s power and signal integrity tools.

But what this move also underscores is something of a recommitment by Cadence to its printed circuit board software. You’d have to go back years to find the last time Cadence completed a significant deal in the PCB space (I’m not including, of course, the failed 2008 “attempt” to purchase Mentor, which eventually cost then CEO Michael Fister his job.)

Cadence’s PCB revenue jumped in 2011, growing by our estimates roughly 23% year-over-year. That makes it by far the fastest-growing player in the PCB EDA space. How long has it been since they could say that?

Coupled with its aggressive support of the IPC-2581 data transfer format, Cadence is showing a newfound vigor toward protecting and even extending its circuit board design position. Mentor remains a much larger competitor in PCB sales, but there are signs of a shift taking place.

To Mod or Not to Mod? That is The Question

Many years ago, I was a product manager at a business-consumer electronics company developing some pretty leading-edge display equipment. Prototyping back then was a long and painful process. A PCB might take a month or two to arrive from fabrication. Parts had to be sourced by digging through massive catalogs and then hoping that what you needed would be on the companies approved vendor list. The whole process was a bear.

Well, the soldering up part wasn’t always so bad – unless you were the poor soul tasked with wire-wrapping or hand soldering the prototype.

Based on how difficult and expensive a board spin was back then, common practice was to just mod up the boards, even in production. Any given PCB might have a dozen or more cuts and mod wires. Those changes might not make it into the PCB for months. These days, though, you can get board fabbed Mod wireovernight, your parts delivered over night, and when you have all of those parts and PCBs, you can get them assembled overnight. I suspect that increase in speed is the major reason mod wires seem to be nearing extinction these days. (note that Screaming Circuits didn’t build the board in this picture. It’s from my personal collection)

It may not seem cheap to pay to have someone respin a board so speedily; especially when set next to hand soldering. But when compared to the cost of idle engineers waiting for the next rev, the cost of adding mods, the reduced reliability from having mods and the additional manufacturing time caused by modding a board; today’s quickturn parts, fab and assembly options can end up saving gobs of time and money in the long run.

Duane Benson
There are more wires in heaven and earth, Horatio, than are soldered on your PC board.

Laminate Libraries?

I was chatting today with Manny Marcano, the relentless force behind EMA Design Automation. He mentioned the company’s webinar tomorrow on library creation and management has several hundred designers registered.

“It is amazing to me that library creation and management is still a big challenge for CAD guys,” he noted. Given the advancements in software, he should be right, but the new parts keep coming even faster.

It did get me thinking, however: when will we see CAD tools begin to incorporate laminate data in the way they currently have the parts libraries? There are so many flavors of laminate these days, it’s nearly impossible to keep up. Yet the material choice plays a huge role in the manufacturability and performance of the finished product.

Thoughts?

How Not to Trick Your BGA Friends

Continuing with yesterday’s theme, I have a couple examples that should have been fine, but due to issues at the board house, improper storage or contamination, ended up very much not fine.

What is wrongBehind door number one, we have an OSP finish that will make you very unhappy. That’s “Organic Solderability Preservatives” in long hand. I’ve also heard it called “Organic Surface Preservative”, but close enough. It is a nice flay surface which is good for BGAs. Years ago, it had a reputation for being poor quality, “cheap”, but newer formulas seem to work pretty good in both leaded and lead free. In this case, the darker pads were likely contaminated in some way – either at the board fab house or subsequently in handling.

Siver migration problemNext is the worst example of surface degradation I’ve ever seen. Yes, it’s an extreme outlier case, but this is where a silver board can go if it wasn’t built with the best quality control, was stored too long, was exposed to polluted air or other contamination and had bad luck. This board probably has all of those issues, but any one alone can be problematic. Silver board especially should be stored in a cool dark place; preferably sealed in the original packaging.

Duane Benson
OSP can also mean Oregon State Patrol, but they don’t care about BGAs. Just safe driving.

http://blog.screamingcircuits.com/

Fiddling with Fiducials Again

I recently posted a note about fiducials but I didn’t have any images. Here’s a couple of examples:

IPC acceptable fiducialsThis first example shows what IPC would like to see. If this is an individual board, this would be it. If it were part of a panel, you would follow the same pattern on the panel rails and also put it on each individual board in the panel.

As I wrote in the earlier post, we don’t require these, but it’s always a good idea. You’ll need them once you go into volume manufacturing anyway.

The next example won’t make IPC happy, but it will make Screaming Circuits happy:

Also acceptable fiducialsIt only uses two fiducial dots, but it isn’t reversible. Reversibility is okay for jackets, but not for circuit boards. Since one of the dots is offset, it can’t be placed on the machine and recognized as correct in any way except in the proper orientation.

The important aspect of both of these examples is that they remove ambiguity. There can’t be any uncertainty, which is good because uncertainty is your enemy. It’s a subtle enemy. It might not bother you 99.9 times out of a hundred, but then, when you’re not looking, it can strike. So, give a hoot and stomp out ambiguity.

Duane Benson
False data can act only as a distraction. Therefore, I shall refuse to perceive.

http://blog.screamingcircuits.com/

Counting Once, Counting Twice…

Panel single scLet’s say you have two options: First, you could send in your boards for assembly as individuals. Second, you could send them in a panel. That’s all fine and dandy. For a few, send individuals. For a bunch, panels might make more sense. But, when you do go to quote and order, how do you count the parts?

Let’s take this example. As a single, this board has 32 line items on it’s bill of materials. That’s 32 unique parts. Counting all of the individual part placements, there are 56 total parts: 42 SMT and 14 through-hole. So, naturally, if you quoted the assembly of 20 of this board at Screaming Circuits, you would enter your desired board quantity as 20, 32 total unique parts, 42 SMT and 14 through-hole.

But what do you do if you send it in panel form? How do you count? It’s actually not as difficult as it seems. In this example, it’s in a panel of four. There are still only 32 BOM line items, but there are four times as many placements. That means that if you quoted this, as a panel, you would enter 32 total unique parts, 168 SMT and 56 through-hole parts. If you still need 20 of the final boards assembled, you would enter 5 as your desired board quantity.

In the end, you will have 20 assembled boards. In case you are wondering about the cost, there won’t be a difference. As long as the final number of boards (after the panel is broken apart) are the same, your cost will be exactly the same for panel vs. one up. You don’t save any money by sending in singles. However, if your board is panelized and all of your parts on on reels, full or partial, you can save money by ordering Short-Run production.

Duane Benson
50 Years ago today
Robert Rushworth flew the X-15 to Mach 5.03 at 100,400 feet altitude

http://blog.screamingcircuits.com/