Wave of Innovation

Old friend Jeff Miller (some readers may remember him from his ACT and Wise days)

3D printed car

took this photo of a 3D printed car this week while at IMTS in Chicago.

Meanwhile, while at PCB West earlier this week, we saw the row of Tesla demo cars on display and waiting for test drives in San Jose. A designer from Telsa’s Palo Alto R&D center (the former HP semiconductor plant) was at the show and was visibly excited talking about the range of electronics he gets to work on.

No one will confuse Tesla’s elegance with the admittedly rough model at the right, but there are some amazing things happening with both board technology and form factors right now, and we are lucky to get a front row seat for this latest wave of innovation.

Why Soldering’s Loss was Design’s Gain

Catching up on your summer reading? Consider Dickie: Memoirs of a Mad Scientist, by Richard Nedbal.

Though not seen around the industry much anymore, Rich, many longtime readers will recall, revolutionized CAD and CAM software as founder of P-CAD, which at one point boasted the world’s largest ECAD installed base, and Advanced CAM Technologies (ACT), which developed the still popular CAM350.

Rich has spent the better part of his post-ACT days working on bettering engine injection systems. (He also was inducted into the Dieter W. Bergman PCB Design Hall of Fame last year at PCB West, which coincidentally takes place in September at the Santa Clara Convention Center.) In his spare time, he has written a startlingly funny and self-deprecating book about his childhood and early adult years.

Rich spins great yarns about growing up in Chicago, his occasionally inspiring parents, learning about electrons (which he mastered) and soldering (which he butchered), first jobs, monkey races (seriously), starting college, and joining the Air Force, where he escaped the hated “Dickie” moniker of his youth, only to be recast by an angry Air Force sergeant as “Airman Kneeball.”

A lifetime love of math and science took him to Carnegie Mellon, where an engineering manager tapped him to help with digital logic design, launching his Hall of Fame career in electronics.

Rich’s wit, intellect and most of all, never-say-die attitude are on display in spades throughout this charming tale, released this summer by Strategic Book Publishing and available via Amazon. I would have expected nothing less.

Does Rising Nationalism Pose Threat to Electronics Supply Chain?

The amount of geopolitical discord around the world at present is stunning: Thailand, Vietnam, Korea and other major electronics manufacturing hubs are seeing a rise in nationalism and severe internal tension over how to address foreign pressure.

Thailand in May endured yet another military coup — its 19th since declaring independence from its monarchy in 1932. Some observers feel the military wants a permanent seat in the national parliament, a move that could hinder its democratic movement.

In Vietnam, citizens are outraged at what it feels is Chinese strong-arm tactics. Its Northern neighbor has provoked many Southeastern nations over the past few years, often by occupying seaborne territory that others had staked claims to in the past. (The Philippines have a similar complaint dating to 2012, when China evicted Philippine fishermen from their long-held fishing grounds.) Lately, Chinese oil rigs took up in Vietnamese waters, leading to riots at Fittec, Foxconn and elsewhere, where domestic workers took aim at their Chinese* employers.

Korea is losing business to Vietnam, aided in part by its own OEMs: Korea is now the largest investor there, pumping in nearly 23% of all outside investments in the first quarter this year. As Samsung relocates its cellphone manufacturing there, Vietnam is on track to produce 250 million handsets this year, versus 200 million in China and just 30 million in South Korea. As the linked article indicates, as of March 2014, Samsung Electronics subcontractors had invested an aggregate $2 billion in Vietnam. Meanwhile, while Samsung buys a reported 53% of its parts from Japan, South Koreans now view Japan as their second-leading military threat, next to North Korea, and resentment from World War II is rising once again.

Indonesia is suffering through a contested presidential election, one that involves an ex-general and the possibility of an overturned ballot result.

Japan, my friend Dr. Hayao Nakahara tells me, has essentially stopped investing in new manufacturing sites in China, with the only new developments minor capacity add-ons to existing plants. The two nations have been at odds over everything from possession of uninhabited islands in the East China Sea to a rehashing of wartime atrocities.

Southeast Asia is home to the bulk of the world’s electronics production, and holds the majority share of products built for the consumer, industrial/instrumentation, telecommunications, PC and peripherals end-markets (not to mention the vast majority of the raw materials and components supply). We’ve absorbed several of nature’s bullets of late — flooding in Thailand, the typhoon in Malaysia and of course the 2011 earthquake and subsequent tsunami in Japan. I am told that the media reports have exaggerated what’s happening on the ground in Southeast Asia, and that on a day-to-day basis little dissent is noticeable. That may be true, and to be sure, the self-inflicted disruptions have thus far been held to a minimum. Given the number of countries involved — unprecedented in recent times — and the enormity of what’s at stake, we can’t help but feel it will take some luck if the next supply-chain breakdown is only as bad than the last.

*Fittec is based in Hong Kong, Foxconn in Taiwan, but most employees and manufacturing for both companies are in China.

Jerry Shore, RIP

I didn’t know Jerry Shore, except by name, so I can’t really comment directly on his passing this week at the age of 88. But he was a significant force in the printed circuit industry for decades, founding Park Electrochemical in 1954 and building it into a laminates powerhouse up until his retirement, in 2004.

My friend Gene Weiner did know Jerry well, however, and he offers his thoughts on his blog here.

To the entire Shore family, including son Brian, who has been running Park since Jerry stepped down as CEO in 1996, our sincere condolences.

A ‘Worthington’ Idea

EMS firm Worthington Assembly last week announced a deal to market its EMS services via CircuitHub.

WAI is a small EMS company located in Western Massachusetts. Like many in the sub-$20 million space, WAI’s owners double as its salesmen, and the firm relies heavily on word of mouth (and engineers changing jobs) for prospecting.

CircuitHub developed a universal parts library and is offering that, along with BoM, bare board and assembly quoting. PCD&F did a piece on the company last year.

Chris Denney, WAI’s CTO (and a sometime CIRCUITS ASSEMBLY columnist) explains the partnership here.

Clearly, more opportunities to order boards from a variety of suppliers via a single website are popping up, with the site typically offering free software in order to gain visitors (FabStream, for example, offers use of a PCB CAD tool capable of up to 12 layer boards, and SnapEDA offers simulation).

I would not anticipate larger EMS firms would go this route. But for smaller ones, whose cost of sales would be proportionally high relative to its income if it employed direct outside sales, using app-based vendors could be a creative and low-cost way to find new customers.

Taiwan’s New Gravity

How bad is the labor problem in China? We are aware, of course, of the steady hikes in wages, which have annually risen by at least double-digits for over a decade.

But now it’s being reported that Taiwan-based component makers have had enough, to the point where some are considering repatriating their production from China, or packing it up for Brazil, Mexico and elsewhere in Southeast Asia.

Now, I’m not going to put too much stock in an unsourced report. That said, the notion that Taiwan could steal back jobs from China has been floating around for months. The average salary in Taiwan has risen just 0.9% in the past decade, despite a working population of just 11 million. (China, by contrast, has an estimated 920 million working aged citizens.) Monthly wages in Taiwan’s manufacturing sector were NT 41,087 (US$1,358) as of October,  and have trended considerably more slowly than China for some time.

All in all, it’s a stunning development, given that just a few years ago China’s promise appeared mostly still in the “potential” stage. Is it possible that promise will ultimately go unfulfilled?

Alder’s Quiet Retirement

In the quiet of the post-Christmas vacation break Kent Alder officially retired as CEO of TTM.

The news should be bigger than it is. It’s been years since the head of a $1 billion a year US-based PCB manufacturer stepped down. In fact, there probably have been only two: Andy Leitz, who left Hadco following its acquisition in 2000 by Sanmina, and James Mills, who was ousted from Viasystems after the tech recession in 2001.

Alder rose to prominence on the wave of the massive influx of outside investment groups that circled the industry in the late 1990s and early 2000. He was president of Pacific Circuits, a Redmond, WA-based board shop owned by Thayer Capital Partners and Brockway Moran, which then acquired Power Circuits in Santa Ana, CA, and renamed the merged entities TTM, with Alder as the head. On Alder’s watch, TTM grew from $125 million in 1999 to about $1.35 million in 2013. Along the way, TTM acquired Merix and OPC, and extending its offerings from that of a traditional regional quickturn PCB supplier to a full-service multinational production house with nearly 20,000 employees. And he did so because TTM managed to consistently do that one thing that has been so difficult for some many of its competitors: turn consistent profits.

It remains to be seen what kind of leader Tom Edman, Alder’s successor, will be. He has an impeccable resume: Yale, Wharton Business School, and 17 years of executive experience at Applied Materials before being tapped for the TTM job. He showed his chops by beating out at least one longtime internal candidate for the post.

But for now, we acknowledge Alder’s role as the preeminent PCB executive of the past decade, and wish him the best in his retirement.

More Fun File Facts: ODB++

In my last post, I wrote about the up and coming IPC-2581 PCB manufacturing file format. While IPC-2581 may be looked at by PCB fabricators and assemblers as a holy grail of sorts, it’s not yet widely adopted by CAD software. But, that doesn’t mean that Gerbers are the only option.

ODB++ was developed by Valor in the waning years of the last century as an improved method for getting manufacturing data into their CAM systems. Valor and, hence, ODB++ was purchased by Mentor Graphics in 2010. ODB++ is still widely available, however there’s concern in some circles that it’s not truly open. That concern is where IPC-2581 came from. In fact, IPC-2581 is somewhat derivative of ODB++.

I can see how a CAD software developer might fear the use of something owned by a rival. However, my understanding is that Mentor does it’s best to treat it like an open standard and has made it available more or less as though it is open.

The history isn’t really important. What is important is that ODB++ is a more complete format than the Gerber and is widely supported. Pretty much everything good that I said about IPC-2581 in my prior post also applies to ODB++.

The bottom line is that, regardless of whether Screaming Circuits is your fab (through our partner Sunstone) and assembly (through our factory right here) provider, ODB++ is a good thing. It makes the job easier and more accurate than does use of Gerber files. Both “easier” and “more accurate” help keep costs down and keep ambiguities to a minimum. As you know, ambiguity is the bitter enemy of both accuracy and quality.

Unfortunately, for all of you Eagle users, Eagle does not yet support ODB++. If anyone out there is really good with Eagle ULP scripting, you might want to create a on ODB++ and/or IPC-2581 creation ULP.

Duane Benson
I was ionized, but I’m better now. 

http://blog.screamingcircuits.com/

Fun Facts about Manufacturing Files

Circuit boards live and die by their manufacturing files. Without complete and accurate information, the board fab house can’t fab the boards, the assembly house can’t assemble your boards and nobody can buy the parts.

Our old standard, the Gerber file, has been around since about the time King Arthur pulled the inductor out of the solder pot. It’s old. We all use it because it’s familiar, but it’s day is done. It’s time to pass the torch.

IPC-2581 is the new standard in manufacturing files. It hasn’t been fully adopted, but it’s showing up in more and more CAD packages. The IPC-2581 format is much more advanced and has the complete data set in one file. While we still work with Gerbers every day, we can also accept IPC-2581 manufacturing files.

I’ve been called the champion of bad analogies, but I’ll try one out anyway.

Imagine, if you will, a map of the city. All of the streets are there. All of the houses are there. What’s missing are all of the street names. No street names, no numbers and no landmarks of any sort are labeled.

Given that information, find John Smith, at 1620 SW 14th Avenue. There is a house at 1620 SW 14th Avenue. There are a dozen or so houses at 1620 something. You just don’t know where 14th is, or which direction 14th runs, or where the street numbering starts.

You can physically walk each and every street until you find John’s name on his mailbox, but it’s not an easy nor error-safe process. And, hopefully, the town only has one John Smith. That’s a Gerber file.

IPC-2581, on the other hand, is an electronic map, with everything clearly labeled, and a GPS guiding you. Which would give you more confidence?

Duane Benson
IPC-2581 is like shatter-proof glasses for Henry Bemis

http://blog.screamingcircuits.com/

 

Designer Salary Data, Elaborated

Every year it seems we received a few requests for additional information from our annual Designer Salary Survey. This year was no exception.

One request asked, “I would be curious to know the salary ranges for those identified as “PCB design” only.  The maximum stated in the article is unclear if it may include some of those in management, engineering or other corporate management roles.”

Ask, and you shall receive: