ML Summit 2013 Speaker Presentations: Enterasys - No Defect is Acceptable
1. NaDIA p-10
No Defect Is Acceptable
Robotic Optical Inspection for Mechanical Assembly
2. Enterasys OneFabric™ Solutions
Modular and flexible approach to solving network challenges
OneFabric Control Center
(Unified security and management)
OneFabric Data Center
OneFabric Edge
OneFabric Security
One piece at a time. Evolve to a fabric-based network at your speed.
2
3. Assembly Complexity
Complex Assembly up to 9 Printed circuit
boards
20 Layer Printed Circuit Boards
As high as 50,000 solder connections per board
As high as 17,000 discrete components in the
assembly
Very tight tolerances and clearance
4. Enterasys Innovation creates the Solution:
Mechanical Automated Optical Inspection
PAST Process Control
Electronic Assembly
Defect containment & rapid feedback
through Automated Optical Inspection and
Automated X-Ray Inspection
Mechanical assembly
Mechanical assembly has not benefited from
the high levels of automation already
achieved in electronic assembly
Problem
• Manual inspection is less reliable
• Customer satisfaction issues
• Costly escapes
Design and deployment of Mechanical AOI
System for Box Build Assembly
SOLUTION
• High resolution Cognex camera mounted
to a 6 axis articulated robot arm
• Programed to automatically inspect and
accept/reject assembly attributes
6. Robotic Optical Inspection
Advanced Manufacturing Quality Improvements
Enterasys NDIA P10 “No Defect Is Acceptable” Perfect 10
Revolutionary Robotic Mechanical Optical Inspection Test
Process implemented Flextronics Romania
Will identify then prevent mechanical assembly issues
Will improve Enterasys Quality for our Partners & Customers
“There is Nothing More Important Than Our Customers!”
6
7. Return on Investment – ROI
Continue to Raise the Bar in Product Quality Improvement!
Improved Product Quality
• 46% improvement in average monthly return rate since implementation
• 78% improvement in average monthly DoA (Dead on Arrival) rate since
implementation
Cost Savings
• >$200K annual reduction in RMA costs
• Logistics, Inventory, Customer support
• >$30K/year rework reduction
• Defect prevention, Improved first pass yield, Reduced number of returns
• >$30K/year pin virus prevention
• Defect detection and prevention, Rapid response and process
improvement
Improved Customer Perception
• Quality is defined by customer experience
First system deployed in Flextronics Romania facility.This is revolutionary Robotic Optical Inspection Test Process, there is NO other vendor with this technology in our Industry.NaDIA p10, inspired by Nadia Comăneci -Nadia was the first gymnast to obtain a score of Perfect 10 (p10) in the 1976 Olympics in MontrealNDIA = No Defect is AcceptableNaDIA will support ETS Product Quality to:1) Contain defects in the manufacturing facility 2) Prevent mechanical defects from getting to our customers 3) Help reduce the number of customer returns (RMAs) even furtherEnterasys Product manufacturing complexity and challenges:Highly complex product portfolio1,100 Active SKUs100% outsourced CMs and Original Design Manufacturers in 10 countries Assembly/test of High-mix & Low-volume ~40,000 average number of Defect Opportunities per SKU~250 mechanical assembly components6 mechanical subassembly levels20 layer PCB’s~15,000 discrete components