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Re-Engineering Obsolete Printed Circuit Boards Webinar
The document outlines a webinar on re-engineering obsolete printed circuit boards, focusing on establishing a return on investment (ROI) and defining the scope of work for redesigning existing products. It provides information on necessary business and technical data needed for proposals, case studies of successful re-engineering projects, and emphasizes the importance of clear communication and customer involvement in the process. Key takeaways highlight the need for budget consideration, product life expectancy assessment, and detailed project specifications to improve accuracy in re-engineering efforts.
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Re-Engineering Obsolete Printed Circuit Boards Webinar
- 1. Printed CircuitBoards Webinar Re-Engineering Obsolete PCB’s 11.22.13 DELIVERING QUALITY SINCE 1952.
- 2. America's Oldest, A Historyof Innovation Privately held company, established in 1952. Estimated 2013: Sales: US$40 Million 100+ Employees Worldwide (70 – North America, 30 – Asia, 3 – Europe) Design and manufacture customized, built-to-print, performance-critical products for all sectors of the electronics industry. Leading provider of printed circuit boards, membrane switches, graphic overlays, silicone rubber products, electronic heaters, fans, motors and custom battery packs. Integrated supply chain management solutions to handle the complexity of today’s global marketplace while making sure that every order is being manufactured at the “right” factory. 2
- 3. Agenda Required Business Information RequiredTechnical Information Define the Scope of Work Define any New Features for Product Case Studies 3
- 4. PCB Design EngineeringServices Electrical Engineering Signal Integrity Analysis Mechanical Engineering Library Management Database Translations PCB Layout Re-Engineering 4
- 5. Re-Engineering Existing Products WhyRe-Engineer? – – – – – Cost Reduction Obsolete Components Obsolete Technology Standards Compliance Yield Improvement Today’s Desired Outcome: – Help you to better understand what information is required for quoting the cost of Re-engineering an Existing Product. 5
- 6. Required Business Information Requirement –You need a proposal for the re-design of an existing product. What do you need to do? – Qualify the Return on Investment • Is there a viable ROI? – You’ll have to invest into this effort to be efficient & successful. – Do you have the time and a budget for this work? – Does the Product Life Expectancy support the ROI? • IP Ownership? – Do you actually own the rights to all of the technology you are looking to re-engineer? 6
- 7. Required Business Information Qualifythe ROI (cont.): – Does the product data include any “reference designs” from a third party that would gate the effort. – Does the “reference design” contain “protection” in the programmable devices designed to prevent direct copying? – Do you have a functional specification available that defines all modes of operation. This includes environmental operational and storage requirements along with agency certifications (UL, FCC, and others). 7
- 8. Required Technical Information Canyou provide the Current Product’s Cost Data? – The Existing Costed BOM with Manufacture & Manufacturer’s Part Numbers and Unit Prices. – The Current Actual Unit Cost Including Assembly Labor. – Target Cost – Projected Product Volumes This data will provide the operational specifications and cost benchmarks required for comparing new and replacement components. 8
- 9. Required Technical Information We’llneed the Existing Product’s Schematic in a .pdf format or the original schematic archive format. – Providing the current design data upfront will help to minimize engineering time. We will need the Documentation or User Manual that provides the User Interface Information. We will need existing product samples to use for verification of the actual design. 9
- 10. Define the Scopeof Work It is very important to define the Scope of Work upfront. – This is best achieved in a written Statement of Work (SOW). Clearly define the Performance Requirements and ReEngineering Objectives. – – – – – – Cost Reduction? Obsolescence Abatement? Functional Improvement? Consolidation? Size/Shape Change? Standards Compliance? 10
- 11. Define the Scopeof Work Scope of Work Options – Investigate possible new technologies that can be implemented to reduce product cost or improve product performance. – Verify the desired product life expectancy requirements (Component Obsolesce). – Review the existing manufacturing processes required to build the PCB (fab) and PCBA (assembly). Research alternatives. • Layer count reductions, single side assembly, consolidations – Review unit assembly and final assembly manufacturing processes to identify any potential process improvements. – Explore logic consolidation opportunities. 11
- 12. Define the Scopeof Work Define Any New Product Features – Identify the new product features / enhancements that are desired – Are there any physical changes required – Evaluate packaging improvements Define Who will Validate/Approve Final Design 12
- 13. Key Takeaways It’s vitallyimportant to qualify the ROI. Quoting re-engineering projects requires an investment on both the OEM and the supplier. Try to determine what the budget is. This will help to avoid a mismatch. Try to determine what the life expectancy of the product is. This will determine if there is a sufficient ROI for the re-engineering effort. 13
- 14. Key Takeaways It’s importantto define the Scope of Work clearly upfront. Providing a written Statement of Work will help to define the requirements and improve the chances for an accurate proposal and lessen the potential for scope creep. Once we have an SOW and have reviewed the customer supplied data, we would recommend a scheduling conference call to confirm our understanding of the Scope of Work and address any issues. 14
- 15. Key Takeaways You needto understand that you will be part of the Re-engineering process. There are key elements of the existing product and re-engineering that only you can answer. Your support is a key component the projects efficiency, cost-effectiveness and successful. The quality of the customer supplied data important to providing an accurate cost estimate. 15
- 16. Case Study #1 16Port, 2 Gigabit Fiber Channel Switch – 16” x 9”, 16 layer PCB – Intel P3 Processor – 696 pin BGAs – Controlled Impedance – 155 MHZ Differential Pair Buses – 2G Differential Pair signals – Fault tolerant system – Hot Swap power supplies – 1867 Components/2400 Nets Deliverables – Logic Design – Consolidated 2 PCBAs into 1 – PCB Layout – Mechanical Design (sheet metal chassis) – Thermal Analysis – Signal Integrity analysis 16
- 17. Case Study #2 DesignCost Reduction & Logic Consolidation Multiservice Access Platform (MAP) Customer’s existing product was in need of redesign for cost reduction and component obsolescence. –Engineering team Provided: • Logic Design • Converted 5V circuitry to 3.3V • Converted PTH components to SMT • FPGA Design and Simulation • Consolidated logic functions • Reduced component count • Design For Supply Chain BOM analysis –PCB Layout • Physical Layout of the PCBA for DFM/DFT • Converted from Double to Single sided PCB –Verification Test • Functionality verification with existing products • Customer performed product validation 17
- 18. Case Study #3 DesignCost Reduction and Logic Consolidation ATE Platform – 14 PCBAs that required PTH to SMT conversion Logic consolidation into FPGAs – Customer acquired existing product from another OEM • Did not have complete documentation • Did not have engineers with product knowledge • Require Engineering team to be very resourceful 18
- 19. Case Study #4 Before: –Motherboard with 2 daughter assemblies – PTH components – 8 I/O channels – 6U Assembly After: – Single Assembly – SMT components except Backplane connectors are press fit, FPGA Used for logic consolidation – 16 I/O channels – Maintained 6U form factor 19
- 20. Our Products Battery Packs Flex& Rigid-Flex PCB’s User Interfaces Fans & Motors Cable Assemblies Printed Circuit Boards 20
- 21. Design Centers &Technical Support Battery Pack & Power Management – Denver, CO User Interfaces – Largo, FL Fans & Motors – Wales, UK PCB’s – New Bedford, MA & Shenzhen, China Flex & Rigid Flex – Toronto, Canada Cable Assemblies – New Bedford, MA Our Engineering and Design teams are ready to help our customers create world class and cost effective product solutions. 21
- 22. Q&A Questions? – Enter anyquestions you may have in the Control Panel. – If we don’t have time to get to it, we will reply via email. 22
- 23. Thank You Check outour previous webinars at www.epectec.com. Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information: 23