Industrialization and
co-operation with Design
Sinikka Lyyra
Manager, DFM
Content
• Elcoteq SE
• DFM in Elcoteq SE
• Competence work
• DFM process flow
• DFM tool development
• DFM & board assembly
Elcoteq’s Service Offering
• Anticipate future customer and market demand
and emerging technologies
• Integrated end-to-end services for the products’
whole life-cycle
• Horizontal integration from design to after-sales
services
Design
Sourcing
New
Product
Introduction
(NPI)
Purchasing
and Inbound
Logistics
Global
Manufacturing
Distribution
and Outbound
Logistics
After-Sales
Services
Global Coverage
• Proximity to the end-markets
• Availability of skilled labor
• Cost benefits
Brazil
Q4/2004
USA
Japan
Russia
Germany
Sweden
Hungary
Estonia
China
Korea
Emerging
markets
Other locations
Mexico
Brazil
USA
Japan
Germany
Sweden
Hungary
Finland
Estonia
China
Korea
Volume production
markets
India
Switzerland
Plant
Country
Founded/
Area
Personnel
Services
acquired
(m
2)
Nov. 2005
Europe
Lohja Plant
Finland
1991
8,700
419
NPI, low to medium volume production
Tallinn
Estonia
1992
42,000
3,730
NPI, high volume production
St. Petersburg
Russia
1997
14,700
285
Medium to high volume production, NPI
Pécs
Hungary
1998
46,000
4,997
High volume production, NPI, after-sales
Offenburg
Germany
2003
14,500
430
NPI, low to medium volume production
Europe, total
125,900
9,853
Asia-Pacific
Dongguan
China
1999
13,000
2,075
High volume production
Beijing
China
2000
19,200
3,082
High volume production, NPI
Shenzhen
China
2003
9,300
808
High volume production
Bangalore
India
2004
5,500
224
High volume production
Asia-Pacific, total
47,000
6,189
Americas
Dallas
USA
2003
2,500
101
NPI
Monterrey
Mexico
1999
18,300
1,372
High volume production, after-sales
Juarez
Mexico
2005
17,000
2,200
High volume production, NPI
Manaus
Brazil
2004
1,500
247
Medium to high volume production
Americas, total
36,800
3,920
Other Elcoteq locations
816
Total
209,700
20,778
Concentration
on communications technology
Consistency
in plant network, machinery,
systems and processes
Continuous improvement
Competitive service offering
Co-evolution
Superb customer service
Confidentiality
Cost-efficiency
All volume capacity in
low-cost countries
Competence
especially in wireless telecom
Coverage
Global service network
and full service range
Design for Manufacturing in Elcoteq
•
The value-added service of instituting "best practices" in the design stage
to improve manufacturability.
•
Objective is simplify the product from manufacturing point of view and
lower manufacturing costs, increase product quality and reduce
production creation time prior to mass production.
•
DFM includes analysis of design for best manufacturing and assembly
and analyses design documentation for production needs.
•
Target: Products design fits to Elcoteq processes and equipment
capabilities
•
DFM in Elcoteq contains:
– DFBA
Design For Board Assembly
– DFA
Design For Final Assembly
DFM
Value added service
SMA
•
DFM guidelines
FA
•FA guidelines (draft)
DFM process flow in
NPI /ES
P
r
o
d
u
c
t
D
e
s
i
g
n
Manufacturing Technology
Development
Testing
•
DFT guidelines
DFM guidelines
and metrics
•DFBA
•DFA
•DFT
COMPETENCE WORK
• Build connections between plants and NPI/ ES centers
DFM process owners
• Share experience and best practises between plant and
NPI/ES members
• Collect capabilities and limitations of existing production
equipments
• Collect and update existing Design Guidelines for
manufacturing
COMPETENCE WORK
Working methods:
• Information sharing, best practise sharing
• Agreeing commen coals and procedures
• Update Elcoteq Design guideline
• DFM templates for reporting results of analyses
• Training to DFM work
Practical DFM work in Elcoteq
• DFBA analyses at board level made by process engineers
and consentrated on assembled boards
• Product Technicians/Proto Managers co-ordinate
documentation related feedback to customers (errors in
BOM, missing information...)
• Final assembly development engineers made DFA
analyses
• Test engineer/designers do test related DFT analyses at
quotation phase
• Elcoteq Design guidelines for board assembly area
• DFA Guideline draft version
DFM process flow
Critical Design phase
Final Design phase
Factory
Costing phase
Project starts
SMA & FA DFM
Transfer review
-input data from
customer
-DFM analyses with
small production team
-DFM meeting with
customer
- DFM analyses report
update after protobuilds
-DFM meeting with
customer
Design state 1
Analyses.
Design state 2
Approval
- Design approved for
production
- Minor DFM problems
- DFM report updated
after protobuilds
- DFM meeting with
customer
Design state 3
Verification
- Verified design for
production
-Minimum DFM
issues
-DFM report update
and meeting with
customer
- Lessons learned of
project
Preliminary Design
state
DFM Guideline
DFM guidelines
DFM competence work
Trilogy 5000
DFM tool development
• Valor Trilogy 5000
• Tool to do DFM work systematically on board
assembly level
– feedback to customer from documentation,
BOM, PWB design and assembly
– systematic way to check documentation
– findings don’t depend on the expertise of the
person, no human factor
DFM feedback documents
• NPI SMA DFM template
• NPI DFA template
DFA template
NPI SMA DFM
DFM & board assembly
• Panel layout will affect on manufacturing cost
– optimized panel - lower cycle time - lower cost
• Co-operation with PWB layout design and plant
engineering and PWB supplier is essential to
achieve best possible solution
– panel layout, which would be optimized to line
– Needed fiducials and other tooling holes
World’s leading EMS provider
to communications technology