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Simplifying Complex NPI

From:    Author:Mark Hardy    Publish time:2021-09-15 14:02    Clicks:22
Imagine for example, combining active die components, WLCSPs, uBGAs and passive SMDs with its interconnecting media such as solder paste and flux into a substrate. It will require series of processes that could consume certain length of time and multiple equipment utilization before it can be completed.
 
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What if after the assembly of the prototype, the product exhibited electrical failure due to material problem or because of poor assembly, another cycle of evaluation run ensued until it achieved acceptable result. Hence, the NPI will take time and could spell success if the prototype making is shorter and shows good performance result or failure if the product time-to-market became too long due repeated problem. This paper is going to present the simplification of assembly by reducing the multiple component attachment, by combining different types of component into one assembly cell and reducing assembly failure due to trial and error assembly scheme.
 
Concept to Realization
 
 
I want more functions:
 
Listen to music
Watch video
Play games
Read email
Use as map
Etc…
What should I do:
 
New design concept
New product development
New product introduction
New process development
Qualify materials
Prototypes
Assembly & Test
What do I need:
 
ICs with more functions
Powerful processors
Smaller size components
High performance components
 
Discussion
 
Established NPI process is essential to the development of new packages and products. Hereinafter is a breakdown of its benefits, the reason of its complexity and its challenges.
 
Benefits of having NPI
 
It enables to establish common ideas, understanding and objectives
It helps organize the tasks, exposes challenges and limitations, defines targets and responsibilities and set milestones
It provides management visibility and tracks progress of activities
Complexity
 
Usually driven by research & development group but involves multiple departments and task groups
Requires cross-functional team from R&D, Engineering, Production, Quality and Purchasing and Logistics
11
 
Challenges
 
People have different ideas and motivations. People itself are complex enough.
Procedures and steps are tedious and complicated
Sample making and prototyping equipment are not always readily available
Making It Simple
 
As in any process and operation, making the NPI procedure as simple as possible is a desirable prospect. So here are the underlying factors that can be considered when efforts are required to be implemented.
 
Personnel
 
Assign a project manager who will define the scope of work, assign resources and coordinate activities among the CFT
Do not change it over the period of the project. Allow all the people involve to have the necessary time to focus and concentrate to fulfill the targets as well as minimize overloading of assignment
System and Procedures
 
Use a known and effective system built within the organization
Supplement it with available NPI management tools (PACE, Stage-Gate, PTC PDS, etc)
Equipment – here is the thing when it gets more challenging. Prior exploring how to simplify NPI in terms of machine side, there are things that can be considered to be critical.
 
Note: Most of the time, First Article Build (FAB) is the critical point.
 
Why FAB is the Critical Point
 
This is where and when the actual assembly is going to be done
Equipment for sample build is not always available
Different type of component may require different machine
First set up always takes a lot of time
This is where the waste mostly occurred because of trial and error
Low yield is always expected on the first batches of sample
Concept of NPI Solutions
 
Having one Pick and Place platform machine that can handle various types of component attach with NPI software is our solution….Because powerful NPI solutions accelerate production.
 
This is the cycle of NPI process:
 
The steps in NPI solutions are presented in the below process flow:
 
Aspects of NPI Solution
 
Machine-side NPI: Achieve a production ready first pass yield
 
Dynamic Production Editing means no tape boards required – no waste
Simple, menu-driven process for new users
Get products into production quickly, efficiently, and effectively
Create and tune feeder, placement, fiducial, and component information quickly and easily
Debug placement problems
Reduce scrap and repair costs
 
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