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Book Excerpt: The Printed Circuit Assembler’s Guide to... Factory Analytics, Chapter 4

In this chapter, readers will learn the importance of efficiency in post-SMT processes such as rework and testing. Key KPIs are discussed, along with the need to reduce rework time, improve first-pass yield, maintain testers, and monitor defect rates. By optimizing these processes, manufacturers can enhance product quality, reduce costs associated with defects, and ensure customer satisfaction.

Scrutinizing Solder Printing

As members of the technical staff at Indium, Adam Murling, technical manager, and Ron Lasky, senior technologist and professor at Dartmouth University, know their way around metallurgy and solder formulation. I corralled them for a conversation on solder application techniques from the solder’s perspective and their insights did not disappoint.

A Leader in Sustainability: Talking With Barjouth Aguilar of Flex

I first met Barjouth Aguilar in March 2024 at Women's IPC Day in Ciudad Juarez, Chihuahua, Mexico, an event organized within the framework of International Women's Day, when she participated in a panel meant to inspire attendants to learn more about the role of women in the electronics industry. Barjouth, a fellow Mexican, has become a woman I admire and respect.

I-Connect007 Editor's Choice: Five Must-Reads for the Week

This week’s Top 5 starts with steps you can take to cultivate a culture of thriving. We also have bullish news from the global semiconductor sector, advice on how to tease out hidden cost drivers during the PCB design cycle, how the Altium-Ansys collaboration will affect design, and Happy Holden’s version of Occam’s Razor—three simple tools to keep your wet processes in line.

Kaynes Technology Selects Delvitech’s 3D AI-Based AOI Solutions to Keep Pioneering India’s Electronics Manufacturing 

Delvitech has announced that Kaynes Technology India Limited, a distinguished leader in electronic system design and manufacturing in India, has selected its cutting-edge 3D AI-based automated optical inspection (AOI) solutions. This strategic partnership marks a pivotal advancement in Kaynes Technology’s mission to remain at the forefront of the dynamic electronics industry. 

I-Connect007 Editor's Choice: Five Must-Reads for the Week

There’s a lot going on in our industry right now. As you’ll see in today’s must-reads, there’s even innovation taking place in drill bit development. We also have articles on cutting costs during the design process, as well as a handy guide to each country’s tech sweet spots, and what it takes to thrive in this segment. Don’t miss our ode to the CAM department, which is where the rubber meets the road for every PCB. 

Why a Culture of Thriving Matters

On every call with senior leaders, I hear the same thing: Their organizations are facing the cumulative fatigue of constant disruptions. Crises from the pandemic to the war in Ukraine to supply-chain issues—coupled with pressures from return to work and constant transformation efforts—have led to widespread burnout. In The Devil Never Sleeps, author Juliette Kayyem argues that the world we now live in will always have some level of disruption, making conditions tough for organizations and individuals.

In Honor of the U.S. Labor Day

Sept. 2, is Labor Day in the United States, always observed the first Monday in September. In its official declaration, we learn that “Labor Day is an annual celebration of the social and economic achievements of American workers. The holiday is rooted in the late 19th century when labor activists pushed for a federal holiday to recognize the many contributions workers have made to America’s strength, prosperity, and well-being.”

Wriggling Out of ‘the Squeeze’

At some point in the growth cycle of most businesses, they inevitably face “the squeeze”—when increasing complexity starts to overwhelm the business processes and management systems. The business then gets squeezed by rising overhead costs, falling efficiency, capacity constraints, and cash flow challenges. These often combine with poor delivery and quality performance to constrain the growth of the business.

Give Yourself an Edge at the IPC High Reliability Forum 2024

For those who support military and defense products, few topics are more important than reliability, particularly as we venture into complex packaging requirements that accommodate next-gen chips and electronic systems. Recently, I visited with Teresa Rowe, IPC senior director, assembly and standards technology, to discuss the IPC High Reliability Forum (HRF), Oct. 9-10, at the McKimmon Center, in Raleigh, North Carolina. With topics that cover high-voltage electronics, standardized test methods, and assembly and solder joint X-ray challenges, it is clear that this event needs to be included on your annual conference calendar.

Why You Need to Take This New ‘Semiconductor Essentials’ Course 

Recently, Andy Shaughnessy and Nolan Johnson met with Soo Lan Cheah, the developer of a new IPC course geared toward PCB manufacturing professionals who have little to no knowledge about semiconductor manufacturing. With her background in PCB and IC design, Soo Lan brings a circumspect vision of these disciplines and how they are inter-related. You don’t need to know a lot of math to take this course, and you’ll come out with a much better understanding of the whole silicon-to-systems approach.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

It is the last weekend before the much-celebrated Labor Day holiday, also known as the official end of summer. Though I am not yet ready for pumpkin spice lattes and heinously early Christmas decorations, I do relish the end of the heat. But the heat in our industry is not set to die down anytime soon, nor should it. Just about one month shy of the end of Q3 2024, things are looking positive for many industry members, so let’s make sure to keep the metaphorical pedal to the metal for a strong quarter-end and a great upcoming trade show season.

Moving from Surviving to Thriving

A few months ago, I shared some thoughts regarding the implications of the survival mode that most of us have lived in, at least for the past several years, within the electronics supply chain. In this article, I would like to share some additional thoughts about how companies can move away from merely surviving and work toward thriving across their supply chain. At a high level, here is what I believe the foundation of thriving looks like.

How IPC Assists in Helping Fund Your Apprenticeship Program

Workforce development issues plague many companies in the electronics manufacturing industry. IPC has structured its teams to provide resources that directly address these issues, including formulating an apprenticeship model that has received national recognition. However, implementing these workforce programs can require additional funding for instruction and training. As director of workforce grants and proposals, I identify and secure funding from federal, state, and local opportunities that drive IPC’s workforce development initiatives, particularly around our apprenticeship program

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

People are on the move, new books are being released, and a new PCB manufacturer is making waves. This week, I'm highlighting the latest ASC/Sunstone book on DFM essentials, our 40th book in the I-Connect007 library and a must-read whether you're a new or seasoned member of industry. I'm also including leadership news from NextFlex, a discussion on integrated passives from Joe Fjelstad, and a new processor chip from Intel meant specifically for automotive applications.

My Drop Shock Testing Experiments to Determine Reliability in PCBs

Tablets, digital cameras, and smartphones are portable electronics that have become increasingly popular. Compact design and improved functionality are common product and package design trends. However, because they are portable, these devices may fall and cause internal damage. In addition, customers may use products in different environments, exposing them to risks that could cause harm. For example, a smart device such as a phone or tablet could be dropped while being used, or a warehouse shipment could be handled carelessly and fall. Products must have sufficient mechanical shock reliability to reduce the likelihood of damage.

New WHMA Board Member Joan Kappell Reflects on Her Prosperous Journey in Wire Harness

Joan Kappell was always drawn to the hum of machinery, even as a child. She remembers waiting eagerly on the shop floor for her mother, who worked diligently on Artos and Komax Gear cutting machines at the Monona Wire Corp in Monona, Iowa, to finish her shift. Joan has remained fascinated by the industry, where she works in sales at one of today’s top wire harness companies.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week 

We’ve finished the first full week of August, and now more than midway through summer. This week brought us quite a lot of military and aerospace news, with headlines from Airbus, Rocket Lab, AST Space Mobile, Menlo Microsystems, CACI, and L3 Harris. In other news, Pete Starkey takes us on a tour of RoBAT in England, highlighting the ever-important topic of high-technology SI testing.

Book Excerpt: The Printed Circuit Assembler’s Guide to... Factory Analytics, Chapter 3

Chapter 3 of this book delves into the critical aspects of the SMT process, focusing on the reflow oven and automated optical inspection (AOI) machine. Highlighted are the key roles of the line operator, manufacturing engineer, and quality manager in maintaining efficient operations and high-quality PCBAs.

Book Excerpt: The Printed Circuit Assembler’s Guide to... Low-Temperature Soldering, Vol. 2, Chapter 3

In this chapter, readers learn about the use of HRL3 alloy in solder joints to balance strength and ductility. Test results show improved performance with HRL3 alloy compared to traditional low-temperature solders.

In-mold Electronics: The Convergence of Innovative Materials and Manufacturing Techniques

Paavo Niskala, a noted expert in in-mold electronics (IME) at TactoTek, recognized the need for an industry-wide standard when one of his automotive OEM clients asked him how to test a prototype TactoTek had developed. That question led to the creation of the first-ever IPC standard of this type, IPC-8401, Guidelines for In-Mold Electronics, to be released later this year.

Reliability Comparisons of FPBGA Assemblies Under Hot/Cold Biased Thermal Cycle

Current trends in microelectronic packaging technologies continue in the direction of smaller, lighter, and higher density packages. The telecommunications industry and particularly mobile/portable devices have a strong need for lighter and smaller products. The current emerging advanced packaging (AP) technologies, including system-in-package (SiP) and 2.5D/3D stacked packaging, added another level of complexity and challenges for implementation.

Real Time with… THECA 2024: Workforce Development Critical to Southeast Asia PCB Industry

In this interview, IPC Asia President Sydney Xiao emphasizes the importance of workforce training and keeping ahead of the staffing needs in Thailand and the rest of Southeast Asia. Ms. Xiao shares details on how IPC is addressing these needs.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

After getting stuck in an airport during the Crowdstrike outage, our colleague Nolan Johnson has a review of the first-ever THECA trade show in Bangkok, Thailand. We have a column by Matt Stevenson on drilling optimization, and an interview with Schmoll America President Kurt Palmer about what it takes to thrive in this industry. We have an article by SMTA’s Tara Dunn that focuses on the organization’s educational offerings, and news about All Flex joining the PCBAA.

Market Spotlight on India

India has long fascinated me. Aside from the fact that I love the cuisine, I have been fortunate to have some close Indian friends who were very generous in sharing their culture, celebrations, and homes. Growing up in the Bay Area (Silicon Valley), my exposure to talented Indian engineers started in the 1990s.

Real Time with... THECA 2024: IPC Focusing on the Needs of a Growing Region

Dave Bergman, vice president of standards and technology at IPC, updates Nolan Johnson on the active development work underway by IPC in the SE Asia region. Dave shares that IPC is very involved in helping to encourage and enable new investment in this region through IPC's core work in standards, education, and advocacy.

Training and Education in the Electronics Industry

The electronics industry is a dynamic and rapidly evolving field where continuous learning is essential to keep up with technological advancements and industry demands. The Surface Mount Technology Association (SMTA) plays a key role in providing comprehensive training and education to professionals in the electronics manufacturing sector.

Impressions from THECA 2024

In American pop culture, we often see depictions of a youth athletic team—eight-year-old boys suited up to play American football or girls in soccer gear—and one of the kids shouts, “We may be small,” while the rest of the team answers, “but we are mighty.” That was the same feeling I had during the inaugural Thailand Electronic Circuits Asia trade show in Bangkok last week.

Justin Worden: Success Through Knowledge

Justin Worden of ROCKA Solutions joined the electronics manufacturing industry just five years ago. He used associations like SMTA to quickly ramp up his knowledge, and he’s quick to credit SMTA with helping him quickly learn to speak intelligently about his customers' challenges and the projects they’re working on. Justin recently became president of the SMTA Austin chapter and comments on the value of networking at a grass-roots level.

World-class in Canada: OES Utilizes IPC Member Benefits for Aggressive Business Goals

Last year, Jeff Stewart, CEO of OES in London, Ontario, Canada, accepted an invitation to attend a local roundtable of EMS providers in Michigan in the Great Lakes region. Frankly, he was just looking to network and find opportunities to expand his EMS supplier business. Not only did OES find the roundtable to be a positive experience, it led the contract manufacturer/OEM to become an IPC member and subscribe to IPC’s workforce training program.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

This week, I’ve been attending Thailand Electronic Circuits Asia 2024. This is the inaugural event, hosted by Thailand Printed Circuit Association (THPCA) in collaboration with the Hong Kong Printed Circuit Association (HKPCA). Thailand has supported a PCB industry for some time—mostly automotive applications—but the China Plus One dynamic has definitely taken root here.

The Importance of a Certification and Training Program

Barry Matties recently visited the Revco facility, where he learned about Revco’s methods of operation. The I-Connect007 Editorial Team followed up for a roundtable-style conversation with Revco’s leadership team: Greg Gonzales, vice president of business development, Ron Gonzales, vice president and operations/quality manager, Miguel Salinas, quality manager, and Carlos Salinas, production manager. Also joining the conversation was Mike Hoyt, workforce training advisor at IPC, who talked about the importance of a certification and training program.

BOOK EXCERPT: The Printed Circuit Assembler’s Guide to... Encapsulating Sustainability for Electronics, Chapter 3

This chapter provides an in-depth analysis of general-purpose and specialist encapsulation resins for electronic applications. Also covered are properties, testing methods, suitability for harsh environments, and thermal management of high-power density electronic devices.

IFTEC: Taking Training to New Heights in France

Like many nations, France has suffered from a global marketing misnomer: Electronics manufacturing can be done cheaper and better in Asia; therefore, education, financial resources, legislation, and business ventures should be shifted to other important industries. Yet electronics are so ubiquitous that they have become like "salt in the sea," says Pierre-Jean Albrieux, president of IFTEC, a French company and resources and training center specializing in the manufacturing processes of electronics (PCBA, PCB, and design). “It is present everywhere, so we end up not seeing it anymore.”

Innovative and Cost-effective BGA Re-balling

A new, high-quality BGA re-balling process, which is integrated into an all-in-one solution of dispensing and placement equipment developed by Essemtec, brings new opportunities for the reapplication of expensive BGA components. This new method seamlessly integrates the sequence of flux deposition and ball (sphere) placement with the subsequent soldering process.

BPMI Inc. Uses IPC Standards to Support the U.S. Nuclear-powered Naval Fleet

Our IPC member profile focuses on Bechtel Plant Machinery Inc (BPMI), responsible for the fabrication, test, delivery, installation, and field support of high-quality nuclear power plant components for installation in submarines and aircraft carriers.

Certificate vs. Certification: Achieving Your Organization’s Goals

The terms “certification” and “certificate” are often used interchangeably, but there are well-defined differences in the world of credentials. These differences have important implications for when and how your organization invests in training and validation programs. In this article, I’ll break down the meaning and characteristics of each term, introduce IPC’s approach to training and certification, and explain how you can leverage each credential to achieve your goals.

From Chips to Systems: Building a Resilient Electronics Manufacturing Base in the EU

Electronics are ubiquitous, underpinning everything from personal devices and electric vehicles to wind turbines and industrial systems. These technologies are essential to nearly every aspect of modern life, making a thriving electronics manufacturing sector crucial for the EU's industrial resilience, regional security, and technological advancement. As industries increasingly depend on electronics for innovation, the role of electronics manufacturers as key facilitators of Europe’s digital and environmental transitions increases significantly.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

Are you ready for the weekend? Fin de semana? I think we all are! In this week’s roundup, we have one article on what it takes to thrive in the industry today, as well as an interview that discusses one student’s drive to succeed as a PCB designer. We also have an article by our newest columnist, Tom Yang, who introduces us to his family-owned PCB company. Columnist Hanna Grace brings us an interview with her mentor, and Anaya Vardya continues his UHDI coverage with an article that explains UHDI’s use in the RF/microwave arena.

SEMICON 2024 Wraps Up and Says Goodbye to San Francisco

In stark contrast to Tuesday’s overcast drive into “The City,” it is a beautiful, sunny day as I depart San Francisco after spending the last few days at SEMICON West 2024. Though I spend most of my time in Phoenix these days, I am a Bay Area baby by birth. Whenever I am in the city, my strong feelings about San Francisco surprise me. I love SF, warts and all. That being said, I applaud the city of San Francisco for keeping the area pristine in front of and around Moscone Center.

Getting Clear About Certification With Charlie Capers

Walk through the entrance at Zentech Dallas and you’ll see a wall of certification plaques prominently displayed. Beyond being impressive and a point of pride, these certifications tell a story to potential customers: This company is ready to do business. Charlie Capers, former vice president and general manager, shares his insights on quantifying the ROI of certifications. You may not see it on paper, but it’s definitely there. He also talks about his expectations for new hires and shares a case study about the importance of collaborating with your PCB designers.

Book Excerpt: The Printed Circuit Assembler’s Guide to... Factory Analytics, Chapter 2

In this chapter, we’ll focus on the most important analytics at the forefront of SMT, from the solder paste machine to placement machines, and breakdown these metrics from the perspectives of the different decision makers involved in the process. The lead SMT shift manager isn’t going to have the same concerns as a quality manager, so it’s important to look at how each machine and operation contains valuable KPIs for each role.

An Interview With My Mentor, Christina Rutherford

I first came to IPC APEX EXPO as a Student Board Member, and during my time on the board, I discovered that the show is not just another endpoint to a conference, but a launching pad for ideas, connections, and inspiration that lasts for decades. As participants leave the conference, they continue sharing knowledge and experiences that linger, affirming the enduring significance of IPC APEX EXPO in shaping the future of electronics.

Sustainability and Workforce Topics Dominate Day 2 of SEMICON West 

​​​​​Sustainability and the workforce were prolific themes for the second day of SEMICON West on July 10 in San Francisco. Sustainability kicked off with keynote speaker Al Gore, the former U.S. vice president and arguably America’s most passionate environmental advocate for nearly 50 years. He once again outlined the serious environmental issues and timelines we are facing and emphasized the importance of the industry’s commitment to sustainability initiatives.

THECA: Thailand’s Coming-out Party

Swaek Prakitritanon is vice president and general secretary of the Thailand Printed Circuit Association (THPCA), and we recently spoke about the inaugural Thailand Electronics Circuit Asia (THECA) trade show, July 24–26, in Bangkok. Among the six specific benefits cited for THECA attendees are valuable insights into the technology transfer to the China + 1 Asian region, specifically Thailand, as a ripe investment opportunity for PCB and PCBA companies. 

New Issue of IPC Community Now Ready for Your Summer Reading Pleasure

If you’re like most of us in this industry, you have a passion for your work—and it shows. In the new issue of IPC Community, which publishes online today, we feature multiple examples of individuals and companies passionate about their jobs and their work in electronics manufacturing. They truly care about #buildingelectronicsbetter.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week 

I spent my week at SEMICON West in San Francisco, returning last night. It was a full week that had me drawing parallels between what is happening in the semiconductor sector and in our segment of the supply chain. I had my mind blown listening to presentations and panels on things like quantum computing. The future is indeed bright. Tech-heavy, but very bright. If there was one phrase from the conference that rings most true in my mind, it is “unprecedented opportunities and unprecedented challenges.” Stay tuned for SEMICON coverage over the next week and additional coverage in our August magazines. 

SEMICON WEST 2024 Kicks Off in San Francisco

Unsurprisingly, it is overcast as I drive into San Francisco to the Moscone Center for SEMICON 2024. The doors did not open until 7:30 am, which left a few of us loitering outside anticipating what we’d find on the other side of the doors. I am one of those strange individuals who kind of loves trade shows and conferences. I have always had a curious mind and thirst for knowledge, so continuing my education on cutting-edge technology and market trends fills me with energy. SEMICON and semiconductors are not our core industry, but everything that they do and work toward informs and trickles down into the reality of the printed circuit board supply chain. 

Counterfeit Detection Course: It’s the Real Deal

Anthony (Tony) Bryant is a trained expert in component counterfeiting techniques who has been collaborating with IPC on a new intermediate-level course on counterfeits. Tony is in final preparation to launch this course and shared his reasons for the course, as well as information about its content and value to EMS companies.

Book Excerpt: The Printed Circuit Assembler’s Guide to... Low-Temperature Soldering, Vol. 2, Chapter 2

The evolution of low-temperature solder alloys requires thoughtful consideration of the thermal and mechanical reliability requirements specific to each application. Thermal cycling and drop (mechanical) shock tests have long been used as board-level proxy tests for evaluating and quantifying the ability of electronics assemblies to sustain abrupt, short-term mechanical stresses, as well as continuous cyclic stresses.

My Experience as an IPC Student Chapter Leader

IPC has played a major role in my student life. In 2019, the IPC Education Foundation established its first student chapter at Auburn University, and I have been associated with this chapter since 2020 when I joined the electronics reliability research group at Auburn University as a PhD student under Dr. Sa’d Hamasha.

The Value Side of Training, Part 1: Five Easy Ways to Measure the ROI on Training

The best thing about a good investment is the yield it provides. This series of articles on the value side of training will focus on how to effectively measure the return on your investment (ROI) when training your staff. I will offer practical, quantifiable metrics you can apply today. Think of it as a quick checklist for every effective training program.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

It’s a holiday weekend in the United States, but the news doesn’t stop just because a few of us have the day off! You’ll have to pardon me; my ears are still ringing from the fireworks. Without further ado, here are the five things you should not miss from this week.

BOOK EXCERPT: The Printed Circuit Assembler’s Guide to... Encapsulating Sustainability for Electronics, Chapter 2

There are many important things to consider when applying an encapsulant. Chapter 2 of this book is an overview of the application process that covers many of the terms and definitions found on a technical data sheet and discusses the primary considerations for each of the process stages. It is worthwhile considering some of the terms and definitions found on a technical data sheet to understand how the different liquid, mixed system, and cured property values can dictate the method chosen to apply materials.

Effectively Using Dashboards at Ascentron

Ascentron is a small EMS company started in Oregon in 2002 from the ashes of what had been a $30 million EMS company that lost 90% of its sales during the dot-com and electronics industry bust of 2001. We started out at $3 million a year in sales and worked to reinvent the business. We transformed it from what was a medium-to-high-volume manufacturer serving automotive, communications, and computer customers into a low-to-medium-volume manufacturer serving aviation, medical, industrial, instrumentation, and military customers. We were successful in our efforts, growing over 600% in six years, reaching $20 million by 2008.

SEMICON West 2024 Preshow Interview, FLEX Conference Review

In this preshow interview for SEMICON West 2024 and the FLEX Conference, we dive into the dynamic world of semiconductor and flexible electronics, revealing cutting-edge insights from industry leaders with SEMI’s Samer Bahou, Gity Samadi and Julie Rogers and Bob Praino from Chasm Advanced Materials who advises the FLEX program. Set against the backdrop of the prestigious Moscone Center in San Francisco, the discussion traverses the history, evolution, and future directions of this critical sector, spotlighting the CHIPS Act, the importance of flexible and hybrid electronics technology for the sector going forward, and touches on issues such as sustainability and workforce. Here’s why you should be attending SEMICON West 2024 and FLEX Conference.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week 

Much of our recent coverage focuses on being ready for the future—technologically and otherwise. We have news about APCT relaunching as AdvancedPCB, and an interview with Freedom CAD’s Scott Miller about their new leadership—young managers who bring new vision to the company.  We also have coverage of “Bold Breakthroughs: Women Reshaping the Engineering Landscape,” a webinar that celebrates Women in Engineering Day. We bring you an interview with Ventec’s Alun Morgan, who discusses the advent of glassless materials, and an article by FCT’s Chris Clark about cost-drivers in the flex and rigid-flex arena.

Webinar Review: Women Reshaping the Engineering Landscape

IPC celebrated International Women in Engineering Day with “Bold Breakthroughs: Women Reshaping the Engineering Landscape,” a webinar moderated by Teresa Rowe, IPC senior director of assembly and standards technology. The event featured a panel of eight innovative engineers representing eight different countries, and each with varied backgrounds and in various stages of their respective careers.

Book Excerpt: The Printed Circuit Assembler’s Guide to... Factory Analytics—Chapter 1

Despite being a widely discussed topic since the advent of Industry 4.0 initiatives, the implementation and utilization of analytics tools by electronics manufacturers has been slow, with an adoption rate significantly lower than anticipated. Most of this stagnation can be attributed to the fact that getting data from the factory floor simply isn’t as straightforward as it should be.

Career Opportunities Are Knocking

Are workforce topics on your mind? In this market, of course they are! Finding and keeping qualified employees is continually cited as one of today’s greatest business challenges. That's why I-Connect007 features Career Opportunities in every magazine issue. Whether you’re looking to hire or be hired, check out the Career Opportunities section in every issue of our magazines.
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