PCB007 Magazine

PCB-Mar2016

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42 The PCB Magazine • March 2016 inputs are done in parallel rather than serially. Transport can also include sending information requests and approvals to customers and sup- pliers. These requests need to be challenged re- garding their usefulness and necessity. Waiting: New part number start-up requires information flow. Oftentimes the process be- comes stalled at various steps when someone is waiting for information. This can happen from within the company, the customer, or the suppli- er. A good NPIP system includes checklists so the needed documentation is quickly identified and missing components can be requested immedi- ately. Team members are focused on rapid com- munication so that there is as little waiting time as possible. Customers, internal team members, and suppliers all need to be intimately involved to foster good communication. Again, parallel processing is an important message. Sometimes a decision followed by a course correction, is a faster journey to the destination than waiting for all the information to become available. Over-processing: In the design and launch startup system, the equivalent of over-processing is over-specification. It is tempting to specify a tighter tolerance than required because designers believe it gives them a larger safety margin. While this is sometimes the case, other times a tighter tolerance will push a manufacturer to make trad - eoffs that reduce manufacturing yields, require additional tooling, and add time to the process- ing sequence. Additional delays occur when ac- ceptance standards are defined in absolute terms. Criteria specifying "no stains" or "no foreign material" can create an inspection struggle until a meeting of the minds occurs between the cus- tomer and supplier. Having a well-documented design and layout guide, as well as having knowl- edgeable manufacturing engineers on the startup team, will help assure that a new part number launches with acceptable manufacturing yields and meets the customer's requirements. Over-production: The equivalent of over- production in a part number startup system is over-design. As in the case described in over- processing, designing in "safety margins" might be desirable, but it can also backfire. An example in the world of flexible circuitry might be speci- fying thicker copper to allow higher amperage capability, but thicker copper can also degrade flexibility. Over-design might also add cost, so one needs to understand if the added cost truly yields a more reliable product. Defects: The result of a poorly executed part number introduction may result in low manufacturing yields causing high scrap rates, late deliveries and potentially defective prod- uct delivered to the customer. A startup process should be rigorous enough to avoid pitfalls seen on previous part numbers. It's not possible to have everyone review every part number prior to product launch, but using multiple subject matter experts to preview design layouts is a good first step. Capturing the collective wisdom of the organization is the goal as this can help identify "gotchas" that can be avoided. This review should be considered a proactive step but in the world of custom flexible circuits and heaters even the best plans may result in sur- prises. When this happens, a team focused on quick reaction is critical. The best NPIP system is a combination of pre-launch proactive review and a reactive team ready to respond quickly when the gremlins inevitably are revealed. All Flex has developed an NPIP system called Jump Start™. It is a continuous improve- ment effort program to supply intensified cus- tomer support during initial part number de- sign and delivery. It is a methodology tailored to a company that provides custom engineered products. Similar methods and disciplines can help reduce the mudas encountered during part number startup. PCB References 1. Leanmanufacturingtools.org Dave Becker is vice president of sales and marketing at All Flex Flexible Circuits llC. To contact Becker or read past columns, click here. lean manufaCturing and npip for flexible CirCuits

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