PCB Chat

The CHIPS Act has hogged much of the oxygen in the tech industry for the past few years, but the industry trade group known as the Printed Circuit Board Association of America is trying to build on that momentum by relentlessly pointing out that the board industry needs love too, or as they put it, chips don't float. With us today is David Schild, the executive director of the PCBAA. Schild and Mike Buetow discuss the prospects of pending Congressional legislation to support the US PCB industry, the need for domestic substrate and bare board production to complete the triad of the semiconductor "stack," and a just-announced Commerce Department plan to allocate up to $1.6 billion in funding to support the packaging supply chain. 

Recorded live during IPC Apex Expo this spring, this is the first of three podcasts from the show floor. This episode features three interviews including: • Gus Mavrou from Seho • Mark Stansfield from Solderstar • Jesper Lykke from Viscom

The challenging world of electronics becomes even more challenging when the end product is destined for harsh environments. For high-reliability products operating in a harsh environment, the quest for reliability is not just a goal—it's an imperative. These are not your everyday gadgets; often they're critical components of systems designed to operate under extreme conditions, where failure is not an option. From the scorching heat of desert landscapes to the unyielding cold of arctic tundra, from the high-pressure depths of our oceans to the radiation-filled expanse of space, the demands on these electronic products are as varied as the environments themselves.   While ocean depths, outer space, and frozen tundra are arguably harsh environments, we don’t have to look too far for examples of product failures in less harsh environments. One example that comes to mind is the state of public EV charging stations. Government reports have concluded that up to 25% of public EV chargers are at any given time. While there are many reasons for this, one may conclude they are not designed and manufactured for the intended in climactic operating environment.   On this episode, we'll uncover the numerous challenges that designers and engineers face in their quest for reliability, durability, and functionality of the final product. As we navigate through this complex landscape, we'll highlight the strategies that enable these products to not just survive but excel in unforgiving conditions.   Our navigator for this episode is, Dr. Andre Kleyner. Dr. Kleyner has 30 years of engineering, research, consulting, and managerial experience specializing in reliability of electronic and mechanical systems designed to operate in severe environments. He received a doctorate in mechanical engineering from the University of Maryland, and a master's of business administration from Ball State University. Dr. Kleyner is a Global Reliability Engineering Leader with Delphi Electronics & Safety and an adjunct professor at Purdue University. He is a Fellow of the American Society for Quality (ASQ), a Certified Reliability Engineer, Certified Quality Engineer, and a Six Sigma Black Belt. He also holds several US and foreign patents and authored multiple professional publications including two books on the topics of reliability, statistics, warranty management, and lifecycle cost analysis.

"Humans just aren't the greatest at designing circuit boards." That's according to Sergiy Nesterenko. Nesterenko is founder and CEO of a new software company called Quilter, whose goal is to accelerate hardware development by fully automating circuit board design. His eureka moment came when an early design at a previous employer couldn't be autorouted, then after it was hand-routed and built, it caught on fire. Listen to why the former Space X engineer thinks the margins designers build in are excessive and how AI-driven, physics-based platform can resolve and even violate some "human" rules and still generate superior printed circuit boards.  

We’ve discussed the silver tsunami on the show numerous times, the unprecedented rate of which employees are retiring. When engineers and other employees retire from companies, they take with them more than a set of gold cufflinks or an engraved plaque. In many cases, they also take with them wisdom and knowledge. Perhaps this is never truer than in the case of Mike Konrad's guest today. And who is that? Doug Pauls. Pauls holds a B.A. in chemistry and physics from Carthage College, and a B.S. in electrical engineering from the University of Wisconsin, Madison. He worked nine years for the Navy, eight years as technical director of Contamination Studies Labs, and more than 20 years at Rockwell Collins (now Collins Aerospace), in the Advanced Operations Engineering group where he is a technical fellow and, a principal materials and process engineer. He was awarded the Rockwell Collins Arthur A. Collins Engineer of the Year Award in 2004 as well as numerous other awards. Paul is a longtime (well over 30 years) IPC chairman and was awarded the IPC’s Hall of Fame Award in 2017. Most notably, he is known for his expertise in surface insulation resistance testing, cleaning and cleanliness assessment, conformal coatings, and how to investigate and qualify manufacturing processes. He has been a U.S. representative to ISO and IEC working groups on SIR, electromigration, and cleanliness reliability standards. He has participated in numerous national and international consortia on electronics manufacturing materials and processes. He recently led a team of SMEs to redefine the cleanliness provisions of J-STD-001, culminating in what is presently J-STD-001H. To take liberties with a famous Mark Twain quote “rumors of my retirement have been greatly exaggerated”. For several years now, I’ve heard rumors of Pauls' retirement. Well, that day has finally come.  Konrad talks with Pauls about his long career within the electronics assembly industry: his triumphs and challenges, and his journey in this ever-changing, dynamic, and challenging industry. If you’re new to this industry, stick around listen to Doug's advice to young people entering our world, the world of electronics assembly.   00:00:00 - Introduction to Doug Pauls' Career in the Electronic Assembly Industry 00:02:57 - Reliability Matters Podcast Introduction 00:06:04 - Sharing wisdom with early career individuals 00:09:34 - Hobbies Outside of Work 00:12:44 - The Minions and World Domination 00:16:23 - Overcoming Shyness through Theater and Public Speaking Lessons 00:19:41 - Lessons Learned from Skilled Trades People 00:23:03 - Working in the Department of the Navy 00:26:21 - Learning from Asking Questions and Trying New Things 00:29:38 - Learning from the Old Guys 00:33:05 - Participating in Standards Development 00:36:32 - The Power of Networking and Technical Committees 00:40:01 - The Value of Leadership Skills in Collaborative Industries 00:43:15 - Collaboration in the Electronics Industry 00:46:18 - Developing Valuable Skills in Problem-Solving 00:49:39 - Transitioning to Rockwell Collins 00:52:59 - The Four Pillars of Career Advancement at Collins Aerospace 00:56:32 - Finding Resources for Personal Growth 01:00:01 - Industry Updates and Resources 01:03:26 - The Value of Old Guy Stories 01:06:46 - The Importance of Understanding How Things are Made 01:10:08 - Retirement Plans, Consulting, and the Future 01:13:10 - An Unconventional Industry Presentation 01:15:59 - Thank You for Listening to the Reliability Matters Podcast    

Businesses are not immune to the many complex social situations present on many prominent college campuses today. Executives and managers must grasp with how best to understand the changing environment as part of their talent acquisition and talent building processes, and implement those methods in practical ways to accommodate today's employees' life cycle.  Audrey McGuckin is a global HR executive who for more than 25 years has lived and worked across the globe in Asia, Europe and the US. She spent more than 20 years at Jabil, rising to vice president and chief talent officer. Today, as head CEO of The McGuckin Group, McGuckin consults with top CEOs and CHROs to solve complex business challenges through innovative talent and people solutions. Her client base includes a broad spectrum ranging from startups to Fortune 100 organizations. She shares her thoughts and approach to business leadership, team building, managing employee movements and needs, and the power of empathy with PCB Chat host Mike Buetow.

This episode was recorded at SMTA's Pan Pacific Strategic Electronics Symposium on the Big Island of Hawaii. Mike Konrad's guests on this episode are Dr. Chuck Bauer, founder of PanPac, Keith Bryant, and Dr. Ron Lasky. We discussed the history of PanPac, technologies introduced at PanPac, and what makes PanPac so unique. We also discuss Dartmouth College's unique engineering innovations program.   Chapters: 00:00:00 - Introduction to the Reliability Matters Podcast 00:01:35 - Introduction: Dr. Chuck Bower and Keith Bryant 00:03:23 - The Motivation Behind Starting IMAPS and SMTA 00:05:16 - Global Participation in the Event 00:07:25 - High Level Participants and Learning Experience 00:09:23 - The Conference of Interesting Things 00:11:01 - Speaking to the Thought Leaders of the Industry 00:12:40 - Preconceived Notions about the Event 00:14:26 - The Best Event for Networking and Fundamental Research 00:16:05 - Networking at Conferences 00:17:42 - The Advantage of Combining Innovation and Engineering 00:19:17 - Fostering Entrepreneurship among Students 00:20:57 - The Future of Young People 00:22:34 - Challenging Stereotypes about the New Generation 00:24:03 - Advice for Emerging Engineers and Technicians 00:27:17 - The Benefits of a Liberal Arts Education in Engineering 00:28:48 - Bringing Students to the Conference for Experience 00:30:11 - Entrepreneurship and Thinking Outside the Box 00:31:46 - The Value of Thinking like an Entrepreneur 00:33:22 - The Advantages of Ignorance in Starting a Business 00:34:51 - Throw caution to the wind and pursue your passions 00:36:25 - Appreciation and Thanks 00:37:49 - Stay Safe, Stay Happy, Stay Healthy

Optimization has become an important goal within the electronics assembly industry. While modern electronics assembly techniques utilize a variety of equipment, one specific type of equipment often consumes a disproportionate percentage of the overall equipment budget, that is the place machine. The cost of the machine, associated conveyors and feeders, require that the machine is running as often as possible. The airline industry refers to this as “wheels up” time. Airlines make money when the aircraft is in the air “wheels up.” On the other hand, anytime the wheels are down, the aircraft is not making money for the airline. I listened to an interview a few years ago with the CEO of Southwest Airlines, a US discount carrier. Unlike most other airlines, Southwest does not charge its customers to check bags. The CEO was asked by the reporter why they have not joined the rest of the industry in charging for checked bags. The CEO's answer was genius. If Southwest Airlines began charging for check bags, it would actually slow the boarding process as more and more passengers would drag their bags onto the aircraft, most likely resulting in a number of those bags having to be checked at the gate.  Southwest Airlines is famous for having the fastest aircraft gate turns in the industry, frequently under 30 minutes. Yet, if Southwest Airlines charged for checked baggage, it would require more time at the gate before the next flight would be ready to depart. That would result in fewer flight segments per aircraft per day. In other words, allowing customers to check bags for free equates to more “wheels up” time and, subsequently, more profit for the airline. The same principal can apply to pick-and place machines. When pick-and-place machines are running product, they are making presumably making money. When they sit idle, they are arguably costing money. What can assemblers do to improve the optimization or “wheels up” time on their pick-and-place machines? Mike Konrad's guest, Larry Welk, believes he has an answer. Welk, a.k.a. Professor Splice, is coowner of Smart Splice, a manufacturer of tape splicing tools. Welk reviews tape splicing best practices and explain how tape splicing, when performed correctly, can lead to higher pick-and-place machine optimization. So, buckle your seatbelt: this podcast episode is officially wheels up! Chapters: 00:00:00 - The Importance of Optimization in Electronic Assembly 00:02:34 - Tape Splicing: Best Practices 00:05:12 - Tape Splicing and its Advantages in the Industry 00:07:42 - Continuous Tape Splicing 00:10:10 - Splicing Techniques in Machine Assembly 00:12:31 - Ensuring Quality and Reliability of Tape Splices 00:14:57 - The importance of alignment in splicing 00:17:21 - Types of Tapes and Their Impact on Splicing 00:19:54 - Challenges with Tape Splicing 00:22:09 - Adjusting Feeder Tension 00:24:25 - Splicing and Reel Management in the Industry 00:26:46 - Splicing Parts in the Electronics Industry 00:29:02 - Common Mistakes in Tape Splicing 00:31:34 - Issues with Tape Splicing 00:34:03 - The Crimping Tool and Tape Issues 00:36:25 - The Importance of Switching Techniques 00:38:53 - Improving Production Efficiency through Component Evaluation 00:41:44 - A demonstration of the old tape splicing method 00:44:08 - Splicing Tape Procedure Comparison 00:46:38 - Faster Splicing Technique 00:49:15 - The Negative Experiences with Splicing 00:51:55 - The Benefits of Splicing 00:54:22 - Transitioning from Technician to Salesman 00:56:40 - Conclusion and Farewell  

Electronic System Design (ESD) industry revenue increased 14% to $4.4 billion in the fourth quarter 2023, with printed circuit board design software leading the way, up 21% for the period.  Wally Rhines, executive sponsor of the SEMI Electronic Design Market Data report, gives his quarterly update on the state of the electronics design software market.

The High-Density Packaging User Group, the nonprofit consortium of electronics manufacturers and suppliers that collaborate on various technical problems in order to reduce cost and time to market, has nearly 25 projects underway, several of which are due to be completed this year. We spoke this month with Madan Jagernauth, marketing director and project facilitator of HDP, about their current research on lead-free solder alloys, the recent conference Best Papers, and whether the consortium members are ready to tackle artificial intelligence.