IPC — WHMA AN INSIDE

OVERVIEW

Presented by: Constantino J. Gonzalez

[email protected]
Membership and Benefits
 Who is IPC
IPC Today
IPC is a global industry association dedicated to furthering the
competitive excellence and financial success for more than 4,300
member sites that make, use, specify and design printed boards and
assemblies, as well as their suppliers and end-product manufacturers,
including those in:

 advanced microelectronics
 aerospace and military
 automotive
 computer and business equipment
 industrial equipment
 medical equipment and devices
 telecommunications industries
 IPC Membership Composition
IPC Today
More than 4,300 Member Companies Worldwide
 Multifaceted Services and Programs
IPC Today

 Training & Certification

 Industry Education
 Conferences & Exhibitions
 Management Programs
 Market Research
 Statistical Programs
 Public Policy Advocacy
 IPC – WHMA Events and Conferences
IPC Today
Membership entitles your site discounts to attend, exhibit, or sponsor any
of IPC & WHMA’s events and conferences throughout the world.

 IPC APEX EXPO

 SEMI ANNUAL MEETINGS
 WHMA ANNUAL WIRE HARNEES CONFERENCE
 ELECTRICAL WIRE PROCESSING TECHNOLOGY EXPO

Most of all, there is peer-to-peer networking at the exhibits and

conferences. You can solve issues with your fellow engineers, see
the latest in technology, and observe industry trends.
IPC - WHMA Standards
Automotive Needs
 Why OEMs, Manufacturers shall care about
IPC Today
Basic IPC & WHMA Standards
The basic standards every company should
have.
For a complete list of all IPC Standards,
go to www.ipc.org/standards.

1. Cable / wire and harness are the arteries

and veins of any automotive products.
2. If they are not design per Industry Standards
– DFM.
3. Enforcing process control instead of
inspection.
4. The need for having a reliable Repair /
Rework System as well as a Standard to
make up for items 2 & 3.
 Why IPC - WHMA Standards
IPC Today
 Developed and approved by industry peers

 Supports design and layout of products for manufacturing,

reliability and excellence

 Provides universally accepted criteria and language for the entire

supply chain

 Improves reliability and quality of products, manufacturing to a

common specification

 Drives manufacturing efficiencies, reduces cost, minimizes rework

and waste
 Popular IPC –WHMA Standards by Market
IPC Today
Segment
 IPC-A-610
IPC Today
Acceptability of Electronic Assemblies
A collection of visual quality acceptability requirements for electronic assemblies.
Presents acceptance requirements for the manufacture of electrical and electronic assemblies.
 IPC-J-STD-001
IPC Today
Requirements for Soldered Electrical and Electronic Assemblies
Describes materials, methods and acceptance criteria for producing soldered electrical and
electronic assemblies.
The intent is to rely on process control methodology to ensure consistent quality levels during
the manufacture of products.
 IPC/WHMA-A-620
IPC Today
Requirements and Acceptance for Cable and Wire Harness Assemblies
A collection of visual, electrical and mechanical quality acceptability requirements for
Cable, Wire and Harness Assemblies.
IPC/WHMA-A-620 can be used as a stand-alone document for purchasing products;
however, it does not specify frequency of:
• in-process inspection, or
• end product inspection
No limit is placed on the number of process indicators or the number of allowable repair/rework
of defects. Such information should be developed with a statistical process control plan.
 IPC-D-620
IPC Today
Design and Critical Processes Requirements for Cable and Wiring
Harnesses
This document provides design and critical processes requirements and technical insight that
have been removed from the acceptance standards for cable and wire harnesses assemblies.
IPC-D-620 intent is to set forth the general design requirements for electrical wiring harnesses
and cable assemblies.
 IPC-HDBK-620
IPC Today
Handbook and Guide to IPC-D-620 and IPC-WHMA-A-620

This handbook is a companion reference to IPC-D-620 & IPC-WHMA-A-620.

The intent is to provide supporting information, guidance and technical insight into the design and
acceptance requirements for electrical wiring harnesses and cable assemblies.
 IPC-REPAIR & REWORK-620
IPC Today
Repair & Rework Guidelines to IPC-D-620 and IPC-WHMA-A-620

This guidelines is in the process of submitting a pin for development.

 IPC-630
IPC Today
Guidelines for Design, Manufacture, Inspection and Testing
of Electronic Enclosures
First acceptability standard for electronic enclosure
It contains acceptability criteria that pertain to the “box build” of the assembly process
Provides best practices for manufacturers and end users of electronic enclosures of
electrical and electronic equipment
Ensures the reliability and function of the end-item assembly for its intended design life.
 IPC-7711/21
IPC Today
Rework, Modification and Repair of Electronic Assemblies
Procedures for repairing and reworking printed board assemblies.
Revision includes expanded coverage for lead free processes, and additional inspection
guidelines for operations such as repair that may not have other published criteria.
Does not limit the maximum number of rework, modification or repair actions to a Printed
Circuit Assembly.
 IPC-6012C
IPC Today
Qualification and Performance Specification for Rigid Printed Boards
One of the most widely used standards for printed circuit board fabrication.
Covers qualification and performance of rigid printed boards including:
• Single-sided, double-sided, with or without plated-through holes
• Multilayer with plated-through holes and with or without buried/blind vias
Other standards for printed circuit board fabrication include:
• IPC-6011, Generic Printed Boards
• IPC-6013, Flexible Printed Boards
• IPC-6015, Organic Multi-Chip Module
• IPC-6016, High Density Interconnect
• IPC-6017, Embedded Passive Devices
• IPC-6018, High Frequency Printed Boards
 IPC-A-600
IPC Today
Acceptability of Printed Boards
Describes the preferred, acceptable, and nonconforming conditions that are
either externally or internally observable on printed boards.
Represents the visual interpretation of minimum requirements set forth in
various printed boards.
IPC Today IPC-2221B
Coupon Generator
• The IPC-2221B Gerber Coupon Generator is a subscription service
• Easy-to-use “Design Parameters/Input File,” utilizing auto quality check feature
• Design rules are automatically maintained for the test designs as established in IPC-2221B
• Generates coupons in minutes
• Test coupons currently available (AB, AB-R, and D)
• Used for acceptance of production lots of printed boards
• Meets the criteria as presented by; IPC-2221B, Generic Standard on Printed Board Designs
Appendix A test coupon designs, as called out in the IPC-6012C-TC Test Coupon Addendum
to IPC-6012C, Qualification and Performance Specification for Rigid Printed Boards
IPC Training and Certification
 IPC–WHMA Training & Certification Program
 Foster a professional workforceGoals

 Provide uniform training programs to enhance understanding of

IPC standards

 Enhance an individual’s ability to correctly apply criteria from a

given standard

 Increase proficiency to achieve acceptable workmanship

 Demonstrate the ability to apply the criteria appropriate for

class or classes of production
 Training and Certification Sources
Industry Guided — Consensus Driven — Reliability Proven

 IPC Certification Program Office

 IPC Training and Certification Advisory Committee
 IPC Technical Training Committee
 IPC Authorized (Licensed) Training Center
 Master IPC Trainer (MIT)
 Certified IPC Trainer (CIT)
 Certified IPC Application Specialist (CIS)
 Certified Interconnect Designers (CID/CID+)
 Training and Certification Sources
The IPC Certification Program Office is responsible for:

 Approve and administer training center licenses

 Approve and administer translation licenses
 Facilitating development meetings
 Provide Periodic audits
 Distribution of training material
 Tracking certified program participants
 Policy interpretation and problem resolution
Training Program Structure — “Train the Trainer”
MIT

CIT CIT CIT

CIS CIS CIS CIS CIS CIS

CIS CIS CIS CIS CIS CIS

CIS CIS CIS CIS CIS CIS

 Certification Portal
The ultimate secure platform for certification in our industry
 Certification Portal

Benefits of the Certification Portal

 Integrity
 Flexibility
 Security
The features of the Certification Portal
 An online examination accessibility
 Multiple versions of exams
 Will allow printing of exams
 Secure login
 Class management
 Purchase bulk credits for future use
Professional Education
 IPC-DFX (Design for Excellence) Course

 Design for Manufacturability

 Design for Reliability
 Design for Test
 IPC Standards-based technical education: knowledge
enhancement and assessment
 Delivered by an IPC-qualified Instructor in a three-day on-site
workshop-exam session
 400+ individuals worldwide participate in the program every year
IPC EDGE
 What is IPC EDGE?

 IPC EDGE is a Learning Management System (LMS)

 Online Learning Platform
• A Platform to Deliver Knowledge and Education
• Response to IPC member feedback to offer more online
education
 An eLearning Experience for All
• From Executives to the Production Operators
 Supports one of IPC’s aspirational goals — Education
• IPC will become the world's leading electronics education and
knowledge provider to the electronics industry
Courses on IPC EDGE
Validation Services
IPC Core Competencies
 Validation Services Vision
Purpose
 Verification that companies can manufacture, assemble and supply
in accordance with IPC standards

Focus
 Products that demand high reliability

Goal
 Build the Network of trusted source in the electronic supply chain
IPC QML/QPL … Filling the Gap
 What is QML/QPL
QML – Qualified Manufacturers List
 Examples: PCBs, PCBAs, Cable and Wire
Harness, and IP Protection

QPL – Qualified Products List

 Examples: Solder Fluxes, Solder Pastes,
Solder Alloys, and Conformal Coatings
 IPC QML/QPL Programs
QML:
 IPC J-STD-001/610
• IPC-J-STD-001 Space
 IPC/WHMA-A-620
 IPC-1071 and IPC-1072
 IPC-6012/600

QPL:
 IPC-J-STD-004, 005, 006
 IPC-4101
Standards Gap Analysis (SGA)
 SGA: A Total Evaluation
 Incoming
• Procurement/Supplier Audits
• Component Handling and Storage (MSD’s)
 Printed Board Assembly Processes
• ESD
• SMT and PTH Assembly (Sn/Pb and Pb-Free processes)
• AOI and AXI Inspection
• Process Control (defined in J-STD-001)
 Soldering (all types)
 Cleaning and Conformal Coating
 Wire and Cable Harness Assembly
 Rework and Repair
 Shipping
• Labeling
SGA Wire & Harness Program Approach
SGA Wire & Harness Program Approach

 Internal training and certifications

 General production facility (appearance)
 ESD
 Assembly materials (solder, flux, adhesives)
 Process Control documentation
 Rework & Repair
 General Manufacturing Quality
 Preventive Maintenance
 Storage and Packaging
 SGA Wire & Harness Program Approach
Assembly Processes: Testing:
 Wire Prep  Continuity and Shorts
 Solder Termination  Dielectric Withstanding Voltage
 Crimping and Crimping Tools  Insulation Resistance
 Insulation Displacement Connections  Crimp Height Pull Force
 Ultrasonic Welding  RF Connector Shield (pull force)
 Splices
 Hardware Mounting
 Over-Molding/Potting
 Marking/Labeling
 Coaxial Cable Shield
 Securing and Braided
 Hardware Insulation
 Solderless Wrap
SGA Case Studies
 SGA Case Studies (OEM)

Pull Force Test Verification (per IPC/WHMA-A-620)

 Reviewed the wire crimp and pull test results from an internal
audit and compared all data to IPC standards
 Customer pull values exceeded IPC specs by an average of
45%
 Wire crimp tool calibration and verification exceeded IPC specs
 Result — Differentiated from competition by exceeding
customer’s requirement
 SGA Case Studies (OEM)
Solder Wetting Issues (per IPC-A-610)
 Reviewed and made recommendations related to the product design
• Changed drilled hole size for stranded wire insertion
• Proper pre-tinning of the stranded wire was implemented
• X-Ray equipment was suggested for inspection

 Complete re-design was suggested long term

• Rigid-flex technology is being considered

 Result – Renewal of Business Contract with a Current Customer

 SGA Case Studies (OEM)
DFX Product Review (per IPC-2221 and IPC-2222)
 Reviewed Printed Board layout and DFX report from the printed board
fabricator
• Suggested thermal relief options and the use of stitching vias
 Reviewed and made recommendations related to the product design
• Selective Soldering clearances were added
• SMT components were too close to plated mounting holes
• Lead to hole ratio was reviewed
• Concerns about achieving proper barrel fill
 Result – New Product Development Program stayed on scheduled
 SGA Case Studies (OEM and EMS)
Solder Splashes and Excessive Voiding (per J-STD-001 and IPC-A-610)
 New product design was using a very heavy component (Power Brick)
• QFN type package that weighted over 10 grams
• Supplier information was lacking manufacturing recommendations
• OEM company needed support and the EMS company was looking for answers
 Reviewed and made recommendations related to the product design
• Suggested Solder mask Defined Pads
• Verified SMT placement force
• Reviewed the solder paste material and suggested changes to the Reflow oven profile
 Made suggestions to the Supplier on either adding a spacer or to pre-bump the
component pads of the package
 Result — OEM is modifying package to accommodate heat dissipation
 COMMITTEES FORMED
THREE COMMITTEES FORMED DURING ROUNDTABLE SESSIONS AT WHMA DALLAS
These topics were discussed in my roundtables and I came up with volunteers [e-mails, names,
phone #s] to work on the content and development of the topics below

 REWORK CRITERIA FOR CABLE & HARNESS

 DESIGN FOR MANUFACTURING FOR CABLE & HARNESS

 OPERATOR TRAINING PROGRAM FOR CABLE & HARNESS – INTRODUCTORY

Constantino J. González
Management & Process Improvement Expert,
IPC Acceptability Committee Chairman
Master IPC Instructor – AIAG/CQI-17 Chairman
IPC Automotive Vice-Chairman

ACME CORP.
American-Hispanic Company — USA

[email protected]
www.acmetino.com USA Mobile #: 605.381.5963
 Management – Process Improvement Solutions
• Scrap, rework reductions, process control
• Supplier process audits • Repair & Rework Systems
• DFM Systems • Technical/Engineer On-Call

IPC Certification & Workshops

• Instructors, Specialists • CQI-17 • Automotive Addendum

GLOBAL PROCESS IMPROVEMENTS, MATERIALS,

DFM SOLUTIONS TO EMS-OEM ELECTRONIC INDUSTRIES.