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FIGURE 53.2 Printed circuit board yield decreases dramatically with increases in the number of solder joints per assembly if the defect rate per solder joint remains constant. For instance, at a 40 defects per million opportunities (DPMO) defect rate, the yield drops from 96 percent at 1,000 joints per assembly to 45 percent at 20,000 joints.

53.1.2 Automated Inspection Inspection is an important source of process information without which high yields are difficult to obtain. Consequently, manufacturers have employed the following range of techniques either simply to enhance visual inspection or automate inspection fully:

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In a coordinate basis, the components of the metric tensor, which can be read off of (10.33), are gtt = 1 2m r , grr = 1 , 1 2m r g = r 2 , g = r 2 sin2 (10.43)

Microscopes, mono- and stereoscopic, with magnification from 4 to 10 Real-time video images created using simple light, x-rays, thermal imaging, or acoustics Fully automated inspection systems using light, laser, or x-ray imaging

The automation of inspection has evolved into systems that resemble the automated test equipment used to make electrical measurements and find electrical defects (faults). These automated inspection systems acquire real-time images, process the images to find and measure features within the image, and make accept/reject decisions based on this image processing. Additionally, they provide data that can be used for long-term statistical process analysis. Thus these automated systems remove the human and human judgment from the inspection process altogether.

Faults, defects, process indicators, and potential defects are terms that are important when discussing test and inspection, so this section will define and explain them:

A fault is a manifestation of a defect An example is a digital device output pin that does not toggle correctly. For simplicity, think about a two-input OR-gate whose output is stuck high. This is a fault and is a manifestation of a defect. The causing defect can be any one of several, including a defective component, an incorrectly placed component, an open input pin, or an open output pin. The fault class is a subset of the defect class. Electrical tests such as in-circuit test (ICT), boundary-scan, built-in-self-test (BIST), functional test (FT), and system test mainly detect faults. A defect is, at the end of the manufacturing process, an unacceptable deviation from a norm There may be defects that do not show up as faults. Examples are insufficient solder, a misaligned component, a missing bypass capacitor, and an open power pin. Inspection systems such as automated optical inspection (AOI) and automated x-ray inspection (AXI) detect many of the defects and also some of the same faults as electrical test. The definition includes the phrase at the end of the manufacturing process, which is important when compared with potential defect.

All defects, which also include the faults, need to be corrected before the product is shipped, if high quality standards are to be followed.

A process indicator is, at the end of the manufacturing process, an acceptable deviation from a norm Good examples are insufficient solder or misaligned components. The insufficient solder may not be so lacking that it requires a repair action. However, if many of these conditions exist, a process improvement action may be required. A potential defect is, in the manufacturing process, a deviation from a norm, that may or may not be a defect at the end of the manufacturing process This category needs to be understood. An example is a pre-reflow misaligned chip component. This component may or may not self-align in the reflow oven. Another example is an insufficient paste volume that may not end up as a defective solder joint at the end of the manufacturing process.

Test and inspection engineers at the end of the line are mainly interested in finding faults and defects. Process engineers responsible for improving the manufacturing process are mainly interested in potential defects, process indicators, and systematic defects. Systematic defects are typically defects that occur on a larger number of boards and are due to some systematic problem, such as a bent nozzle on a pick-and-place machine, soldering issues with one type of component, or a design for manufacturing (DFM) issue.