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53.3.4 Statistical Process Control SPC requires reliable data that can be analyzed either in real time or historically. Visual inspection collects defect data, such as the number of solder joint defects per assembly right after the solder reflow process (either reflow or wave soldering). Some manual and automated inspection techniques also take quantitative measurements of key assembly parameters, such as solder paste volume or solder joint fillet height. To the extent that these data are repeatable, manufacturers use defect data or measurements to characterize the amount of process variation from assembly to assembly or from solder joint to solder joint. When the amount of variation starts to drift outside its normal range or outside its control limits, manufacturers can assess the assembly process and monitor or choose to take action until the process is adjusted to eliminate this drift. Historical analysis of the defect or measurement

data also helps discover the cause of process variation. Eliminating the sources of process variation reduces the process defect rate, thus creating savings in rework costs and increasing product reliability. As shown in Figure 53.4, various charts to display available data from the automated inspection can be made available for corrective action and process control.

Other chapters of this book have covered the lead-free process, but this section covers the lead-free process from an inspection point of view. In general, the lead-free process is a less forgiving one because the wetting forces for lead-free alloys are not as strong as for tin-lead, which means that defect levels are likely to increase and the need for inspection for process control and defect containment will increase. The figures illustrate wetting issues of the leadfree process. Figures 53.5 and 53.6 show x-ray close-ups of two gull-wing joints on the same type of quad flat pack (QFP) device. A key issue for manufacturers is the lead-free alloy melting point of 217 C, higher than the 183 C for lead alloys. The higher melting point will have significant impact on manufacturing processes and potentially on component reliability.

During the transition to a lead-free process, it is Side fillets are the important to understand all of the materials in use, as same size mixing lead-free and traditional tin-lead components will create many issues during the transition to a leadfree process Ideally, all lead-free components and materials will be utilized, but this is not always possible Note good Figure 535 is an x-ray image of a tin-lead example A heel and toe good heel formation and toe formation can be seen The formation side fillets are approximately the same, indicating that the component pins are centered on the pad Note also that very little solder appears on the pad below the toe Sn/Pb in the photo; all solder is around the component pins Figure 536 is an x-ray image of a lead-free example and reveals a couple of wetting issues Solder is over the full pad.

The pad sizes on both boards (Figs 535 and 536) are approximately the same Also, note that the side fillet Sn/Pb to the right is stronger than to the left, indicating that the FIGURE 535 An x-ray image of a component is misaligned on the pad The toe fillet is tin-lead example insignificant The heel fillet has formed correctly; a void can be seen in one of them A void is also visible on the same pin further down on the pad Side fillets are different During the transition to a lead-free process, expect to sizes since part is see many of these types of defects Defect levels are misaligned expected to increase The following types of defects are typically noticeable during lead-free transitions: opens, bridges, misalignment, tombstones, and voids Because of the higher reflow temperatures, component defects are also expected to increase.

Watch what other people do with their hands as they speak either formally in a presentation or informally in conversation. You ll notice habits of touching the face, brushing hair back, scratching any one spot repeatedly, and other annoying, unnecessary movements. Anytime someone repeats a mannerism over and over, it s easy to get distracted by watching the movements and forget to listen to the words. Some people tap their ngers, click a pen, or shuf e papers just to have something to do with their hands. To become aware of your own hands, watch a video of yourself, or have a colleague give you feedback. Then practice keeping them still except to gesture.