DFM Expert

Intelligent DFx analysis

intelligent software, pleasant work

www.vayoinfo.com
 It happens around us whatever you notice or not
Major reason of AirAsia
QZ8501 crash on year 2014
is a cracked solder joint on
PCBA.
On year 2013, Hitachi
On year 2013, GM recall elevator free fall due to
Due to abnormal 380,000 vehicles due to defected board in China, a
behavior of PCBA, defected engine control lady was injured in this
Taiwan high speed board. event.
train lost power on
year 2013. On year 2013, Chrysler
recalled >470,000 vehicles
due to defected board.
On year 2014, Mitsubishi
recall 115,000 cars due to
defect board of light switch.
Are you always willing to stay with those issues?
Quality/reliability defects
No thermal consideration,
 leads to cold solder, impact Silkscreen cross brings
solder strength build and rework risk
Stage Defects Remark

• No thermal >30% PCB

consideration design
• Annual ring small comes with
Design • Silkscreen error problem.
• Silkscreen
incomplete
• …

• Short >60% Tombstone Bridge Nonwetting Void

• Open defects
Manufacturi • Tombstone could be
ng • Cold solder found prior
• Void
to build
• …

• Solder joint crack Repair rate

• Solder joint peeloff for Via is too close to parts, it
• … consumer Crack risk leads to poor solder joint,
Post-sales product: impact solder joint strength
5%~37% in
initial 3
years

IPC research:
80% defects could be found and resolved at NPI
stage.
 Change from DFx

Past Yesterday Today

Above issues puzzles most of us. Vayo customer solved this issue. They may still happen at your side.
Ex.: Venture/SurfaceArt/Sierra/Sandisk…

Vayo DFx software help you detect defects from the initial beginning.
 Company introduction
 Founded on Jan of 2005, headquarter in China/Shanghai;
 Dedicates to intelligent NPI software to accelerate design to manufacturing;
 Fully in-house development, owns copyrights and patents;
 Product installed >20 countries and regions worldwide;
 Strategy partnership with equipment and EDA provider: Keysight/ViTrox/TRI/Fuji/Panasonic/Altium…

>10 years dedication on NPI technology brings up the world-class product.

 Customer reference
 Vayo software products installed in >20 countries and regions world wide
(China/USA/Mexico/Japan/Singapore/Malaysia/Thailand/Vietnam/Philippine/Russia/India/Germany/UK/Romania/Spain/Taiwan/…)
Telecom & Automotive/ Energy/
Computer Consumer Security/Medical
Contract manufacturer Others Partner
network parts

“I was impressed by Vayo NPI
tool, it is really world class
solution in the industry!“
Murad Kurwa
Senior Vice President
“From the selection of Vayo
solution on the year of 2007, we
are able to support these data
source whatever we receives what
kind of data from new customer,
and then quickly complete
placement programming. ”
Tony Zhou
CEO, IPC board director
Customer Testimonials
“We started with Vayo at year
2009 and has not been turning
back since then. What differentiate
Vayo from the rest is their
willingness to listen to
customer’s needs with fast
respond.”
CHIA Kar Lin
Head of Innovation Centre
“ Accelerator allowed us to
reduce a lot the quantity of
mistakes in the projects and the
time required for their
preparation. “
Sergei Fedorov
Product Director
“From years of experience with
DFT and CAD SW's, VayoPro-Test
Expert is the best. It is fast,
accurate and easy to use. Its DFT
report is very comprehensible for
our customers.”
David Kim
Test Development Manager
“With VayoPro-Test Expert
solution and great support of
Vayo team, we could accelerate
our product review for DFT
(ICT/Boundary).”
Tong Chang
Production Associate Manager
“Vayo tool has been extremely
useful for us in identifying
assembly issues much ahead of
the actual assembly process. This
has drastically reduced holdups in
the production line, increasing our
productivity.”
Atar Mittal
General manager
“Communication is important
for every filed, good conversation
shall bring joyful experience, Vayo
is such company we worked
with!”
CC Cho
Sr. Manufacturing Engineer
“We have been impressed with
the product capabilities, their
communication and commitment
to supporting their products is
truly world class.”
Kent Kim
Vice President
”by introducing Vayo‘s
intelligent software tool it is now
possible for operators to perform
data conversion requiring little
skill, while reducing the work time
required to a fifth of what it
was.”
Mitsuo Imai
General manager
“Vayo tool is a very intuitive and
user-friendly. You can match parts
and pds visually and new pd can be
created easily. Part Data Editor and
Parts Verification ensure every
location has correct part, size and
orientation.”
Eddie Chang
SMT engineer
“The accelerator function could
help us a lot on component
placement orientation, we don't
need to do mapping Gerber file
and check placement orientation
one by one any more.”
Mohamad Azlan Ahmad,
GPEO-M PE,
 Core product: Intelligent NPI software for PCBA

 Reduce design & mfg cycle: 30%-70%

 Reduce quality defects: 30%+
Intelligent DFx  Increase reliability: 30%+
analysis
 Increase design and mfg efficiency: 40%+
DFM Expert & DRC+  Reduce design and mfg cost: 20% +
PCB layout Eng.,
process Eng.
NPI Eng. Process Eng., Debug tech,
SMT programmer Testing Eng. Industry Eng. others…
SMT Expert/ Document Other NPI sw
Test Expert
Accelerator Expert
Fast placement DFT/Testability, Work instruction Board troubleshooting,
programming, support ICT/FP/AXI/AOI document Gerber conversion,
Fuji, Panasonic, ASM, programming preparation assembly drawing, NPI
Juki, Yamaha… team collaboration

* NPI：New Product Introduction

DFx is must capability for every
electronics company
 Why DFx: predict/solve process issue

IPC research:
80% defects could be found and
resolved at NPI stage.
 Predict defect opportunity,
increase manufacturing quality
and reduce cost

With DFx consideration:

Increase process difficulty &
steps; rapid solder/assembly
defects; increase rework rate
and work loading; lower work
efficiency and increase
manufacturing cost
 Why DFx: Improve product reliability
Medical/automotive/military/aerospace/… product
require high reliability
 Improve reliability, reduce
repair rate, protect brand
reputation.
Increase PCBA lifecycle

Stability of consumer electronics products impacts brand loyalty

and service cost.

DFM Expert performs comprehensive

checks on solder joints to ensure high
reliability.
 Why DFx: reduce design cycle

Product design challenge

Fast product replacement
 Concurrent engineering, reduce
High density, smaller
prototyping times, shorten time-to-
Difficult to transfer knowledge & training
market
Concurrent design process
new people
 DFM Automation Software
 Traditional manual method
 Check one by one manual No DFM software
 Can’t do comprehensive check (Manual check > 2 weeks)
 Low work efficiency, long cycle
 Invisible report for communication
 Long cycle (time to market)

 DFM automation software theory

Based on design data, interacts with entity parts library, respects to rich industry
standard to design & manufacturing, intelligent simulate/analysis prior to manufacturing,
find out defects & risk of design at the first time

 DFM Expert software

 Comprehensive check of PCB
 Quick to final result Save
 Cover design, fabrication, assembly
With Vayo Professional
 Improve DFM capability quickly
DFM analysis software
 Practical Rules PCB Fabrication Check

PCB Assembly Check

Component Library

Validate Signal
Validate Drill
Validate Solder
 mask/Silkscreen...
Standard IPC rules
Industry Experience Validate footprint/pad
BOM Analysis Configurable Validate spacing/distance
Comprehensive library
Validate soldering …
Quick manual create
Detailed parts info.

Result Query & reports

Internal
validation
BOM&CAD Validation
Support alternative part
CAD/Gerber Source
Interactive check
Easy to share
Powerful/Configurable

DFM Expert
Support all CAD Design for Manufacturing Analysis
Gerber/Drill import

Comprehensive, Automatic, Easy

 DFM Expert Scope: PCB Fabrication

 Check rules: 300 items

 Check content
 Signal layer
 Silkscreen layer
 Solder mask layer
 Solder paste layer
 Drill
 …
 DFM Expert Scope: PCB Assembly

 Checking rules: 900 items

 Check content
 Screen printing process
 Placement process
 Reflow process
 Manual insert process
 Wave soldering process
 Test & inspection
 Rework
 …
 DFM Expert Workflow

1. Import PCB data 3. Link part library, virtual 5. Interactive results

(CAD/Gerber) assembled boards query

2. Import material info. 4. Perform analysis 6. Select critical issues for

(BOM/AVL) with thousands rule report output
 Support CAD data source
 Support all existing PCB CAD, intelligent detect file type
No CAD (File name) No CAD (File name)

1 Accel (*.pcb) 14 Mentor (Neutral)

2 Cadence Allegro (*.val, *.cad) 15 DB++ (*.tgz)

3 Cadence Allegro (*.brd) 16 ODBxml (*.xml)

4 Cadence Allegro (*.fil,*.fim) 17 OrCAD (*.min

5 CR3000 (*.BSF, *.CCF, …) 18 ODBGateway (*.odb)

6 CR5000 (*.ftf, *.pcf) 19 PCAD (*.pdf)

7 Docica (*.docica) 20 PowerPCB/PADS (*.asc)

8 Fatf (*.asc) 21 Protel (*.pcb)

9 Gencad (*.cad, *.gen) 22 Protel3/Altium (*.pcbdoc)

10 Gencam (*.gcm) 23 TopCAD (*.txf)

11 HPLink (*.plk) 24 Unidat(*.uni)

12 HP_EGS (*.df) 25 Viscadif (*.paf)

13 IPC356 (*.ipc)

 Support XY data + Gerber source

 Automatic BOM Import & Validation

 Support multiple BOM Formats

 Excel, Text
 BOM .Vs. CAD Validation
 Mismatch parts quantity
 Duplicate part number
 In BOM not in CAD
 …
 Minimize human interfere errors
 BOM Comparison

Save >70%
manipulation cycle
 Rich Component Entity Library

 Under SQL Database

 Actual geometry/dimension data
of part body enables the possible
for virtual PCBA
 Based on datasheet
 Support multiple shape
(Rectangle/Circle…)

 Multi-layers body
 Detailed pin info.
(Shape, size, direction, location, …)

 2D & 3D View
 Fastest part creation approach
among the industry
 Intelligent capture info. from CAD
 Practical Checking Rule

 Support IPC standard

 IPC-7351
 IPC-A-600
 IPC-A-610
 IPC-TM-650
 IPC-2221
 IPC 7095
…

 Vayo experience rules

 Thousands checking rules
 Configurable parameter
 Rule customization service
 Customer internal guideline
conversion service
 Interactive Result Query

 Interactive query
 Snapshot defects
 Add remark/comments
 Colorful warning level
 Result Report Export

 Comprehensive Content
• Defect Level
• Defect Name
• Rule Info.
• Actual Value
• Picture
• Locations
• Layer/Side Info.
• ……
 Export Report
• Excel, PDF, …
• Customization service
Sample DFx issue: material not match PAD design

Impact
Package not match Package not match • Stop production, waste
product line resource
• Delay shipment & go-to-
market

Missing via, small copper Package not match

size
Sample DFx issue: components too close

Impact:
• Require high precise equipment
• Risk of assembly conflict
• Difficult to rework
Sample DFx issue: Via distance to pad

Impact:
More via on boards, it shall be more easy
to bring short, bridge, and insufficient
solder issues.

Good design
Sample DFx issue: annual ring design

Via offset to pad Annual ring too small, even missing

Impact:
Easy to cause weak structure; lead to crack/ broke & malfunction
in severe usage conditions.
Sample DFx issue: risk for via under component

Impact:
May cause bridge/short when PCBA goes through wave process.
Sample DFx issue: Via under BGA pad

Impact:
via in BGA pad, it might lead to weak solder joint strength because of void. It
shall impact product reliability.
 Sample DFx issue: BGA pad design

Solder mask defined pad, it shall easily cause the root of solder joint crack
especially in frequently shock environment.
Sample DFx issue: no thermal consideration

Poor design Good design

Poor design

Impact:
It might cause tombstone if there is no thermal consideration. Or it might cause insufficient solder for
PTH parts, and then impact solder joint strength and product reliability.
Sample DFx issue: PTH part to mask strip

Poor design
Impact:
PTH part approach mask strip too near, easily cause solder issue
like short.
Sample DFx issue: poor test point design

TP size impact contact of probe, then impact faults reject rate of test.
Sample DFx issue: poor silkscreen design

No polarity mark Cross of part reference name

Impact
• Wrong polarity during assembly
• Replace with wrong material during rework
Sample DFx issue: no local fiducial for fine-pitch parts

Impact

Brings offset risk during assembly

Good design
Sample DFx issue: Orientation of part pass through oven

Good design Poor design

Impact:
Part placement orientation shall be consistent with wave process, otherwise it may
casue bridge.
 Sample DFx issue: BOM content error

DFM Expert perform

intelligent check of BOM
content, report any
quantity mismatch error.

Impact:
Component mismatch may leads material shortage for the work order, which leads to
production stop, waste equipment resource; Or cause excessive material purchasing
and extra inventory.
Sample DFx issue: Alternative part analysis

DFM Expert compare

dimension between alternative
part with primary part, and alter
upon big size difference.

Impact
Big size difference between alternative part with primary part may cause assembly
problem, solder joint defect or poor reliability.
 DFM Expert
Function & feature
300 check items, cover potential risk in those layers (signal, silk
Fabrication
DFM screen, solder mask, …) & drill
Analysis 900 check items, cover the process of screen printer, pick&place,
Assembly
reflow, manual insert, wave, testing, repair & etc

Cadence Allegro/OrCAD, Mentor/PowerPCB/Pads, Altium/Protel, Affordable DFM/DFA solution!

CAD
Zuken CR3000/CR5000, ODB++, GenCAD, …
Data Gerber RS-274-D, RS-274-X
source
BOM Powerful parser, support varies dynamic content
Rev.
CAD rev. difference check, BOM difference check
comparison
200K parts and typical package free of charge, detail and actual
Parts Build-in library
component dimension
library Creation tool Easy for parts/package creation
Support IPC standard ( IPC-7351, IPC-A-610, IPC-2221, …),
Build-in rules
Check Vayo industry experience
rules Management
Flexible, configurable, support multiple library, access rights
control
Query Interactive query, link to PCB location
Results Reports Export critical issue to Excel/PDF/Html formats
query, 3D view &
reports 3D PCBA view, output DXF 3D data
output
& output
Part list Output material/parts data
 Business benefit

 Reduce trial-run times: 2 ~ 3 times

 Reduce quality defects: 5% ~ 10%
 Reduce manufacturing cost: 2% ~ 5%
 Reduce design cycle, time to market: 5% ~ 10%
 Save labor cost (DFM analysis): 50% ~ 80%
 Improve product stability
 Leverage Design & Manufacturing capability
intelligent software, pleasant work
Thanks!

www.vayoinfo.com