Recorded conversations and interviews on electronics design and manufacturing with the editors of PCD&F/Circuits Assembly, brought to you by the Printed Circuit Engineering Association (PCEA)
Episodes
Tuesday Jun 18, 2024
Tuesday Jun 18, 2024
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.
Sunday Jun 02, 2024
Sunday Jun 02, 2024
"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.
Monday May 20, 2024
Monday May 20, 2024
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
Saturday May 11, 2024
Saturday May 11, 2024
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.
Tuesday Apr 23, 2024
Tuesday Apr 23, 2024
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
Monday Apr 15, 2024
Monday Apr 15, 2024
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
Monday Apr 08, 2024
Monday Apr 08, 2024
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.
Sunday Mar 17, 2024
Sunday Mar 17, 2024
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.
Thursday Mar 14, 2024
Thursday Mar 14, 2024
Today, we delve into an increasingly critical aspect of technology and electronics manufacturing - the pursuit of environmentally responsible electronics manufacturing. Our industry has witnessed many environmental revolutions.
The elimination of popular cleaning solvents brought on by the Montreal Protocol in 1989, soon followed by strict VOC regulations pertaining to cleaning chemicals.
The switch from lead-based solders to lead-free alloys, led by the Restriction of Hazardous Substances Directive, known as RoHS, implemented within the EU in 2003 and adopted nearly worldwide, regulations regarding the disposal of electronic waste (e-waste) resulting in many countries mandating regulations and programs for the safe recycling and disposal of electronic products, and more.
These regulations and others have inspired some companies to seek eco-friendly alternatives to traditional printed circuit board (PCB) fabrication.
The combination of numerous environmental regulations has resulted in many companies’ implementation of sustainability programs.
As our world becomes more connected, the demand for electronic devices continues to rise, and with it, the importance of mitigating the environmental impact of their production.
On this episode of The Reliability Matters Podcast, Mike Konrad speaks with Mark S. Edwards. Mark wrote an article entitled “Environmentally Responsible Alternatives to Traditional PCB Fabrication.”
He works as a strategic account manager within MacDermid Alpha Electronics Solutions, on the global Business Development team for Circuitry Solutions. Mark has been involved in electronics manufacturing since the late 1980s and brings a passion for process automation, circuit assembly, solders/fluxes, adhesives, coatings and PCB fabrication – all with a focus on repeatability and reliability.
Edwards holds a B.S. degree in mechanical engineering technology from Oklahoma State University and began his career at a defense electronics company in Dallas, Texas, that was later acquired by Raytheon.
He has uncovered trends and synthesized customer needs for electronic hardware in the telecommunications, defense, automotive, industrial controls segments in the Americas, and now globally, in his newest role.
Chapters:
00:00:00 - The Pursuit of Environmentally Responsible Electronics Manufacturing
00:02:23 - Uncovering Trends in Electronic Hardware
00:04:56 - Circuit Board Fabrication and Environmental Responsibility
00:07:25 - The Changing Priorities of the Manufacturing Industry
00:09:40 - Green Alternatives to Traditional Circuit Boards
00:11:59 - Sustainable Alternatives to PCB Fabrication
00:14:21 - Fabrication Performance and Reliability
00:16:43 - Green PCB Fabrication Challenges and Obstacles
00:18:58 - The Challenges of Adopting Greener Solutions
00:21:22 - Environmental Sustainability in the Supply Chain
00:23:43 - Environmental Impact of PCB Fabrication Methods
00:28:20 - The Disappointment of EV 85 Fuel
00:31:07 - The Cost Implication of Going Green
00:33:31 - Recycling and the Circular Economy
00:35:55 - Recycling Circuit Boards and Extracting Precious Metals
00:38:15 - Simplifying the PCB Fabrication Process
00:40:40 - The Importance of Standards and Regulations in the Electronics Industry
00:42:54 - Demand for Environmental Responsibility in PCB Fabrication
00:45:10 - The Importance of Sustainability in the Supply Chain
00:47:20 - The Importance of Sustainability in Circuit Assembly
00:49:49 - Environmental Impact of Board Fabrication
00:52:02 - The Green Movement in Business
Tuesday Mar 12, 2024
Tuesday Mar 12, 2024
Matthias Wagner is chief executive and cofounder of Flux, a developer of a browser-based PCB design platform and programmable simulator.
When spoke with Matthias last spring, the company was introducing Flux Copilot, an AI-powered hardware design assistant. Flux Copilot uses a large language model that the company’s engineers trained and integrated into its design tool.
Flux recently added vision capability to its signature tool, whereby users can upload photos of images such as block diagrams to CoPilot and it can recommend parts for their design.
This week, we talk about those advances, some real-use cases Flux is seeing, the Renesas-Altium merger, and more.