Traceability for theelectronics industryManufacturing execution solutions forglobal electronics manufacturing

Siemens PLM Software provides a comprehensive composition ofMES solutions for traceability, production control and enterpriseintegration to help ensure that cost and delivery targets aremet consistently.

www.siemens.com/plmSiemens PLM Software

The business imperativefor traceability

As outsourcing increases, brandowners (OEMs) are concernedabout protecting their brandimage. Electronic manufacturingservice (EMS) providers need toaddress this concern by providingtraceability information to retainexisting customers and to acquirenew manufacturing contracts.Environmental and safetylegislation such as RoHS,WEEEand the Congressional Tread Actfurther compounds the needfor traceability by forcingmanufacturers to self-declarecompliance and provide fortraceability queries on demand.Traceability also helps to mitigateliability by reducing the extentof product recalls should anyissues arise. Providing traceabilityoffers manufacturers a significantcompetitive advantage byaddressing overall customer,market and legislative needs.

Complexity in providing formanufacturing traceability

The dynamics of electronicsmanufacturing today ischaracterized in many casesby extremely short productlifecycles with high productmix running simultaneously onthe shop floor.Miniaturizationand constant developments incomponent technologiesincrease the risk of qualityissues that may only be discoveredlater in a user environment.

Furthermore, legislative demands,such as lead-free assemblycompels manufacturers to captureand retain shop floor events wellafter products have beenintroduced into the marketplace.In today’s manufacturingenvironment, traditional meansof performing traceability areno longer practical.

The types of traceability queriesthat will arise are:

Was this product assembled witha defective component or process?

Is the whole manufacturing orderaffected or is it limited to a specificcomponent batch or lot?

Was this product assembled withcompliant processes?

What is the overall productionhistory of this board or box?

These types of queries canno longer be answered bymanufacturing organizationsusing stand-alone shop floorsystems since the number ofevent transactions on the shopfloor has increased to a ratewhere traditional data captureis no longer feasible. The abilityto capture exception eventsand integrated data sharingis a must to meet traceabilityrequirements in today’s dynamicproduction environment.

Covering all possibletraceability requirements forelectronics manufacturing

The Tecnomatix® Traceabilitysoftware solution from SiemensPLM Software covers all possibletraceability requirements fortoday’s electronics manufacturers.From component level to fullsystem build, manufacturers canperform full traceability querieson demand eliminating guess-work and ambiguity. Since ourtraceability solution is scalable,manufacturers can work with theSiemens consultant to select whatlevel of traceability is requiredleading to a deployment plan thatwill meet specific organizationalneeds. Traceability coverage canbegin with component to PCBboard or extend throughout theproduction lifecycle to offercoverage for: materials, machine,process and full system buildrelationships.

Being specifically designedfor the electronics industry,theTecnomatixTraceabilitysolutions offer significantcompetitive advantage toenterprises that need toprotect brand equity andcomply with a variety ofenvironmental and safetydirectives.Whatever therequirement, Siemensprovides manufacturers anearly off-the- shelf trace-ability solution that can beconfigured to meet specificbusiness needs.

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Traceability solutions for electronics manufacturing

Traceability is a component of manufacturingexecution systems (MES)Today’s production environment has substantially increased thenumber of issues that need to be managed in real time prompting theevolution of MES from primarily providing for quality assurance tocovering nearly every issue of shop floor management. These issuesinclude:managing materials in WIP to assure correct productionsetup; equipment utilization monitoring to maximize all productionresource opportunities; production event capture for process control;route enforcement; repair management; overall visibility in real timeto monitor and improve key performance indicators (KPI). Today’sMES is a composition of traceability, production control andenterprise integration.

• Traceability through real-time data collection during theproduction process and powerful reports through which thisproduct and process information can be traced

• Production control by automating manufacturing rules andverifying processes to prevent deviation from planned processesthus dramatically reducing mistakes and enabling improvementof key performance indicators (KPI)

• Enterprise integration to leverage the return on investmentfrom today’s business applications

MES integration to ERP/MRP/PDM/order management andproduction planning applications ensures that these applicationsdon’t live in isolation.

Key benefits of Tecnomatix traceability solutions

• Minimize size of product recalls and internal reworks

• Satisfy customer and regulatory requirements quickly

• Manage new challenges like RoHS transition and WEEE quickly

• Expandable as the foundation for complete production controlthus enabling improvement of key performance metrics

PROVEN RESULT S

“With more than 50 percent of planned ordersbetween now and the end of 2005 requiringcompliant parts, manufacturers must take actionnow to safely error-proof their processes whiletransitioning inventories and demonstratingcompliance.MES applications that were previouslyviewed as nice-to-have for competitive advantageare rapidly becoming requisites for survival. Look toexecution products from vendors with experience inthe high-tech arena such as [Tecnomatix].”

Simon JacobsonAMR Research

MES = traceability + production + enterprisecontrol integration

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Component and board traceability

The Tecnomatix component and board traceability solution enablesPCB assemblers to meet basic traceability requirements from mountedcomponents through board and batch history. Beyond meeting the coretraceability requirements, the solution allows manufacturers to verifysetup, eliminating incorrect component mounting errors and providingfull visibility to material locations in WIP for better inventory control.The solution can integrate with your PLM/ERP/MRP systems for BOMand material count synchronization and data retention.

Meeting traceability requirements for PCBboard assemblersThe Tecnomatix component and board traceability solution traces boardhistory down to the component level. The solution captures mountedparts including the vendor source;manufacturing batches and lots; andboard mounting history by date, time and machine.

A comprehensive range of traceability queries are available including:

PCB Components SMT lineBy serial number By date code By locationBy product By supplier By time horizonBy revision By kit By customer orderBy work order or lot By assembly machine By work order or lot

Queries are available on demand via web interfaces allowingmanufacturers to extract data in logical formats that are recoveredin minutes.

Providing business benefits beyond satisfying componentand board traceability requirementsInherent to the solution are functionalities for managing materiallocations and verifying kitting and SMT setup. This is a substantial benefitthat will eliminate mounting errors due to human error associated withmanual verification and production signoff. Furthermore,materiallocations are traced giving manufacturers real-time visibility to materiallevels in WIP. This provides inventory planners better tools to manageplant-wide component requirements and reduce inventory buffers tooffset material count discrepancies. Better material management toolsalso give manufacturers improved flexibility in issuing parts to the shopwith the ability to track locations against specific work orders.

Part verification systemVerify setup at kitting stationsand on machines to eliminatepart placement and build errors.

Material trackingReal-time visibility of actualmaterial locations in the plantand dedicated to WIP forvendor/lot traceability. Abilityto synchronize with ERP/MRPsystems enables more accuratematerial counts andcomponent traceability.

Component and board traceability

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WIP monitoringBoard manufacturing routes aremonitored and every pass ofa WIP station is time and datestamped for process traceability.

Traceability reportsPerform web-based traceabilityqueries by component, boardlevel and SMT line history.Archive data for post-producttraceability and to answerfield queries.

Nearly out-of-the-box component and boardtraceability solutionThe solution has been developed to be independent of machine typesand is architecturally light being a web-based, point, scan or clickpackage. Configuration typically focuses on factory workflow which isthen defined in the system. The solution supports most commonbarcode label types, including: 1D, 2D and laser and utilizes the latestWIFI communication equipment.

Expandable to meet more advanced traceabilityand production management requirementsAs part of the Tecnomatix MES solution for electronics, the componentand board traceability solution is wholly expandable to meet the fullrange of MES requirements for electronics manufacturers includingtraceability for full system build, material management, lead-freeassembly support, production monitoring, quality assurance and fullenterprise visibility.

Key benefits of component and board traceability

• Minimizes scope and size of product recalls

• Accurately tracks manufacturing events by capturing all PCB assemblyand inspection points

• Automatically associates specific suppliers > lots > date codes to PCBserial number thereby avoiding all guesswork

• Eliminates mounting errors associated with wrong part placements byverifying kitting and machine setup

• Gives instant visibility to material levels in WIP, allowing improvedinventory planning

• Wins more business by complying with core traceability requirements

Materials traceability

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Material traceability

Full material traceabilityenables contaminated andnoncompliant materials to belocated and purged beforeassembly.

Moisture sensitive device(MSD) managementby timing exposure thresholdsand alerting before thresholdsare exceeded.

Manage leaded/nonleadedcomponents on the shop floorand tracking locations despitepart-number commonality. Assurethat correct components areallocated to the correct processes.

With the onset of RoHS compliance by mid-2006 along with advancesin component technologies, Siemens provides detailed material trackingand traceability to meet legislative and environmental compliance aswell as eliminating risk of contamination of processes by noncompliantor over-exposed materials on the shop floor.

Facilitating RoHS (lead-free) complianceThe European Union’s RoHS directive is the major driver of theindustry’s movement to lead-free assembly.During transition tolead-free, a number of anticipated issues are expected, from processmanagement to production quality.One major issue is materialmanagement on the shop floor where a large number of part suppliersare expected to maintain existing part numbers thus creatingconfusion and leading to the risk of mixed components (compliantand noncompliant) being mounted on the same board. Furthermore,manufacturers will retain both leaded and nonleaded parts in theirinventories while component suppliers obsolete their leaded cataloglines. This means that dual inventories and dual processes must bemaintained. The contamination risk is real if a proper materialmanagement system is not in place. Lead-free assembly still has manyunknowns; for example, issues related to metallurgical behavior maymanifest itself well after production when the product is in thefield. RoHS directives therefore require manufacturers to maintainproduction records for up to four years.Without automatedtracking, providing for these traceability requirements will beextremely tedious. Siemens provides full lead-free support inthe production lifecycle from material management throughprocess control.

Handling and tracking MSD and other packagingtechnologiesFurther miniaturization along with shorter product lifecycles increasesthe challenges in handling different component packaging technologies.

Introducing moisture sensitive devices (MSD) presents a range ofcomplexities to the shop floor that is expected to increase with moreminiaturization and migration to lead-free. Packaging technologyadvances occur within shorter durations,meaning operational issuesmay only be known at the field level thereby increasing warrantyservices. The ability to track specific component and package typesallows manufacturers to: consume materials before exposure expiry(for MSD); purge contaminated materials in WIP; and track specificvendor and packages to specific product builds in case of an increasein field failures and warranty claims.

Key benefits of material traceability

• Supports lead-free assembly by distinguishing between leaded andnonleaded components, assuring that the correct components areallocated to the correct process and by providing post-productiontraceability as demanded by the RoHS directive

• Manages exposure time of moisture sensitive devices (MSD) andtracks material locations in the event of an alert, including materialpurging when appropriate

• Provides full traceability for component related queries, reducingthe scope of recalls and warranty service provision

Process traceability

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Change traceabilityfor tracking changeson the shop floor, includingintroduction of BOM revisions,new parts and on-the-flychanges (including alternatepart numbers).

Defect and repairtraceabilityby logging all process eventsincluding capture of defects atthe board level with repair routesundertaken such as replacedcomponents and operator activity.

Machine performancetraceabilityby capturing machine events,(including machine/feeders usedduring mounting process), errorsduring mounting, verificationthat process is performed asplanned and tracking componentsmounted to the referencedesignator level.

Process traceability

Process traceability enables manufacturers to provide traceabilityfor specific production events including part and process changesintroduced on the shop floor. This includes any defects captured andthe associated repair processes along with operator activity andSMT machine events including placement by reference designators.Providing for process traceability together with material, componentand board level traceability allows manufacturers to achieve fulltraceability thereby significantly reducing the scope of potentialrecalls while meeting nearly every possible traceability requirementfor PCB assemblers.

Tracing changes on the shop floorFrequent changes are now standard on the shop floor, whetherthese are to the job (i.e. a revised BOM) or changes with partreplenishment (i.e. from different lot or alternate part number).Capturing such process and part changes is critical for accuratepost-production traceability.

Capturing defects and repair historyLogging discovered defects against boards at time of inspectionand test provides users the means to trace possible root causes –particularly if the cause is a component failure from a specific vendoror production lot. Furthermore, capturing all repair events is criticalin assuring traceability for environmental and safety compliance.For example, assuring that only lead-free components were used duringrework is a factor in declaring RoHS compliance. Besides assuring thatcompliant parts and processes were performed during repair,manufacturers will also need to trace operator certification confirmingthat only certified operators with the appropriate skill

and training performed the necessary repairs. By tracing defect andrepair histories, manufacturers can perform traceability queries againstdefect root causes such as a defective component or process. Byperforming defect and repair traceability, the scope of potential recallsand warranty services are significantly reduced.

Tracking SMT machine events activityCapturing machine events allows manufacturers to trace machinerelated defects such as inverted or missing components includingtracing placement to the reference designator level. Machine interfacingalso offers manufacturers the additional benefit of automaticallyaggregating machine events into OEE (overall equipment efficiency)reports for improved line utilization. Furthermore, interfacing enablesan automatic stop should there be any setup error where correctiveaction was not taken.

Key benefits of process traceability

• Provides a truly accurate traceability solution by automaticallylogging all change management events including part replenishmentfrom different vendors

• Significantly reduces recalls by offering visibility into root causesof product and process defects by providing comprehensive boardhistory including test results and which repair activities wereundertaken, such as replaced parts and operator activity

• Enables highly detailed traceability by integrating with machineenvironments allowing tracing by reference designators andmounting errors

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Box assembly traceability

Tracking changescaptures all ECO changes andallows users to make certainthat changes followed thecorrect sequence of events andincluded the correctsubassemblies and components.

Repair traceabilitycaptures all repair activity andassures that disassembly andreassembly was performed in thecorrect sequence of events with thecorrect subassemblies andcomponents.

Route traceabilityby time and date stamping the boxassembly progress in WIP.

Build genealogycaptures all relationships in a fullsystem build from BOM to PCB tofinal box build.

Box assembly traceability provides final box assemblers a totaltraceability solution for full system builds. All aspects of the box buildprocess are captured including: genealogical (parent/child) relationships,route tracking, repair process traceability and change managementtraceability. The box and board level traceability solutions provideelectronics manufacturers end-to-end traceability coverage.

Providing genealogical traceabilityAll aspects of the parent/child relationships are captured from BOMto PCB to box assembly. Integrated with board-level traceability,manufacturers can perform virtually any component and subassemblytraceability query.

Capturing assembly routesCapturing WIP progress is performed both passively by automaticscanning at selected WIP points and actively by operators whenperforming specific tasks. By capturing routes, manufacturers can traceactivity to specific locations, including operator activities, allowingidentification of specific lots/batches should field issues arise.

Capturing repair historyBy capturing box repair history, manufacturers can trace operatoractivity to make certain that the correct sequence of events wasfollowed during the disassembly and reassembly, while also confirmingthat the right subassemblies were used.

Capturing engineering change order (ECO) introductionsAs with board-level traceability, by capturing changes introducedin production via BOM revision or alternate parts and processes,manufacturers will ensure that their traceability efforts willbe complete.

Key benefits of box assembly traceability

• Provides complete traceability from component level tosubassemblies to final system build

• Captures all routes for process traceability

• Assures that the correct sequence of events and componentswere used by capturing all repair activities, allowing tracingof disassembly and reassembly processes

• Provides highly accurate box build traceability by capturingall ECO introductions

Box assembly traceability

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Tecnomatix for the electronics industry

Electronic solutions

Electronics manufacturers must bring cost-effective products tomarket faster than ever while meeting a variety of challenges includingthe introduction of a large number of new products in record time;manufacturing a growing mix of complex products; meeting customerand regulatory demands like traceability and lead-free manufacturing;and introducing new technologies, components, software, equipmentor processes.

Beyond these day-to-day manufacturing challenges, global electronicsmanufacturers face the challenge of acquiring new facilities; selecting theright equipment; balancing the workload between factories; managinginventory and quality on a global scale; and managing the outsourcingbusiness process.

Tecnomatix for electronics solutions addresses these criticalissues by providing the most commonly used digital manufacturingsolutions for designing, managing and integrating the NPI process,production execution on the shop floor and the outsourcing businessprocess at the single plant, corporation and extended enterprise levels.

Use this complete, end-to-end manufacturing solution to design, optimizeand execute board- and box-level production processes. Tecnomatixhelps you introduce new products faster by more easily programmingand optimizing the widest variety of assembly machines and testequipment in low- and high-mix scenarios, logging defectsin the repair process and managing all aspects of manufacturingexecution – from material management to machine monitoringto quality management to full product and process traceability.

Tecnomatix enhances your enterprise competitiveness by allowingyou to:

• Get the NPI process right the first time

• Optimize throughput even in high-mix conditions

• Cope effectively with change

• Tighten your grip on shop floor execution

• Minimize size of product recalls and internal reworks

• Analyze production information and get to the root cause of issues inreal time to prevent mistakes from eroding your cost margin

• Meet ever growing customer and regulatory demands

• Streamline the OEM-ODM/EMS/CM outsourcing business process

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Global professional services

Maximize the benefits of your Tecnomatix solutionSiemens offers customers much more than depth of expertise.Wetake great pride in our ability to deliver the highest level of professionalservices so that you can achieve maximum benefits from ourTecnomatix solutions in the shortest possible time.

Whether you face challenges at home or in a remote part of theworld, Siemens has the flexibility and the people in place to respond.Our professional service experts share vast experience andbusiness knowledge in project implementation, project designand project methodology. They are your experts in TecnomatixMPM technology.

We are ready to help you achieve maximum impact on your businessprocesses by providing end-to-end MPM solutions matched withconsulting, development, implementation support and engineeringservices that fit your environment and objectives.

Prepare, predict, perform better manufacturing processes

The Siemens professional services team can help you to:

• Maximize market potential for your products

• Optimize and manage global distributed manufacturing

• Respond quickly to new market opportunities

• Accommodate frequent changes in where and how you produce,as well as what is produced

• Deliver speed and flexibility across the extended enterprise

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About Siemens PLM Software

Siemens PLM Software, a business unit of the Siemens IndustryAutomation Division, is a leading global provider of productlifecycle management (PLM) software and services with nearlysix million licensed seats and 56,000 customers worldwide.Headquartered in Plano, Texas, Siemens PLM Software workscollaboratively with companies to deliver open solutions thathelp them turn more ideas into successful products. For moreinformation on Siemens PLM Software products and services,visit www.siemens.com/plm.

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