PCB manufacturing defects

alandaniel132 · Oct 4, 2022

During the manufacturing of 10,000 units, there are 10% defects.
As an electronics test engineer, what can I do to solve this issue?

JimB · Oct 4, 2022

The first thing would be to make some kind of a table which lists the defects.
Until you know what the defects are, there is no way to find a solution.

Typical problems could be:

Poor design
Incorrect assembly
Faulty components from the suppliers
Faults caused by poor testing techniques or faulty test equipment.

JimB

For The Popcorn · Oct 4, 2022

Seems to me (and I should think anyone qualified to be in that position), the first step is to investigate how the "units" are failing.

Are the pcbs failing? Open or shorted tracks?
[How could you tell? If the board itself is the problem, why and how do you remedy the problem?]

Is there an assembly issue?
[Same question as above.]

Is there a component issue?
[Defective, counterfeit, use of different parts than specified?]

Is there a flaw in the circuit design?

Is there a board layout issue?

After that, the possible causes are endless.....

I suggest searching for "edn tales from the cube" and reading every one of them to gain a tiny bit of understanding about what you've asked.

alandaniel132 · Oct 4, 2022

For The Popcorn said:
Seems to me (and I should think anyone qualified to be in that position), the first step is to investigate how the "units" are failing.

Are the pcbs failing? Open or shorted tracks?
[How could you tell? If the board itself is the problem, why and how do you remedy the problem?]

Is there an assembly issue?
[Same question as above.]

Is there a component issue?
[Defective, counterfeit, use of different parts than specified?]

Is there a flaw in the circuit design?

Is there a board layout issue?

After that, the possible causes are endless.....

I suggest searching for "edn tales from the cube" and reading every one of them to gain a tiny bit of understanding about what you've asked.

What is the meaning of ""edn tales from the cube"?

Thank you

alandaniel132 · Oct 4, 2022

JimB said:
The first thing would be to make some kind of a table which lists the defects.
Until you know what the defects are, there is no way to find a solution.

Typical problems could be:

Poor design
Incorrect assembly
Faulty components from the suppliers
Faults caused by poor testing techniques or faulty test equipment.

JimB

Thank you.

Is there any standard guidelines or standard protocol to follow for this process?

For The Popcorn · Oct 4, 2022

alandaniel132 said:
What is the meaning of ""edn tales from the cube"?

Perhaps you don't have the proper mindset for the position you seek. If you ask "what's that?" rather than having the initiative to to take a look for yourself ("I suggest searching for "edn tales from the cube" and reading every one of them,"), you're not going to do much good trying to solve problems.

alandaniel132 · Oct 4, 2022

For The Popcorn said:
Perhaps you don't have the proper mindset for the position you seek. If you ask "what's that?" rather than having the initiative to to take a look for yourself ("I suggest searching for "edn tales from the cube" and reading every one of them,"), you're not going to do much good trying to solve problems.

I did search for "edn tales from the cube"

What is this phase meaning?
EDN : EDN is an electronics industry website and formerly a magazine

That is not related to the questons.

For The Popcorn · Oct 4, 2022

What are Tales From The Cube about? What are you being asked to do? If you don't see the relationship, the job is not right for you.

alandaniel132 · Oct 4, 2022

For The Popcorn said:
What are Tales From The Cube about? What are you being asked to do? If you don't see the relationship, the job is not right for you.

https://www.edn.com/category/blog/tales-from-the-cube/

this website?

ronsimpson · Oct 4, 2022

Is this a school question or are you really getting 10% defects? If I had 1% defects, I would be very unhappy.

Nigel Goodwin · Oct 4, 2022

ronsimpson said:
Is this a school question or are you really getting 10% defects? If I had 1% defects, I would be very unhappy.

I would presume all his threads are homework questions, that's he's too lazy to do himself

alandaniel132 · Oct 4, 2022

ronsimpson said:
Is this a school question or are you really getting 10% defects? If I had 1% defects, I would be very unhappy.

the 1% defect is just an assumption.

ronsimpson · Oct 4, 2022

There are many things to do.
First go to the company that makes the boards and ask them. Chances they know more than you do. They will want to see examples of "defects".

eTech · Oct 4, 2022

alandaniel132 said:
During the manufacturing of 10,000 units, there are 10% defects.
As an electronics test engineer, what can I do to solve this issue?

If you are referring to PCB fabrication defects, then...
Establish an "acceptable quality level" (AQL) to be used by your PCB receiving Inspection department. Then hold the PCB fabrication company accountable to it. The AQL is usually established by your company through collaboration between production manufacturing, quality control, and engineering. Once an AQL is established, it must be agreed to by the PCB Supplier to enable them to be a "supplier". In my day our AQL was 1%.

alandaniel132 · Oct 4, 2022

eTech said:
If you are referring to PCB fabrication defects, then...
Establish an "acceptable quality level" (AQL) to be used by your PCB receiving Inspection department. Then hold the PCB fabrication company accountable to it. The AQL is usually established by your company through collaboration between production manufacturing, quality control, and engineering. Once an AQL is established, it must be agreed to by the PCB Supplier to enable them to be a "supplier". In my day our AQL was 1%.

Thank you and very infomative.
We should help each other and share knowledge. Thank you

DFM for PCB · Feb 5, 2023

I hope you have already solved your trouble , 10% PCB with defects is too high to be accepted if you have confirmed it is not a design related issue. it would be good to go back to your PCB fabricator and ask for failure analysis . it is reasonable to ask for 8D report from your PCB supplier .

Reloadron · Feb 5, 2023

Nigel Goodwin said:
I would presume all his threads are homework questions, that's he's too lazy to do himself

That's why this had an eerie familiarity. It was sort of like a Deja Vue when I read it. Normally focused on QC issues. Thank you Nigel.

Ron

boblie · Mar 28, 2023

Hi, where are your PCBs made? 10% PCB with defects is not acceptable, unless it's a PCB design issue.
The PCB maker must have Incorrect assembly or Faulty components.
In fact, it's important for a PCB supplier to have a strict PCB quality control. I ordered 100k units from a Chinese PCB maker called ELE PCB, they have strict quality control and great service.
https://www.elepcb.com/

Pommie · Mar 28, 2023

Of course, joined today, great review of a particular company. Not at all suspicious.

Mike.

Pommie · Mar 28, 2023

Actually, can someone explain how bad PCB design can cause high failure rates? Surely, it's either right or wrong.

Mike.

PCB manufacturing defects

New Member

Super Moderator

Well-Known Member

New Member

New Member

Well-Known Member

New Member

Well-Known Member

New Member

Well-Known Member

Super Moderator

New Member

Well-Known Member

Well-Known Member

New Member

New Member

Well-Known Member

New Member

Well-Known Member

Well-Known Member

Similar threads

Privacy & Transparency

Privacy & Transparency