Do Research Parks Slow Advances?

A recent visit to Champaign, Illinois, home of the University of Illinois, got me thinking about the relationship between industry and academia.

On south First St. just past the Assembly Hall, looms the Illinois Research Park. It is growing like crazy, with lots of big names in there. Yahoo, Littlefuse, SAIC and Raytheon are just some of the tech companies there, while Caterpillar and John Deere are among the others onsite and Intel and others are nearby.

The site’s Tech Incubator was in 2011 named in 2011 as one of Inc.com’s “10 Start-up Incubators To Watch,” and is home to more than 30 startups.

And given Illinois has one of the top engineering programs in the world, plus a low cost of living, it’s an attractive place for an OEM or software developer to park a design or engineering lab.

Lots of reasons to be proud, right?

Well, maybe. Certainly there needs to be some relationship between industry and academia. They fill in each other’s gaps. Industry provides the real world need and direction, while universities can engage in the long-range blue sky type of research that future groundbreaking technologies can be built on.

Not to throw a wet blanket on the fun, but is it possible whether the close proximity over time might have a potential negative effect? Is it possible that the near-term thinking industry might corrupt the focus on basic research that is the foundation of academia? Could the tight daily interaction provoke university researchers to limit their thinking to the obvious and doable, instead of dreaming the impossible?

The leveraging of academia shows no signs of abating. The question is, should it?

A Look at Reshoring

A recent article by Software Advice ERP analyst Derek Singleton looks at what products can be manufactured in the US.

In it, Singleton looks at what’s driving the reshoring trend, which industries are good candidates to come back, and profiles three companies (Hurst, General Electric and Peerless Industries) that have brought production back from Asia — and why.

Read more here.

Removal of Conformal Coating with Small Sandblasters

Development of conformal coating technology was driven to a large degree by the military and aerospace industries. While conformal coatings are mostly used on populated, printed wiring boards (PWBs), they are also used to protect components such as transistors, diodes, rectifiers, resistors, integrated circuits (ICs) and hybrid circuits including multichip modules (MCMs) and chip-on-board (COB).

Recent environmental regulations and concerns have had a significant impact on both coating materials and application methods, particularly with regard to control of volatile organic compounds and chlorofluorocarbon compounds. VOCs and CFCs have been extensively used as solvent carriers. Manufacturers and suppliers of conformal coating materials have responded by developing non-solvent based coatings and environmentally acceptable methods of application, curing and removal.

It is important to consider how the choice of a conformal coating material affects the rework and repair issues. The need for rework or repair of a conformal coating can occur any time after completion of an assembly due to a variety of process or product requirements and component replacement issues.

A number of methods are available for rework of conformal coatings. These include thermal, chemical, mechanical, plasma and laser-based systems and small sandblasters or “micro abrasive blasters,” which will be the focus of this column.

Micro-abrasive blasters used for conformal coating removal are small sandblasting systems that are commonly used for metal deburring and etching as well as surface preparation. The cutting media is introduced into a compressed air stream and is ejected through a hand piece utilizing tips as small as 0.026″. This is directed at a component or surface area on PCB where the conformal coating has to be removed. This system can remove conformal coating from a single test node, an axial leaded component, a through-hole IC, an SMT component or an entire PCB without any modification to the system for a variety of coating materials. This method provides the most practical and environmentally friendly means for removing conformal coating from PCB assemblies.

Although these small Micro Abrasive Blasters provide the most practical and environmentally friendly means of removal, they also pose a problem. Micro Abrasive Blasters can generate static electricity as the high velocity air and particles impinge on the PWB surface. The ESD voltage generated at the point of contact can cause damage to components and electrical circuits on an assembly.

Equipment manufacturers have used several different approaches to solving the ESD problem. These are: 1) the installation of AC or DC pulsed ionizer bars in the chamber results in a rapid decay of ESD voltages in the work cell and tubing 2) the installation of a point ionizer at the end of the nozzle to dissipate any static charge built-up in the media stream at the point of contact 3) the use of an inline, auto balanced ionizer where the air source is split, one side flowing to the media and the other side flowing to the inline ionizer. This ionized air is then injected into the media stream just before it leaves the nozzle, eliminating the static charge buildup in the media chamber. The ionized air is also pumped into the work chamber. With this type of system, ESD levels are reportedly in the +10V range.

Whose Fault Is It, Anyway?

The change in administration at IPC will inevitably dredge up lots of the past as various factions position themselves for a seat at the table.

Those whom hew to the line that IPC’s emphasis over the past decade has shifted to the assembly market are correct: IPC followed the money, and since the massive shift of printed circuit board fabrication to Asia starting in late 2001, assembly has where the North American money has been.

But that assessment  just as inevitably turns to anger and blame — fingers get quickly pointed at IPC for somehow failing the domestic PCB market. I’m not sure that’s justified.

IPC’s interest in programs for fabricators has waned; of that, there is no doubt. But it has waned in large part because fabricators themselves stopped supporting those programs. The PWB Presidents Meetings and the TMRC are shells of their former selves, it says here, because the members stopped forcing the issue. Keep in mind, IPC has long followed a “build it and they will come” model. That’s not a good strategy for a trade association. But fabricators who abdicated leadership over the IPC share much of the responsibility for what it’s become. It’s not that the IPC board of directors no longer reflects the needs of small guys so much as it’s that the board no longer reflects the needs of the private owner, large or small. No one complained IPC wasn’t doing enough for fabricators when representatives from large fabs like Photocircuits were on the board.

Could IPC provide better direction for the North American fabrication industry? Yes. But the Chinese have done just fine without the help of a strong domestic association. Given that, it’s hard to argue that IPC was the cause of the decline. Back in 2000, when the forecasts for high layer count boards were staggeringly optimistic for the foreseeable future, old friend Jack Fisher lamented that it would keep the domestic industry from investing in HDI for another couple years. He was right: none did. Then the bottom fell out, and none of them had the cash to invest in the newer technology, thus relegating them to third tier status. As one who participated in the IPC Technology Roadmap going back to its first incarnation, I can say microvias were clearly expected to take hold. In that respect, the IPC did its part; the industry just didn’t follow.

It’s uncomfortable to admit we got beat, and no, the playing field with China has never been level, and yes, IPC’s lobbying and related activities have been confused and ineffective, but there’s plenty of blame to go around, and not all of it was a trade group’s fault. We’d all be better off, I think, to focus on the needs of the future rather than the sins of the past.

Dark Cloud

Cloud computing advocates beware: Apple’s cofounder thinks you’re nuts.

Holding forth in Washington last week, Steve (Woz) Wozniak said, ” ‘I really worry about everything going to the cloud. I think it’s going to be horrendous. … With the cloud, you don’t own anything. You already signed it away’ through the legalistic terms of service with a cloud provider that computer users must agree to.”

I will admit to not being familiar with all the various cloud IP agreements. But if the Woz is correct, this does suggest a serious wrinkle for those who see the cloud as a panacea.

New CEO Mitchell Breathing Life in IPC

The early feedback is that new IPC CEO John Mitchell has brought a much-needed breath of fresh air to an organization that had lost its drive and character after 11 years under the previous regime.

Among the early changes include a recognition that IPC has become out of touch with many segments of its membership. Designers were so disenchanted, a group of the Designers Council leaders were preparing to bolt the organization altogether. Fabricators’ antipathy toward IPC is well-documented and may even run deeper, as many smaller and private shops have long since labeled IPC as disinterested in their concerns. Even some assembly equipment suppliers have shared concerns over the standards process and perceived biases toward certain groups.

Much of that is turning around under Mitchell. He has moved quickly to make the rounds of various constituents, and in a departure from his predecessor, has not relied on staff to vet member opinions. He has begun to shed some of the entrenched “lifers” who had alienated too much of the membership to continue in their roles. And he has made clear, according to sources, that the staff focus going forward needs to be on the members, which is a long overdue switch from a decade of “Is It Good for the IPC?”*

Further, he is repositioning the organization to better reflect the way the industry is structured. One new division is simply called Member Success, which he describes as a group of functions (membership, member support, events and industry councils and market research) “focused on helping our members be more successful and taking an active role in helping them more fully benefit from their IPC membership.” Most of these areas had grown stagnant to the point of calcification. One of the problems many had identified with IPC is that it existed as much (or more) to ensure its own success but had lost its vision on how to improve members’ profitability. Recognizing that the onus needs to be on IPC to help its members (and not the other way around) is a long overdue and welcome shot in the arm.

Dave Torp, whom many feel is a talented but marginalized asset, is now clearly in charge of the technology and training programs, a role where his background in engineering at Rockwell Collins and sales and marketing at Kester will truly help him excel.

There is a renewed interest in Public Policy, which will in the future coordinate with Brussels and Beijing (and perhaps other key spots). IPC plans hire a new vice president for this space, a sign that it needs fresh input and energy if it plans on making a difference with the legislative branch.

Mitchell seems highly motivated to invest in IPC’s international operations, a space where the trade group’s board had been critical of the previous president for moving at a glacial pace. To that end, IPC is casting about for a president of its China organization, a smart move and a tacit nod that in Asia, titles mean something, and the approach of using a middle manager with no real authority was not working. It says here that if vice president Dave Bergman stays on, he should move to Shanghai, where his experience at IPC (30 years) could better be put to use.

One very smart move was to create a Special Projects function, which allows IPC to look at new or short-term initiatives without distracting staff from the core functions.” We see this as wise because new projects often either sap all the attention and resources from important but functioning efforts, thus potentially leaving those programs to wither, or vice versa, attending to existing programs can act as a excuse for letting new efforts simply dangle. Mitchell has brought on a former colleague named Ed Trackman to run this area.

IPC holds a critical place in the electronics supply chain, but that spot had slowly been eroding over the years. It’s early, and the proof will be in the results, but based on several conversations with IPC members who are much happier today than I’ve seen them in years, Mitchell appears the right person for the job.

*With apologies to Office Space.

Addressing Ergonomics & Repetitive Motion Injuries in Manufacturing Facilities

In today’s manufacturing environment, ergonomics and repetitive motion injuries are major issues that every business must address to ensure production levels remain at expected levels and employee injuries remain as infrequent as possible.

Although many of the hand assembly processes have been replaced with automated equipment over the past 20 years, there is still a surprising number of manual operations still required for many applications. A good percentage of these manual assembly processes still involve the use of conventional hand tools, such as pliers, screwdrivers, crimping tools, etc. Whenever a manual hand tool is being used to perform a function, repetitive motion injuries may be the result. Taking steps to reduce or eliminate these injuries before they occur is important.

Whenever the application dictates, replacing hand tools with pneumatic or hydraulic tools should be considered. For example, if a technician is cutting leads on a circuit board for 6 to 8 hr. a day using a conventional cutting plier, the fatigue and repetitive motion factor escalates quickly. Replacing that hand cutter with a pneumatic cutter will dramatically reduce those factors. In addition, production levels will improve. The same process holds true for other hand operations such as crimping, pinching, turning fasteners, etc. Now, not all hand operations can be performed efficiently with a pneumatic tool, but whenever possible, making this switch will yield immediate results.

Typically, pneumatic tools can be operated with either a hand-lever control, or remote footswitch control. Most of these tools can also be hand-held or fixtured for hands-free operation. If the operation does not lend itself to the use of a standard, off-the-shelf tool, a custom designed tool can often be provided to meet a specific application.

Jim Norton is president of Custom Products & Services, Inc. (custom-products.com).

India Goes Dark

Some 300 million Indians are without power today as no fewer than six states there lost power for an extended period of time. Add this to the growing list of recent potential and real supply-chain disruptions. There are at least 80 EMS companies affected by the outages, based on the number of entries in the CIRCUITS ASSEMBLY Directory of EMS Companies.

While the extended length of this weekend’s outage was an exception, according to Reuters, “blackouts lasting up to eight hours a day are frequent in much of the country.”

This is not to say that companies shouldn’t manufacture in India. However, the national power concerns should be a consideration for those who choose to put all their eggs in one (offshore) basket. Spread the risk.

 

 

 

Welcome, New Readers

Today we start welcoming readers from another blog we run called Laying It Out. We’ve imported the blog posts from the past several years to this site, and readers are able to sort all the old (and new) postings from Laying It Out by Pete Waddell, Judy Warner and myself by clicking on the Laying It Out category.

Why the switch? We’ve realized that many readers were using both blogs because some of the content on the Hot Wires blog overlapped quite a bit with the design and fabrication segment (Duane Benson, I’m looking at you!). Merging all the content into one space should save all of us some time each day.

Thanks for reading!