### Foreword:
The automotive electronics market ranks as the third largest application area for PCBs, following computers and communications. As automobiles evolve from traditional mechanical designs into intelligent, information-rich, and mechatronic high-tech products, electronic technology has become integral to vehicles. This includes applications in engine systems, chassis systems, security systems, information systems, and in-vehicle environmental systems, all of which rely on electronic components. Consequently, the automotive sector has emerged as a significant highlight within the electronic consumer market, driving the growth of automotive electronics and the adoption of automotive PCBs.
Today, automotive PCBs hold a crucial position among key PCB applications. However, due to the unique working conditions, safety considerations, and high current requirements of vehicles, there are stringent demands on the reliability and environmental adaptability of PCBs. Additionally, the variety of PCB technologies involved presents challenges for PCB manufacturers. Companies looking to penetrate the automotive PCB market must invest in understanding and analyzing this evolving landscape.
Automotive PCBs place a strong emphasis on high reliability and low DPPM (Defective Parts Per Million). It is vital for our company to assess whether we possess the necessary technology and experience for high-reliability manufacturing. Does our direction align with future product development? In terms of process control, can we meet the standards of TS16949? Have we achieved a low DPPM? These factors require thorough evaluation. Simply recognizing this lucrative opportunity and entering the market without preparation could lead to detrimental outcomes for the company.
Below are some specialized practices observed in the testing processes of several representative companies focused on automotive PCB production, offered here as references for fellow PCB professionals:
1. **Second Test Method**
Some PCB manufacturers employ the “second test method” to enhance the detection rate of defective boards following the initial high-voltage electrical breakdown.
2. **Bad Board Foolproof Test System**
An increasing number of PCB manufacturers have integrated “good board marking systems” and “bad board error prevention boxes” into their testing machines to effectively reduce human error. The good board marking system labels tested PASS boards within the testing machine, thereby preventing defective boards from being inadvertently released to customers. Conversely, the bad board error-proof box ensures that during testing, when a PASS board is evaluated, the system signals that the box is open; when a bad board is tested, the box remains closed, guiding the operator to correctly handle the tested circuit board.
3. **Establish the PPM Quality System**
[The content continues…]
1. Currently, the PPm (Parts per million defect rate) quality system is increasingly being adopted by PCB manufacturers. Among our many clients, Hitachi Chemical in Singapore stands out as a noteworthy example in terms of its application and results. In this factory, over 20 personnel are dedicated to the statistical analysis of online PCB quality issues and returns due to defects. Utilizing the SPC (Statistical Process Control) methodology, each defective board and returned faulty unit is categorized and statistically evaluated, alongside auxiliary tools such as microsectioning to identify which stages of production lead to these issues. Based on the statistical findings, we can effectively address process-related problems.
2. Comparative Testing Method
Some clients conduct comparative testing using two different brands of PCBs across various batches, tracking the PPm of each corresponding batch. This allows them to assess the performance of the two testers and select the one that offers superior results for automotive PCBs.
3. Enhancing Test Parameters
It is advisable to set higher testing parameters for stringent PCB inspections. By opting for elevated voltage and threshold levels, and increasing the high-voltage read leakage, the detection rate of defective boards can be improved. For instance, a major Taiwanese PCB manufacturer in Suzhou utilizes 300V, 30M, and 20 ohms for testing automotive PCBs.
4. Regular Verification of Testing Machine Parameters
After prolonged use, the internal resistance and other related test parameters of the tester may deviate. Therefore, it is essential to adjust machine parameters periodically to maintain testing accuracy. Many large PCB companies perform maintenance on their testing equipment every six months to a year, fine-tuning internal performance metrics. The pursuit of “zero defect” automotive PCBs remains a key objective for many in the PCB industry. However, due to limitations in process equipment and raw materials, even the top 100 PCB companies globally continue to seek ways to reduce PPm.
If you have any PCB manufacturing needs, please do not hesitate to contact me.Contact me
The automotive electronics market ranks as the third largest application area for PCBs, following computers and communications. As automobiles evolve from traditional mechanical designs into intelligent, information-rich, and mechatronic high-tech products, electronic technology has become integral to vehicles. This includes applications in engine systems, chassis systems, security systems, information systems, and in-vehicle environmental systems, all of which rely on electronic components. Consequently, the automotive sector has emerged as a significant highlight within the electronic consumer market, driving the growth of automotive electronics and the adoption of automotive PCBs.
Today, automotive PCBs hold a crucial position among key PCB applications. However, due to the unique working conditions, safety considerations, and high current requirements of vehicles, there are stringent demands on the reliability and environmental adaptability of PCBs. Additionally, the variety of PCB technologies involved presents challenges for PCB manufacturers. Companies looking to penetrate the automotive PCB market must invest in understanding and analyzing this evolving landscape.
Automotive PCBs place a strong emphasis on high reliability and low DPPM (Defective Parts Per Million). It is vital for our company to assess whether we possess the necessary technology and experience for high-reliability manufacturing. Does our direction align with future product development? In terms of process control, can we meet the standards of TS16949? Have we achieved a low DPPM? These factors require thorough evaluation. Simply recognizing this lucrative opportunity and entering the market without preparation could lead to detrimental outcomes for the company.
Below are some specialized practices observed in the testing processes of several representative companies focused on automotive PCB production, offered here as references for fellow PCB professionals:
1. **Second Test Method**
Some PCB manufacturers employ the “second test method” to enhance the detection rate of defective boards following the initial high-voltage electrical breakdown.
2. **Bad Board Foolproof Test System**
An increasing number of PCB manufacturers have integrated “good board marking systems” and “bad board error prevention boxes” into their testing machines to effectively reduce human error. The good board marking system labels tested PASS boards within the testing machine, thereby preventing defective boards from being inadvertently released to customers. Conversely, the bad board error-proof box ensures that during testing, when a PASS board is evaluated, the system signals that the box is open; when a bad board is tested, the box remains closed, guiding the operator to correctly handle the tested circuit board.
3. **Establish the PPM Quality System**
[The content continues…]
1. Currently, the PPm (Parts per million defect rate) quality system is increasingly being adopted by PCB manufacturers. Among our many clients, Hitachi Chemical in Singapore stands out as a noteworthy example in terms of its application and results. In this factory, over 20 personnel are dedicated to the statistical analysis of online PCB quality issues and returns due to defects. Utilizing the SPC (Statistical Process Control) methodology, each defective board and returned faulty unit is categorized and statistically evaluated, alongside auxiliary tools such as microsectioning to identify which stages of production lead to these issues. Based on the statistical findings, we can effectively address process-related problems.
2. Comparative Testing Method
Some clients conduct comparative testing using two different brands of PCBs across various batches, tracking the PPm of each corresponding batch. This allows them to assess the performance of the two testers and select the one that offers superior results for automotive PCBs.
3. Enhancing Test Parameters
It is advisable to set higher testing parameters for stringent PCB inspections. By opting for elevated voltage and threshold levels, and increasing the high-voltage read leakage, the detection rate of defective boards can be improved. For instance, a major Taiwanese PCB manufacturer in Suzhou utilizes 300V, 30M, and 20 ohms for testing automotive PCBs.
4. Regular Verification of Testing Machine Parameters
After prolonged use, the internal resistance and other related test parameters of the tester may deviate. Therefore, it is essential to adjust machine parameters periodically to maintain testing accuracy. Many large PCB companies perform maintenance on their testing equipment every six months to a year, fine-tuning internal performance metrics. The pursuit of “zero defect” automotive PCBs remains a key objective for many in the PCB industry. However, due to limitations in process equipment and raw materials, even the top 100 PCB companies globally continue to seek ways to reduce PPm.
If you have any PCB manufacturing needs, please do not hesitate to contact me.Contact me
