PRINTED CIRCUIT FABRICATION FACILITY COMPANY PROFILE

Transcription

1 PRINTED CIRCUIT FABRICATION FACILITY COMPANY PROFILE Version March 2003

2 1. INTRODUCTION esat Ltd, PCB manufacturer since 1961,. At esat Ltd, we aim to be innovative and successful, with our customers as well as our employees and suppliers. Our completely new facilities, built in 1999, are based on two cornerstones. One is esat Ltd s Series factory aimed at series production of high-end rigid PCB s and semi-flex circuit boards. The other cornerstone is esat Ltd s Specials department aimed at production and quick turn-around (QTA) of both standard boards and special products such as flexible and flex-rigid PCB s. Through our employees, with many years of experience in the PCB business, esat Ltd is expertly qualified within the English, Dutch and German speaking markets. International contacts allow us to successfully operate in most countries. In actively working with our suppliers, we are able to better-fit materials to the demands of our customers, raising performance and efficiency. We are convinced that esat Ltd s outstanding technical performance, reliability, quality and service make us in every way the reliable and strategic partner in PCB s for our customers. 2. GENERAL INFORMATION VISION In the market of electronics, Printed Circuit Boards remain an essential component. Customer focus, quality, reliability, flexibility and clear communication are absolute requirements for continuity in a sector with constant changes regarding price, global competition and technology. esat Ltd see these changes and requirements as a challenge. We are well placed for this, with one of the most modern PCB facilities in Europe, a financially solid base and a favourable geographical location. Our expert employees are entrepreneurial, decisive and dependable. Relationships with customers and suppliers are built on integrity, openness and, primarily, the satisfaction of our customers. 1

3 MISSION To ensure continuity through superior products and services and be a reliable partner for our customers, employees and suppliers. STRATEGY Create the solution to our customers complete PCB needs. Anticipate technological and logistical developments and needs of our customers. Develop esat Ltd from a product organisation to a service organisation. Cooperate with other PCB-suppliers for sub-contracting. Specialise through focused choices regarding market sector, suppliers and customers. Eliminate vulnerability and dependability, both internally and externally. Raise efficiency and productivity. Improve flexibility and, where possible, make fixed costs into variable costs. TURNOVER Turnover shows a drop in 1999, resulting from the fire in The lower turnover of 2001 and 2002 is a result of the worldwide recession in electronics. Turnover Million Euro's (fcst) Year 2

4 EMPLOYEES esat Ltd has a transparent organisation with flexible customer account teams. Its organisational structure is geared to achieving in all aspects the best results and the maximum level of customer satisfaction. For optimal customer convenience and reliability, our specialists on product innovation and our quality department directly support the account teams. In total there are 120 people working at esat Ltd. Together, these employees put their knowhow and experience to work to exceed the customer s expectation. They are: Enthusiastic, competent team-players with the discipline to take their own responsibility, Curious knowledge-sharers who continuously strive for improvement and for whom only the best counts, Committed to the results of our customers, suppliers and esat Ltd. 3

5 CUSTOMERS Our aim is to achieve perfection, exceed customer expectation and to deliver a good performance in consistent quality and reliable delivery. We supply major electronics companies in Western Europe, directly or indirectly, as well as many small and medium-sized specialists that use electronics in their products or processes. We provide tangible added value by acting as co-makers and co-developers in the production of specialty products and prototypes or in series production. Business sector Our clients are active in the following sectors. Of these, our ECM clients operate especially in the industrial, medical and computer sectors. Business sectors Avionics / Defence 11% Other 12% Industrial 39% Telecom 18% Automotive 20% 4

6 SUPPLIERS The quality of our processes and products depends to a large extent on our suppliers. We set high standards for our long-term relationship and partnership with them. That s why ESat Ltd works with successful, innovative companies that are always ready to go that extra mile. Our suppliers include such companies as: Agfa, Barco, Chemproha, Cimnet, Circuit Foil, Dielektra, Dupont, Enthone OMI, Isola, ITC, KKE, Kuttler, Lantronic, MacDermid, MASS, NEC Europe, Polyclad, Rogers, Vinho, Werner Peters. 5

7 QUALITY At esat Ltd quality means excellence in business performance. Our quality philosophy is based on control and continuously improving yields, eliminating defects and reducing cycle time for each process to meet our customers increasing expectations on Delivery, Price and Quality. The natural result is a first-class product. Our quality management system are certified against the ISO 9001 standard. Using structured problem solving techniques and tools, e.g. Standard Process Control (SPC), Design of Experiments (DOE), Failure Mode and Effects Analysis (FMEA), we strive to ensure that root causes are identified and durable solutions are developed to ensure ongoing Customer Satisfaction. Through our early supplier involvement, using design and process FMEA techniques, we are able to develop true Design for Manufacture, allowing us to build better solutions for our customers. We are committed to the continuous improvement of the environment. Every effort is made to minimize the environmental impact. The Lloyd s Register Quality Assurance ISO certificate was granted to esat Ltd in May Most of our customers require UL approved PCBs and we apply our registered UL mark (file no. E44697) to every board to show it performs to this standard. All products also comply with IPC 6012 class 2 specifications. The real momentum behind esat Ltd s quality comes from our people. ESat Ltd is committed to providing the stimulating environment employees need. Teamwork with colleagues, suppliers and customers gives job satisfaction and superior performance that make us proud to work in our world class company. 6

8 3. PRODUCTS CORE BUSINESS esat Ltd makes double sided and multi-layer boards up to 16 layers, from prototyping service to high volumes. ESat Ltd also makes flex, semi-flex and flex-rigid boards and boards with special materials and surface finishes dm² Volume 500 dm² ESat Ltd Flow ESat Ltd Specials 0 dm² Technology PRODUCT SUMMARY Standard manufacturing is: series of 1 m² 25 m², double-sided 16 layered multi-layer boards and semi-flex boards, with a standard production time of production days. Special manufacturing is: double-sided boards 16 layered multi-layer boards, flex-rigid, semi-flex and flex boards, with a standard production time of 2 6 days, and an ultra short production time of 8 16 hours. 7

9 For a complete overview of esat Ltd s products, consult chapter 4 on our capabilities. Product mix Most of esat Ltd s production consists of double-sided boards and four-layered multi-layers. Productmix ML % Flex 11% DS 33% ML8 6% ML6 14% ML4 26% FLEX CAPABILITIES esat Ltd supplies three types of flexible PCB s. These offer optimal solutions for different needs. Early involvement and Design For Manufacture (DFM) are essential, as design and choice of materials are decisive for cost-efficient production. Semiflex Semiflex PCB s are useful for static applications with a limited number of movements (needed for montage) and a limited radius for bending (dependent on design). The material is epoxyglass FR4 which can be bent once after the components have been placed. This PCB is cost friendly compared to other flexible materials. Flex Flex PCB s can be taxed dynamically under frequent movement (dependent on materials, typically unlimited) with a minimal radius for bending. The material is poyimide which endure frquent bending applications. A coverlayer (soldermask) can be applied to protect the copper pattern. Flex-rigid Flex-rigid PCB s offer an ideal solution for high demands on connection-reliability and electrical resistance, as well as space-restrictions in an application requiring placement in three dimensions. A large diversity of materials and combinations with rigid materials, allows numerous designs and constructions. 8

10 4. CAPABILITIES GENERAL The specifications given in this chapter form the standard capabilities of ESat Ltd. Upon request, other specifications may be agreed upon. Logistical We apply online tracking and tracing of your orders, providing us real-time information on their progress through the production process. We support Finished Goods Inventory systems (e.g. KANBAN), creating a stock-room facility for our customers. This allows cost reduction and guarantees just-in-time delivery. Technical For exceptional or unusual assignments, we actively involve our in-house specialists on product innovation to ensure successful production and product performance. PRODUCTION FACILITIES ESat Ltd s production facilities were built in For stability of our processes and safety of our people, our plant is fully air-conditioned and equipped with sprinkler systems. ESat Ltd s plant size is: Total plant size = m² Of which production = m² And waste water treatment = m² The production facility is entirely located on the groundfloor, while waste water treatment and storage of chemicals are situated in our basement. ESat Ltd s three Clean Rooms are: Innerlayer clean room is Class Outerlayer clean room is Class Soldermask clean room is Class

11 WORK PREPARATION Digital communication FTP. Ftp.eSat.ltd.uk Please apply for login Modem 56k6 Please apply for login Maximum file-size: 25m addresses: CD-ROM (CD-R & CD-RW) Floppy disc 3,5 (DOS/UNIX) Not preferred 4 mm Dat UNIX tar only Not preferred Data formats Data format DPF (Barco),, Gerber RS 274 X (Extended),, Gerber RS 274 D (needs aperture list),, ODB++ Drill and route info Sieb&Meyer, Excellon Documentation Office 97 documents,, Plain ASCII,, Drawings in HPGL (no HPGL 2) Drawings To specify by the customer Material specification,, Build-up ESat Ltd standard build-up preferred,, PCB specification See below,, Tool size and tolerances,, Routing measure and tolerance,, V-cut measure and tolerance PCB specification IPC-A-600 ESat Ltd standard IPC 6012, class 2 ESat Ltd standard When not specified, this is used Other specification To be agreed 10

12 MATERIALS Types Double sided FR4 Other material types on request,, FR408,, Multilayer FR4,,,, Prepreg type 1080, 2125 & 7628 Semi-flexible Flexlam,, Flex Polyimide flexmaterials,, Flex-rigid Polyimide flexmaterials, FR4 &,, no-flow prepreg Thickness Double sided 0.8, 1.0, 1.2, 1.55, 2.0, 2.4 & 3.2 mm incl. Cu cladding other thickness on request Multilayer Inner layer thickness 0,10 mm excl. Cu cladding other thickness on request,, Finished thickness: 0.8, 1.0, 1.55, 2.0, 2.4 & 3.2 mm incl. Cu cladding and base Cu; excl. plating and soldermask other thickness on request Semi-flexible mm Flexlam Flex & Flex-rigid 25, 50, 75 µm Other thickness on request Cu-thickness (base laminate) Double sided 18, 35, 70 µm Multilayer Innerlayers: 18, 35, 70 µm,, Outerlayers: 12, 18, 35, 50, 70 µm Semi-flexible 35, 50 µm Flex & Flex-rigid 18, 35, 70 µm PANEL SIZES Double-sided and multilayer Panel size 610 x 530 mm Panel size 610 x 455 mm Semi-Flexible Panel size 610 x 455 mm Net PCB-size 575 x 504 mm Net PCB-size 575 x 429 mm Net PCB size 560 x 415 mm 11

13 Flex & Flex-rigid Panel size 305 x 455 mm Other panel sizes on request Net PCB size 265 x 405 mm HOLES Minimum drill size 0.20 mm Maximum aspect ratio final board thickness / drilling diameter = 8 TRACK WIDTH AND SPACING Minimum track width and Innerlayer: 100 m at 18 µm Cu thickness conductor spacing,, Outerlayer: 100 µm at 18µm Cu thickness, depending on Cu balancing due to plating distribution COATINGS Solder mask (photo imageable) Solder mask (screen printed) Peelable mask Legend print Via mask Carbon print Lackwerke Peters Elpemer GL2467 SM and SD2467 SM Lackwerke Peters SD2462 NB-M (for semi-flex) Lackwerke Peters SD2954, blue transparent and SD2952, dark blue Lackwerke Peters SD2692, white and SD2617, yellow Lackwerke Peters SD2361 T Tamura PLATING Electro Deposited Cu Rigid boards: 10 m panel / 15 m pattern minimum 20 µm in hole plating nominal,, Flexlam: 15 m panel plating minimum 15 µm in hole FINISHES Hot-Air-Solder-Levelling (HASL) 1 40 m Organic Solderability Preservative (OSP) ENTEK Plus Chemical Ni/Au 3 6 m Ni and 0,05 0,20 m Au Chemical Sn 0,6 µm Galvanised Ni/Au 4 8 µm Ni and 0,8 1,2 µm Au 12

14 MASKS Solder mask Cu thickness 18 m Cu track thickness + 30 m 35 m Cu track thickness + 30 m 70 m Cu track thickness + 30 m * Depends on circuitry. 35 m average thickness 10 m minimum edge of solder mask coverage *,, 8 m minimum edge coverage *,, 4 m minimum edge coverage * Peelable mask Thickness 250 m Holes 2 mm can be covered on board thickness 1,5 mm MECHANICAL FINISH Routing Outline, slots & position V-Grooving Min. material thickness Rest material Tolerance XY position Tolerance 0,1 mm 0,4 mm 0,2 mm 0,1 mm 0,125 mm ELECTRICAL TESTING Standard against CAD data INSPECTIONS Inspections in processes Limited incoming inspections SPC on relevant processes Automated Optical Inspection (AOI) Inspections (samples) Standard Final Inspection Form Certificate of Compliance (COC) supplier available upon request delivered with each shipment 13

15 PACKAGING Packages of max. 25 pieces sealed in non static plastic and packed in a strong paper box PCB s < 10 cm² may be packed in bags (untied) LABELLING Every package obtains a label with File number,, Lot number,, Customer,, PCB number,, Order number,, Quantity,, Date of confirmed delivery 5. EQUIPMENT ESat Ltd is one of the most modern factories in Europe, having been rebuilt and newly equipped in For material handling, our processes are linked through (un-)loaders, to reduce operator handling to a minimum and realise a maximum process quality. ESat Ltd uses the following equipment in production. Type and manufacturer per machine, per department. Photo plotting Laser plotter Barco Silver Writer 24 Film puncher Bacher APS 600 Developer Agfa Rapiline Auto. Film-inspection Yachiyo Yachiyo 14

16 Inner layer Chemical cleaner MacDermid Equipment MecBrite Clean roller Rayon RY 505E Laminator Youngwha YH 6300 ACL Post laminator Youngwha YH 6300 ACL Roller Coater Bürkle / Systronic Exposure ORC EXM 1210 Equipment cont Developer IS Devmaster 2000 Etching machine IS Cupric etcher Resist stripper IS Stripmaster 2000 AOI AOI Camtek Camtek (2x) ML pressing Post etch punch Bacher PEPS Cu oxidiser MacDermid Equipment Multibond Lay up Print Process Rivomat ML press Burkle 6 floor vacuum (2x) Scrubber IS Scrubbex Contour router Pluritec Contour 300 Drilling / X-ray driller Pluritec Inspecta 4 spindle driller Pluritec Multistation (4x) X-ray camera Pluritec Vista Panel plating Scrubber IS Scrubbex Desmear MacDermid Equipment Permanganate Blackhole MacDermid Equipment Blackhole Panel platter (10 m) MacDermid Equipment Continuous vertical plater Photo copy outer layer Auto. Film-inspection Yachiyo Yachiyo Mechanical cleaner IS Pumex Clean roller Rayon RY 5050 E Preheater Youngwha YH 6300ACL Laminator Youngwha YH 6300 ACL Post laminator Youngwha YH 6300 ACL Exposure ORC EXM 1350 Foil stripper Advanced equipment PMS 01 Developer IS Devmaster 2000 Patter plating Pattern platter (15 m) MacDermid Equipment Continuous vertical plater Resist stripping / etching / Sn stripping Resist stripper IS Stripmaster 2000 Etching line IS Akaline Etcher Sn stripper MacDermid Equipment Solder mask Mechanical cleaner IS Pumex 15

17 Curtain coater MASS SM300 Screen printer Cugher Vertiprint Exposure / cleaner ORC EXM 2000 Developer IS PSSM Solder mask Dryer MASS VDH 248 (continuous vertical) OSP OSP line MacDermid Equipment Entek Solder levelling Pre clean line MacDermid Equipment MacBrite Fluxing line Penta Roller flux HASL Penta Penta 580 Washer IS 4 brush flux washer Screen printing Screen printer Thieme 1010 E-S (3x) Dryer MASS IR (3x) Scoring / routing Scoring machine Löhr & Herrmann LH 305 HS-SM Router Pluritec Contour 300 (4x) Washer IS Small board washer 16