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Lifecycle analytics for reliable electronics
Uzi Baruch, GM & VP Automotive & Electronics
Solution for automotive electronics
Month 2019
© OptimalPlus 2019. All rights reserved.
It’s a changed worldTechnological innovation has transformed our lives.
Products and devices are more intelligent and connected.
These products rely on thousands of electronic components.
2
© OptimalPlus 2019. All rights reserved.
Electronics reliability is criticalComponents must be more reliable than ever before.
3
© OptimalPlus 2019. All rights reserved.
Automotive innovation exemplifies the challenge
4
© OptimalPlus 2019. All rights reserved. 51) Automotive change drivers for the next Decade, EY, 20162) BMW - AEC Automotive electronics reliability workshop, 20173) NHTSA Recall Data4) Audi, DVCon Munich, 2017
Automotive innovation reliability challenge
90%
22%
3x
car innovations & new features are driven by electronics1
warranty costs related to electronics & semiconductors2
car recall increase from 2014-2016 due to electronics3
15x Drive per day4: 1.5hr traditional car vs.22.5hr autonomous car
1 car failure
every hour4
Reliable electronics is a must
Audi says
$10Bn50Bn cars
Toyota’s gas pedals recallFord’s failure-to-park recallTakata’s air bag recall
© OptimalPlus 2019. All rights reserved.
Growth of electronics creates safety and reliability challenges
6
of car innovations and new features are driven by electronics90%
© OptimalPlus 2019. All rights reserved.
Just ask Audi
7Source: Audi, DVCon Munich, 2017
7,000 4,000 1 dppm
1 carfailure
an hour
semiconductor devices per car
cars each day
failure rate
x x
© OptimalPlus 2019. All rights reserved. 8
Recall
400,000 Jeep, Chrysler and Dodge cars recalled in 2017 due to electrical component failure
© OptimalPlus 2019. All rights reserved.
Growth of electronics creates safety and reliability challenges
9
car recall increasefrom 2014-2016 due to electronics
3X
© OptimalPlus 2019. All rights reserved.
Growth of electronics creates reliability challenges
10
New cars < 3yrs are significantly prone to recalls
x3.5 Total car recallsdue to electronic components
© OptimalPlus 2019. All rights reserved.
Growth of electronics creates safety and reliability challenges
11
of warranty costs are related to electronics and semiconductors22%
© OptimalPlus 2019. All rights reserved.
Growth of electronics creates reliability challenges
12
Majority of semiconductor fails within warranty period
Warranty share of electronics 0 to 24 months
© OptimalPlus 2019. All rights reserved. 13
…only synergy enables new potentials“
© OptimalPlus 2019. All rights reserved.
Autonomous cars will only intensify the reliability issue
14
1.5 hrs/day traditional car drives
22.5 hrs/day autonomous car drives
vs
Our electronics need to get much more reliable
© OptimalPlus 2019. All rights reserved.
Supply chain shift from value “pyramid” to “hub and spoke”
15
Autonomous driving will disrupt the automotive industry…
“
© OptimalPlus 2019. All rights reserved. 16
Our roleWe deliver unprecedented manufacturing efficiency and reliability to the Automotive, Semiconductor and Electronics supply chains.
We provide actionable insights through unique data analytics to prevent bad products from reaching the market.
We call it lifecycle analytics
© OptimalPlus 2019. All rights reserved.
Lifecycle analytics – Following the product journey
17
Chip Board Product In use ReturnsECU modules
Machine • Process • Test • Rework • Genealogy • Performance • Reliability • Usage • Warranty
© OptimalPlus 2019. All rights reserved.
Analyzing huge volumes of data
18
100bn+devices per year
© OptimalPlus 2019. All rights reserved.
Our expertise
19
Semiconductor Automotive Electronics Consumer Electronics & Computing
© OptimalPlus 2019. All rights reserved.
Significant business impact
20
Reliability50% case avoidance
Efficiencyup to 25% cost savings
Yieldincrease up to 10% NPI2% HVM
Speedfrom weeks to days NPI, TTM, RCA
© OptimalPlus 2019. All rights reserved.
We help our clients transform data into automated actions
21
Collect Detect Act
• Data harmonization
• Product, machine and process data
• Prescriptive analytics
• AI / Machine learning
• 24x7 analytics engine
• Real-time
• Automatic
• Distributed
• Controlled
© OptimalPlus 2019. All rights reserved. 22
Accelerating innovation
Open platform synergetic with any big data strategyMachine learning | Artificial intelligence | Prescriptive analytics
© OptimalPlus 2019. All rights reserved.
Trusted by leading brands
23
Customers
Supply chain
© OptimalPlus 2019. All rights reserved. 24
Supply chain visibility + Lifecycle analytics = Reliable electronics
Thank you
Use cases
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Use Case #1: Process to inspection yield
27
Input: Welding process parameters
Output: SAM inspection yieldEV inverter
• Quality Index is computed based on process parameters data and correlated to inspection yield
• Monitoring and controlling the uniformity of the process contributes to the overall quality of the product
© OptimalPlus 2019. All rights reserved.
Use Case #2: PCB functional test final assembly
28
Instrument cluster• Homogeneity Quality
Index of functional test data is correlated to the yield of the final assembly
• The yield is strongly dependent on the accumulated variation of the upstream process steps parametric measurements
Input: Functional test parameters
Output: Assembly yield
© OptimalPlus 2019. All rights reserved.
Use Case #3: Process to assembly yield (ADAS)
29
• Lens modulation transfer parameters are measured during the stacking assembly process.
• Overall 17 curves are obtained, each at 12 different spatial frequencies (overall >200 values are produced for each of the 2 lenses).
• The final product undergoes testing at system level
Lens assembly
Spatial frequency ContrastLens 1
cmos sensor cmos sensor
Lens 2
FPGA
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Use Case #4: Process to assembly yield (ADAS)
30
• Homogeneity Quality Index of lens assembly data is correlated to the yield of the final assembly testing.
• The yield is strongly dependent on the accumulated variation of the upstream process steps parametric measurements
Input: Lens optical parameters
Output: Final lens assembly yield
© OptimalPlus 2019. All rights reserved.
Use case #4: Improve tier-1 quality & supplier yield (Win-Win)
31
With visibility
Tier-1
Chip supplier
σσ
Outlier detection with tighter control limits on
the 10 tests
Without visibility
No information shared with
OCM
“Blind” outlier detection on 100 tests
σσσσσ
Outlier detection only on 10 tests
σσ
Supplier yield loss:
Tier-1 yield loss:
Tier-1 quality:
0.4%
1.0%
10 DPPM
0.5%
0.5%
1 DPPM
0.7%
1.0%
10 DPPM
Appendix
© OptimalPlus 2019. All rights reserved. 33
Global company
Founded in2005
Employees250+
HQ and R&DIsrael
Sales and supportUSA | EMEA | APAC
Market leader in lifecycle analytics
Transforming product manufacturing data
Providing end-to-end supply chain visibility
with domain expertise in electronics supply chain
into intelligent actions in real-time
for best reliability, efficiency and fastest TTM
© OptimalPlus 2019. All rights reserved.
Cloud or on-prem.
O+ central analytics24x7 rule execution & orchestration
O+ data platformCentral repository
Central
System architecture – Automotive & Electronics – generic
34
Factory C
Edge (factory floors)
Factory B
Factory A (internal or outsourced)
Actionable insights across all mfg. lines and facilities
Portal+PLM, ERP, CRMMES
Act
ion
Act
ion
Dat
a
Act
ion/
Rul
esD
ata
Dat
aD
ata
O+ edge analytics24x7 rule execution & orchestration
O+ data platformEdge repository
Data
Data
Action/RulesData
Release to
factory
Work activity
Other equipment & data sources
3rd party incoming material
Process activity
Verify Work activity
Final verify
O+ agent
Data
Assy.
Work Verify
© OptimalPlus 2019. All rights reserved.
Cloud or on-prem.
O+ central analytics24x7 rule execution & orchestration
O+ data platformCentral repository
Central
System architecture – Automotive & Electronics – SMT example
35
Factory C
Edge (factory floors)
Factory B
Factory A (internal or outsourced)
Actionable insights across all mfg. lines and facilities
Portal+PLM, ERP, CRMMES
Act
ion
Act
ion
Dat
a
Act
ion/
Rul
esD
ata
Dat
aD
ata
O+ edge analytics24x7 rule execution & orchestration
O+ data platformEdge repository
Data
Data
Action/RulesData
Screen printer
SPI
Other equipment & data sources
3rd party incoming material
Pick & place
Reflow oven
AOI/AXI
FT
O+ agent
Data
ICT
Work Verify
© OptimalPlus 2019. All rights reserved.
System architecture – Automotive & Electronics – single factory
36
Single factory
Actionable insights across all mfg. lines and facilities
MES
Act
ion
Act
ion
Dat
a
O+ central/edge analytics24x7 rule execution & orchestration
O+ data platformSingle repository
Data
Data
Release to
factory
Work activity
Other equipment & data sources
3rd party incoming material
Process activity
Verify Work activity
Final verify
O+ agent
Data
Assy.
Work Verify
PLM, ERP, CRM
Act
ion
Dat
a
Portal+
Act
ion
Dat
a
© OptimalPlus 2019. All rights reserved.
Solutions for electronics verticals
37
OptimalPlus BI
Vertical’s solutions
Data analytics open platform
Sup
port
& S
ervi
ces
Sec
urity
Automotive Electronics Solutions
Safety & Reliability
Suite
Productivity & YieldSuite
RampSuite
Consumer Elect. and Computing Solutions
Quality Suite
Productivity & YieldSuite
RampSuite
Semiconductor Solutions
Quality Suite
Productivity & YieldSuite
RampSuite
© OptimalPlus 2019. All rights reserved.
Column store databaseMetadata index +“Hot” cacheSQL over Hadoop
Optimal+ data pipelinePortal+ desktop & web UI
Analytics engine & API
Data pipeline
Optimal+ platform
Customer data lake
IBM Streams
Customer platform
(public, private, hybrid)Cloud
Customer data
OptimalPlus and 3rd party big data platform synergy
38
Synergetic with any big data strategy
Connect to existing infrastructure
Open for all kinds of data
Accelerate innovation
Optimized“Manufacturing”data
© OptimalPlus 2019. All rights reserved.
We collect and harmonize data
39
Data harmonization
Time series
Parametric measurements
Bin/Error code data
Any data granularity
Any data source
PCBA machines
Field failures
Pass/Fail data OptimalPlus parser
Unified schema
Inspection tools
Rework
MES, WMS, QMS…
Test
Streaming • Host PC • PLC • DB • Manual data
© OptimalPlus 2019. All rights reserved.
DNA based analytics
40
Generate product DNA Advanced analytics and machine learning
Advanced solutions
© OptimalPlus 2019. All rights reserved.
Homogeneity – Improving product performance
41
ECU ADAS
EV inverter Instrument cluster
Process variability reduction = Better control Automatically leads to quality (& yield) improvement
© OptimalPlus 2019. All rights reserved.
Turning data into actions
42
Action categories
Equipment actions
•• Pause
•• Engineering tool Alert
Process actions
•• Put materials on hold
•• Re-binning
Recipe adjustment
•• Re-test skip/add
•• Adaptive testing
Data augmentation
•• Feed-forward
•• Feed-backward
•• Virtual operation
Alerts
•• Quality outlier alerts
•• Yield alerts
•• Predictive/Anomaly alerts
© OptimalPlus 2019. All rights reserved.
Diagram editable – DO NOT DELETE, KEEP IN HIDE
43
22%Electric/Electronic
100%Annual
warranty costs
23%Active & passive
components
7% ESD/EOS
23%Active & passive
components
77%Semiconductors
77%Semiconductor
24% Test Coverage
48% Systematic
failures
15% Random failures
6%*
* Re-tested without observed failures
Failure pareto
24% Front-end
41% Final test
22% Design
12% AssemblyS
emic
ondu
ctor
failu
re m
echa
nism
s
22%E/E – ECUwarranty
costs