This case study draws upon data from diverse customer lines, showcasing the effectiveness of Cybord Aquila in identifying potential failures. Standard root cause analyses were conducted alongside Cybord Aquila’s findings to validate its accuracy.
Recall and rework calculations were performed in collaboration with the customer, considering the associated costs. Rework savings considers all expenses incurred throughout the process for suspected boards, while recall savings accounts for the costs of recalling and replacing defective boards, along with any associated logistics and engineering expenses.
Case Study #1
- Item type: Current limiter
- Manufacturer: MPS
- Mfr. PN: MP5087AGG-Z
Cybord Indication: Contaminated leads on multiple components
Lab report:
- EDS test: Contaminated leads including Silica and Carbon residuals.
- Cross section test: Non-soldered terminals due to contamination
Action taken: Cybord instructed to remove the contaminated lots from the SMT assembly line to avoid any contaminated components reaching good boards.
Event magnitude: 3 reels (5K each) -total 15K contaminated components
Savings from the event: Avoided rework cost: $45K | Avoided recall costs: $1.2M
Case Study #2
- Item type: DC-DC power
- Manufacturer: Texas instruments
- Mfr. PN: CSD96497Q5MC
Cybord Indication: Contaminated leads and heat dissipation pads on multiple components (Ref. of Good component is on right upper corner)
Lab report:
- 3D OM test: Partial wetting due to contaminated heat dissipation pad
- SAT test: Die delamination due to extreme heat applied on the component.
- High res. Microscope test: Micro-cracks due to extreme heat applied on the component.
Action taken: Cybord instructed to rework all the boards containing the contaminated components before those will proceed to its next production stages.
Event magnitude: 7 reels (2.5K each) -total 17.5K contaminated components
Savings from the event: Avoided rework cost: $385K | Avoided recall costs: $2.13M
Rework was done immediately after SMT stage, and not after completing all the rest of the integration stages.
Case Study #3
- Item type (1): Ceramic CAP 0402
- Manufacturer: Kemet
- Mfr. PN: C0402C104K4RAC7411
- Item type (2): Ceramic CAP 0805
- Manufacturer: AVX
- Mfr. PN: 08051C391K4Z2A
Cybord Indication: Defected leads on both components (1 & 2)
Lab report:
- Microscope liquid test: left terminal is partially pilled off due to mechanical damage
- Microscope liquid test: right terminal is contaminated in two areas
Action taken: Cybord sorted out the suspected boards from the production flow so the customer can rework the defected discrete components over the boards
Event magnitude: 12K boards were assembled in this lot, out of it 324 boards were sorted out due to bad components assembled in it.
Savings from the event: Avoided rework cost: $7.2K | Avoided recall costs: $127K
Rework was done immediately after SMT stage and not after completing all the rest of the integration stages.
Conclusion
Cybord Aquila is a transparent AI software tool that reviews and analyzes 100% of the components assembled over boards during the standard assembly process. It can identify bad component lots or single bad component events, helping to protect production lines and minimize exposure to potential warranty claims or recall events. With no capital investment required and a seamless charge per board, Cybord Aquila is a cost-effective solution for manufacturers of all sizes.
Key benefits:
- 100% component inspection
- Identification of bad component lots or single bad component events
- Minimization of exposure to potential warranty claims or recall events
- No capital investment required
- Seamless charge per board