Solutions for greater efficiency of production processes, considering issues such as cost, time, and production monitoring.
Focusing on factory projects, the CERTI Foundation has developed its own system that details all the stages of implementation: from the development of feasibility studies and conceptual design, market results, definition of products to be manufactured, technologies to be used and expected production levels during manufacturing, to the complete executive project of factory units – including the implementation and monitoring of construction, study of the production chain, products to be manufactured, production and plant operation and production costs, factory layout design, technologies to be used and expected production levels during manufacturing. CERTI also uses FIDIC (International Federation of Consulting Engineers – Fédération Internationale des Ingénieurs-Conseils) contract models to plan, coordinate and manage factory projects, and adds to this internationally adopted good practice in the execution of civil works.
Step-by-step development of new product manufacturing processes, to accelerate the introduction of these products into the market, help companies in a systematic and agile manner to diminish time to market, and use integrated engineering to allow development of the productive process . The steps include: Project Analysis, Assembly Analysis (DFA), development of assembly flowchart, time and method studies, detailed design of new assembly lines (including workbenches, movement, necessary tools/equipment and layout) and detailing of assembly instructions or process sheets.
Manufacturing process development
All of the new product production process development activities are based on simultaneous engineering, lean manufacturing and best practices and quality assurance processes. The development is conducted by specialists in the main processes involved, from project analysis to the preparation of assembly instructions.
Step-by-step development of the electronic manufacturing process, to accelerate the introduction of a new product in the market, helping companies in a systematic and agile way, reducing the time to market for their products. The steps include: Project Analysis, Process Development, Solder and Adhesive Application, Component Insertion, Welding (Reflow, Wave and Selective) and Application of Conformal Coating
Development of Electronic manufacturing process
The CERTI Foundation offers a process for the development of a system for transfer of process parameters in an agile and assertive manner, considering new products and circuit board assembly. This work can be done in conjunction with the development of the introduction of new products, or in cases involving the introduction of new technologies to the client’s existing manufacturing processes, such as: DGAs, PoPs, 01005s, flip chips, etc. The big advantage is in the fact that it is not necessary to use the client’s production line to develop a new production process, substantially reducing the time for setup and possible process adjustments.
Design for Excellence for New Products, Circuit Boards and Electronic Products (DFM, DFA, DFT and DFI)
CERTI offers a series of routines and services related to the development of new products with an eye on best manufacturing practices, ensuring that the design, manufacture of parts and manufacture of the product take place with as few defects as possible. In addition, for circuit boards and electronics products, it develops projects to ensure that a circuit board is designed, manufactured, assembled and tested with as few defects as possible. It takes full advantage of the structure of the PCB manufacturer and the assembler.
DFM: This is an analysis technique based on design rules that involve the capacity to manufacture the printed circuit board. The objective is to identify design characteristics that would make it impossible to manufacture the circuit board or that would cause defects during the process.
DFA: Similar to DFM analysis, DGA is applied to the circuit board assembly process. Based on more than 16,000 rules, this automated analysis prevents circuit boards from presenting systemic defects caused by the capacity of the assembler.
DFT: This is a set of rules designed to facilitate and maximize the scope of circuit board testing and inspection. Circuit boards that have followed DFT and DFI rules are more flexible and can be tested and inspected in different scenarios, without leaving the shared test solution overly dependent on a single technique. In addition, the adoption of DFT rules has a strong impact on the cost of the test solution, especially in the assembly of fixtures for ICT/MDA.
DF1I: Adaptation of the circuit board so that various automated inspection techniques – such as AOI, SPI, and AXI – can be applied to it.
RoHS compliance of electronic products
This involves adaptating electronics manufacturing designs and processes to comply with the RoHS directive, mainly to reach international markets. Adapting non-compliant electronic products to the guidelines and guaranteeing new processes without raising failure rates due to changes in materials.
The CERTI Foundation applies techniques to optimize existing industrial procedures, through advanced analytical tools and the use of process development methodologies. The engineering team, familiar with state-of-the-art manufacturing, fully analyzes the countless possibilities for reconfiguring processes and implementing improvements, with a focus on productivity indicators, process capacity, reliability, and cost reduction, to achieve excellence in advanced manufacturing.
In this field, CERTI Foundation presents solutions in the form of process development, realized concurrently with product design and development of the guarantee of the quality of the process, based on the best lean manufacturing practices. Among the activities developed, the following stand out: analysis of ability to assemble (DFA), assembly flowchart development, time and method studies, detailed design of integration line (including workbenches, movement, necessary tools/equipment and layout) and detailing of assembly instructions or process sheets. The developments focus on a better return on investment associated with production, and may also include process automation studies and the development of a factory floor management system (PIMS). This type of project can be developed in a “turn-key” form, in which, after validation of the assembly line and integration through a pilot production, the client receives the assembled production line with a trained team, ready for production.
This CERTI Foundation product is designed to improve the control and monitoring of the production area through online, real-time monitoring of the main steps of manufacturing processes, providing production and quality indicators, as well as the complete traceability record of the manufactured products.
The software architecture of the system is organized in modules, implemented for the complete traceability of production processes using manufacturing functionalities and controls. Among the principal benefits of the PIMS system, the following stand out:
Visual Factory Floor management
Development of systems for real-time information collection from the factory floor that enable activities such as visualizing production line status and machine and the operation of machines and indicators; graphic visualization of the main manufacturing indicators on dashboards (TV/Digital panel) or via the internet; use of state-of-the-art graphic technologies, enabling easy visualization of the most important information, a faster reaction time to potential process defects and a higher decision-making success rate.
Systems for product traceability and integration
Development and implementation of customized software for manufacturing traceability, offering a complete history of each unit produced; systems with computerized assembly instructions, ensuring greater agility in integration/manual assembly processes; and application of identification and localization technologies (bar codes, Datamatrix and RFID) for all stages of the production process.
Development of Supervisory systems for industrial applications
Development of Supervisory Control and Data Acquisition (SCADA) systems from Open Technologies to monitor and control industrial processes. Communication with equipment (machines and sensors) using different protocols, historical records and reports, alarms and events, and the possibility to integrate proprietary algorithms for data processing and automation. Graphic interfaces for process operation and middleware for integration with external software.