CERTI carries out projects and advisory services to develop, operationalize and restructure industrial quality assurance systems. These systems can be used by client companies from the development phases of their products and production procedures (quality planning) to routine industrial production operations (continuous quality control and improvement).

QUALITY CONTROL PLANNING

Planning takes place from the definition of quality characteristics – considering GD&T specifications in the case of mechanical design – to the specifications for measurement systems and their laboratory infrastructure.

Production quality control planning
CERTI operates in different types of activities and applies distinct and integrated methods of quality engineering in the area of quality control planning as applied in industrial production. The following methods may be highlighted:

• Critical analysis of product design specification documentation (see more details in the item about this subject)
• Analysis of modes and effects of failures (DFMEA/PFMEA) (see more details in the item about this subject)
• Preparation and implementation of quality control plans (see more details in the item about this subject)
• Documentation and standardization of quality controls (see more details in the item about this subject)
• Acceptance planning by sampling (see more details in the item about this subject)

Analysis of coverage and strategy for circuit board production tests
Development of strategies for automated inspections and testing for circuit board production, based on: analysis of opportunities for board defects; analysis of coverage and definition of test strategy; DFT analyses; preparation of the Production Tests Requirements Notebook and evaluation of implementation viability at potential circuit board suppliers.

Specification of inspection and testing equipment applicable for the circuit board assembly process
CERTI assists the customer in specifying and selecting inspection and testing equipment to be used in the circuit board assembly process. This work is carried out based on an analysis of coverage and evaluation of different strategies and on specification/evaluation of the requirements of different types of circuit board inspection and testing equipment. This considers, for example:

• Solder inspection - SPI
• Automated Optical Inspection - AOI
• Manual Visual Inspection - MVI
• Automated X-ray Inspection - AXI
• Electronic MDA Test (Manufacturing Defects Analyzer)
• Electronic ICT (In-Circuit Testers)
• Boundary Scan Testing - BST
• Flying Probe Tester – FPT

Measuring equipment selection

• Development of measuring methods and procedures and calibration plans
• Design of measuring laboratories and rooms
• Implementation of statistical process control (SPC) and measuring system analysis (MSA)

QUALITY PLANNING IN THE DEVELOPMENT OF NEW PRODUCTS AND PRODUCTIVE PROCESSES

The CERTI Foundation team operationalizes quality planning systems based upon differing methods of quality engineering, to prevent, detect and control internal failures and defective products in a production process and to evaluate and validate new products or processes developed and new production parts furnished by third parties.

Analysis of Product specifications and requirements
Assist clients by offering technical support to the specification of the requirements considered in the development of new products and processes. Research, survey and study of information, preparation and proposition/discussion of requirements related to verification and validation testing, the necessary markers, the applicable norms and/or certifications to be considered to comprise the document that specifies requirements for new products to be developed.

Planning and execution of product verification and validation tests
Determination of a verification and validation testing strategy, comprehensive planning of prototype tests (alpha and beta) and of product samples (pilot production), coordination and/or execution of the required tests, preparation of all associated documentation, preparation and publication of reports containing results of tests carried out during new product development – including, for example, performance, reliability, lifetime, security, EMC, and other tests needed to obtain certification.

Verification tests for new product certification
Identification, evaluation and selection of accredited test service providers, interface between the different areas involved (client, project development team, certification bodies and/or accredited testing laboratories) and coordination of contracting of tests related to obtaining certification for new products. Critical analysis, discussion with those involved and evaluation of the results obtained in services providing the preliminary investigation of new product construction, and/or in services providing verification and conformity assessment tests – established by the respective applicable norms related to obtaining new product certification.

Planning and execution of reliability tests
Planning, preparation and execution of tests to ensure reliability in the development of new electronic products. Including, for example:

• Environmental studies (mechanical and climatic)
• Product lifetime studies
• Highly accelerated life test – HALT
• Accelerated stress test – AST
• Others
• Evaluation, development and qualification of suppliers and new production items
• Evaluation, development and qualification/approval of suppliers, and application of approval processes for production parts and packaging.

Critical analysis of documentation of product design specification
Critical analysis of documentation of product design specification (drawings and specification sheets) prepared by the product design teams, employing an integrated perspective regarding the needs of the other areas involved (internal clients), such as: purchasing, quality control of receiving, processes, etc.

Analysis of modes and effects of failures (DFMEA/PFMEA) Identification of potential modes of failure for items of a product (DFMEA) and/or for operations to be performed in a given manufacturing and/or assembly process (PFMEA). Meetings with multidisciplinary team to fill out FMEA forms (causes and effects of failures), severity assessment, occurrence and detection, and calculation and classification of risk priority number (RPN). Formulate and carry out a plan of action seeking to reduce the higher RPNs.

Preparation and implementation of quality control plans Quality control plan preparation, including receipt control plans (RCP), operations control plans (OCP), and manufacturing control plans (MCP). Preparation and operationalization on the factory floor of inspection stations/posts, production tests, pilot application, and testing and validation of the controls developed (RCP, OCP, MCP). Preparation and provision of quality control documentation (record sheets, inspection/test sheets, failure reports) and training of professionals from the client company (inspectors, operators, and quality analysts).

Standardization and documentation of quality controls
Preparation and issue of documentation for standardization of quality control processes. This includes:

• Receiving control plan – RCP
• Manufacturing control plan – MCP: control of parts, products and subsets (MVI, tests and inspections of production)
• Operation control plan – OCP: control of critical process parameters
• Record Forms of Controls Realized
• Inspection Sheet and Production Test Sheet
• Failure Report and Record Form
• Documents offering criteria for product acceptance/rejection and for the standardization of different types of defects
• Sample-based acceptance planning
• Presentation of the basic concepts related to how statistical tables and standardized sampling plans work. Support in the preparation of plans to determine the size, or sizes, of samples to be used and the criteria to be employed in acceptance or rejection of lots. Preparation of sampling tables for use by quality control professionals.

ASSESSMENT AND IMPROVEMENT OF PRODUCT QUALITY

Planning, preparation and execution of tests to determine thermal performance or resistance to different types of stress (thermal, humidity, vibration) – which can be applied individually or in combination – with the goal of identifying and eliminating weak points in product design and improving the reliability of circuit boards and electronic products. The process includes analysis of specifications and conformity assessment and identification of avenues of possible improvement are conducted using measurements. In addition to technical competence, ample laboratory facilities are made available for reference measurements and process capacity analysis.

Planning and execution of thermal performance and reliability tests
The following tasks are carried out to help the client to improve the reliability of their circuit boards and electronic products:

• Planning, preparation and execution of tests to improve reliability of electronic products (e.g. environmental, highly accelerated life test – HALT, combined stresses, etc.)
• Planning, preparation and execution of tests to increase thermal performance of circuit boards and electronic products
• Implementation of the use of geometric product specifications in accordance with ASME or ISO
• Statistical studies of the capacity of manufacturing and measurement processes
• Reverse engineering and dimensional analysis

SPECIAL PROJECTS FOR ASSURING INDUSTRIAL QUALITY

Quality planning systems
Conception, development and implementation of new systems and tools to ensure quality in new product and production process development and improve the qualifications of external suppliers.

Quality improvement and control systems
Development and implementation on the factory floor of new systems and tools to control and improve industrial quality.

Support in the definition of quality and productivity indicators
Presentation and proposal of different options for quality and productivity indicators for use by manufacturers, considering different types of performance indicator categories, such as: Process Indicators, Acquisition and Supply Indicators, Market and Client Indicators and Innovation Indicators.

Industrial quality planning for new factory operations
Quality planning in the development of new production processes and process designs needed to ensure industrial quality and control – including their implementation. Training and capacity building to transfer knowledge related to applicable industrial quality assurance methods. This involves activities ranging from the detailed study of the products and determination of the equipment needed for quality control, to the processes to be used to evaluate the qualifications of potential suppliers and new production parts provided by third-parties, to the detailing of proposed solutions and support for the implementation of the new operation.

Development and qualification of circuit board supplier
Apply evaluation methods (methods already developed, tested and validated) assisting client companies to identify new alternatives for circuit board assemblers and suppliers that have the appropriate conditions to perform the assembly and supply of circuit boards with the required quality and reliability.