6.2 Operational Effectiveness
6.2a
New technology is a constant driver for meeting customer
needs while controlling cost. The Chemically Bonded Deposition
Process (CBDP) developed by Collin in 1998 was recognized
by EIC as a best practice and is now deployed under
Collin license across the industry for low current densities and
a very high number of lines. It uses a deposition process on
bare substrates and does not utilize copper-etching techniques.
This process results in fewer numbers of layers, smaller and
lighter boards, and improved reliability. Production capabilities
were established in 2002 as volume exceeded the laboratory
capacity. The prototypes built in R&D rely on nanotechnology
and will produce a lower-cost interconnect solution utilizing
carbon fibers placed on substrates in ultra-fine lines. These
prototype designs are currently in customer evaluation.
Closed-loop controllers monitor and correct processes. The
best prevention tool to improve quality and reduce cycle time
and cost is control through robust process capability studies
and ongoing process control. All processes are designed
to operate within a minimum Cpk of 1.45. Changes in any
parameter must meet the minimum Cpk requirement. This has
resulted in quality levels with yields so that high defects are
measured as defective PPM opportunities.
All inner and outer layers of boards are automatically identified
to enable continuous tracking throughout production
and to maintain complete traceability records on CNet. The
identification on the boards automatically alerts the production
process for any changes as an individual order proceeds
through production.
Circuits are designed with an external test point used as an
indicator of fault coverage percentage. Programmable testing
and inspection equipment within the production line ensure
high quality without manual intervention. The testing laboratory
is focused on quality assurance and the reliability testing
required when qualifying a design for customers.
Unique circuit identification has eliminated virtually all errors
associated with handling, packaging, and shipping.