Patty, Rob, and The Professor finished their tasks in Shenzen and were flying to Shanghai for their last set of challenges in electronics assembly. Then they would head back to the US, Rob and Patty being only a week away from their wedding day.
As usual Rob, conked out as soon as the plane lifted off. Surprisingly, The Professor also drifted off to sleep. Patty was too excited to sleep. Rob’s mother had given her and Rob their wedding presents early … an iPad for each. They decided to bring only one laptop and one iPad. Patty was a little nervous about using the iPad for presentations but it worked quite well. She was still surprised that the iPad did not have a USB port. The Professor also gave each of them an early wedding present, a Pickett slide rule for Rob and a K&E slide rule for her. She must be the only person in the world right now that was watching a movie on an iPad and solving a math problem with a slide rule!
True to form, The Professor was passionate about how learning to use a slide rule helped improve a person's innate math ability. He showed Patty and Rob how to use them and gave them several assignments. Rob was better with his slide rule than Patty due to the amount of “one on one” time he had with The Professor. She had to admit that using the “slip stick” gave one more of a feel for calculations and it was consistent with one of The Professor’s adages: “Always know approximately what the answer to a calculation should be…..it will help you to avoid errors."
In addition to the iPad and slide rule, Patty was excited to be going to Shanghai at the time of the World Expo 2010. Our trio had scheduled some time at the expo into their busy schedule.
Their plan was for Rob and The Professor to work on some productivity issues and for Patty to take on some of the process materials related problems. The three of them again met with the site GM for ACME’s newly acquired plant in Shanghai, a Mr. Wong. Wong was relieved to find that they all spoke Mandarin, as his English was a little rough. When The Professor addressed him in excellent Shanghainese, everyone was speechless. Patty was determined to ask him about this later. No American spoke Mandarin, Cantonese, and Shanghainese!
They again agreed to stick to Mandarin. Patty headed out to the line, accompanied by a young Chinese engineer, Zhou Chang, who seemed to be taking more interest in her than expected. She tried to make her engagement ring visible, but she wasn’t sure the he knew of the significance of it. When she got to the line that was experiencing yield problems, the Engineering Manager, Fei Ding, met her. He showed her some of the fails and she quickly identified the head-in-pillow (HIP) defect as the likely culprit. After investigating some more fails, looking at stencil printing, some of the BGA components, and component placement, she asked Zhou Chang what spec was used to thermal profile the line.
“I don’t understand what you mean,” Zhou said in Mandarin.
“How do you determine what the reflow profile should be?” Patty responded.
With more discussion, Patty determined that they had one profile for all products! Fortunately most of the products were of similar, small thermal mass.
“What solder paste do you use for this line?", Patty asked.
The embarrassed silence suggested that Zhou did not know! They grabbed a tube and Patty was relieved to see that it was one of her favor solder pastes. Since profiling was so rarely performed, Patty and Zhou had to go to another part of the complex almost a mile away to find a reflow profiling unit. After taking the profile, the likely solution appeared. The 11 zone oven was very long and the reflow profile had a long thermal “soak” before the temperature went above liquidus. This long soak probably exhausted the flux, so that when the PWB went above liquidus, there was little flux left, resulting in oxidation and poor reflow.
All during their time together she had mentioned that her fiancé Rob was here, with her on the trip. This information seemed to do the trick.
“Zhou, why don’t you look up the solder paste spec on the web and then set up the right type reflow profile,” Patty suggested.
It was clear that Zhou was troubled. It became obvious to Patty that Zhou did not know how to profile a reflow oven. Patty set about working with Zhou to accomplish this mission. Within an hour they had re-profiled the oven and, over the next two hours, 300 PCBs were manufactured with the yield improved to 95%.
Patty asked Fei if she could give a brief presentation on the head-in-pillow defect to his team and he cheerfully agreed. Fortunately for Patty, her friend Mario Scalzo had given her his presentation that he gave at APEX 2010 on HIP (head-in-pillow). Patty always enjoyed visiting Mario in Utica, NY, as he always knew the best restaurants in town.
Her major points were:
HIP is caused by the failure of the BGA sphere to reflow with the solder paste. There are 3 major reasons for HIP:
1. Supplier Issues
a. Solder BGA sphere oxidation
b. Silver segregation to the BGA sphere surface
2. Process Issues
a. Stencil Printing
i. Registration accuracy
ii. Insufficient solder paste
b. Component Placement
i. Off pad
ii. Out of plane
iii. Non optimum pressure
i. Inappropriate reflow profile
ii. Flux exhaustion
iii. PWB warpage
3. Material Issues
a. Poor solder paste transfer efficiency
b. Insufficient solder flux oxidation barrier
c. Solder paste slump
d. PWB or BGA warpage
Patty went on to say that she had investigated all of these issues with Zhou, and that the reflow profile was not optimum as the very long soak time had exhausted the flux. The other possible issues in the list did not seem to be a concern.
At the end of the day Patty, Rob, and The Professor met at the GM’s office to leave together for dinner and the Expo. Patty had to ask, “Professor, how can you possible know Mandarin, Cantonese, and Shanghainese?”
“Actually I speak Min reasonably well too,” he replied.
“How can this be?", Rob inquired.
“Mother and father were missionaries with Wycliffe Bible Translators,” The Professor answered.
“I grew about around many languages during my youth. Mother and father speak more than I do,” he finished.
Patty went on to tell about the interest that Zhou Chang seemed to have in her, and how she had to discourage him.
“The burdens of being a beautiful young woman,” Rob teased.
Patty elbowed him, but they all left the taxi laughing as they headed for a restaurant near the Expo.
The Shanghai, slide rule, and HIP images are from: