Reliability Matters

Today, we're diving deep into the world of electronics manufacturing from a unique vantage point—that of the press.  My guest today is someone who has spent decades at the forefront of reporting on the electronics manufacturing industry. Mike Buetow, editor-in-chief of Circuits Assembly magazine, has covered everything from the latest technological advancements to the biggest challenges facing manufacturers today. If there's a major trend shaping the industry, you can bet Mike has written about it, analyzed it, and spoken with the experts behind it. Mike is also the host of his own podcast, PCB chat, available at pcbchat.com. I am so proud to say Mike also syndicates this show at pcbchat.com.In this episode, we'll explore the evolving landscape of electronics manufacturing, from supply chain disruptions and AI-driven automation to the future of ultra-high-density interconnects and the real impact of reshoring efforts. We'll also get an inside look at what it takes to cover this ever-changing industry—how stories are chosen, what topics are making waves, and what challenges lie ahead.  Printed Circuit Engineering Association (PCEA)https://pcea.netCircuits Assembly Magazine:https://circuitsassembly.com/ca/

This episode is a little different in two ways. First, I didn't record it in my studio. I recorded it at the SMTA Pan Pacific strategic Electronics symposium, affectionately known as PanPac, in beautiful Maui Hawaii.Each year, I record a Reliability Matters podcast at PanPac. Normally, the format of the show is I ask questions, and my guests provide answers. On this episode however, I decided to let my guest do all of the talking. The theme of this episode is Electronics: Down Memory Lane and a Vision for the Future. My three guests on this episode will share their view of the history of electronics from three different perspectives. My guests are Dr. Ron Lasky from Dartmouth College, Dr John Evans, and Dr. Tom Duval, both from Auburn University. They'll share their perspectives on the history of the electronics industry in presentation format.

Today, we're putting the spotlight on a critical component in surface mount technology, the stencil. These precision-engineered tools are the unsung heroes of electronic assembly, playing a pivotal role in ensuring accurate solder paste deposition and, ultimately, the reliability of your circuit assemblies.It's been long said that reliability begins at the solder print, and the print begins with the stencil.Joining us today is Elias Malfavon Jr, President of Metal Etch Services, Inc. a stencil manufacturer operating in San Marcos California. Metal edge services was founded 20 years ago in 2005. We'll explore the fascinating journey of stencil production, from design and material selection to the advanced laser cutting technologies that ensure microscopic precision. We'll also discuss the latest innovations in stencil technology, their impact on modern assembly processes, and how the industry is evolving to meet the challenges of ultra-high-density interconnects and miniaturization.So, sit back, relax, and let's uncover the critical role of SMT stencils in today's electronics manufacturing landscape.Elias Malfavon Jr's Contact Info:eliasjr@metaletchservices.comMetal Etch Services, Inc.https://metaletchservices.comThe D-Code Podcasthttps://www.youtube.com/@The-D-Code

Today, we're tackling a topic that has become increasingly vital in recent years: supply chain management. With global supply chains recently under immense pressure from disruptions, shortages, and growing complexity, the need for smarter, more efficient solutions has never been greater. And what better way to explore this than by discussing the cutting-edge role of AI-powered supply chain management software.My guest today is Sebastian Schaal, the founder and CEO of Luminovo, a company at the forefront of transforming how supply chains are managed in the electronics industry. Sebastian Schaal is the founder of Luminovo, a leading software provider revolutionizing the electronics supply chain. He holds two masters degrees—one in Electrical and Computer Engineering from the Technical University of Munich and another from Stanford University, where he was a Fulbright scholar focusing on Management and Computer Science. Before founding Luminovo, Sebastian gained diverse industry experience, working on AI algorithms for signal processing and computer vision at Intel and robotics companies NavVis and Magazino. Additionally, he served as a consultant at McKinsey, advising on data strategy.Sebastian and his team are leveraging artificial intelligence to streamline processes, enhance collaboration, and future-proof supply chain operations. In this episode, we'll explore how AI is reshaping supply chain management, the unique challenges facing the electronics industry, and what companies can do to stay ahead in an ever-changing global landscape. This conversation is packed with insights you won't want to miss.So, sit back, relax, and get ready to learn about the innovations that are revolutionizing supply chains worldwide. Luminovohttps://luminovo.com

Today we're diving into a critical yet sometimes overlooked component that powers so many of the devices we rely on: batteries. Batteries are the heartbeat of countless electronic products, from medical devices and electric vehicles to consumer gadgets and industrial systems. Choosing the right battery is not a one-size-fits-all decision. It requires a keen understanding of the application, performance needs, and environmental demands. The right selection can make the difference between a product that excels in reliability and one that, quite literally, fails to deliver.  But there's more to batteries than just selecting the right chemistry or capacity. Safety is paramount. Poor battery selection, design, or management can lead to performance issues, overheating, or catastrophic failures. As we've all seen in headlines, battery malfunctions can result in recalls, damage to brand reputation, or, worse, safety hazards for users.  To shed light on this vital topic, we're joined by an expert in the field of battery technology. Alex Norman is a Battery Management System Designer at Pro Technologies, a well-established and trusted custom battery pack manufacturer, providing engineering capabilities from concept through production. Their leading edge manufacturing facility and headquarters is based in Pilot Mountain, North Carolina. Alex has deep experience in Printed Circuit Board Design, Product Development, Battery Management Systems and more. Alex is also a content creator, focusing mostly on electronics, battery, and BMS content available on his LinkedIn page and YouTube channel.Today, we're going to explore how to choose the right battery for your assembly, best practices for integration, and how to mitigate potential safety risks.  So, if you care about keeping your products powered, reliable, and safe, don't bolt just yet – this podcast on batteries is positively charged with insights! Stick around and top off your battery knowledge!Alex's Contact Info:Alex Normananorman@eetengineer.comProTechnologies, Inc.http://protechnologies.comAlex's YouTube Channel:https://www.youtube.com/@eetengineerChapters:00:00:00 Choosing the Right Battery for Electronic Assemblies00:02:44 Exploring Battery Technology and Safety Concerns00:05:21 Starting a YouTube Channel: Journey and Growth00:07:55 Performance and Safety: Alkaline vs. Lithium-Based Batteries00:10:28 The Future of Sodium-Ion Batteries vs. Lithium-Ion00:13:12 Causes of Samsung Phone Battery Fires00:16:01 Advancements in Solid State Battery Technology00:18:44 Dangers of Swollen Lithium Batteries and Battery Safety00:21:19 Battery Charging Myths and Optimization Techniques00:24:04 Importance of Battery Management Systems (BMS)00:26:51 Primary vs. Secondary Batteries Explained00:29:28 Comparing Performance: Alkaline vs Rechargeable Batteries00:32:11 Impact of Temperature on Battery Performance00:34:51 Optimizing Battery Performance in Extreme Cold00:37:28 Lead Acid vs. Lithium Iron Phosphate: Battery Safety and Advancements00:39:56 Optimizing Battery Performance in Electric Cars00:42:36 Advanced Lithium Iron Phosphate Cells  00:45:24 Battery Regulations Impact and Safety Standards00:48:05 Battery Safety and Standards in Consumer Electronics00:50:49 Quality and Safety in Consumer Vs. Industrial Battery Cells00:53:25 The Importance of Proper Battery Recycling00:56:05 Lithium Iron Phosphate vs. Nickel Metal Hydride Batteries00:59:51 Humor and Technology: Creating Engaging Content01:01:10 Get Involved with Reliability Matters Podcast

On this episode, we'll dive into the world of electronics testing with an expert within the electronics testing industry, Robert Boguski,  President and Owner of Datest. Robert brings 44 years of experience in the design, fabrication, assembly, and testing of printed circuit boards (PCBs) and electronic systems. Under his leadership, Datest has become a premier provider of advanced, integrated PCBA testing and inspection services, serving both contract manufacturers and original equipment manufacturers since its founding in 1984. Robert's extensive background includes active participation in industry associations such as APICS, SMTA, and IPC, reflecting his commitment to advancing the field. He is also a columnist for Circuits Assembly Magazine, where he shares his insights on industry trends and challenges.  In this episode, we'll explore Robert's journey in the electronics manufacturing industry, the evolution of testing technologies, and his perspectives on the future of electronics testing. Join us as we gain valuable insights from a leader whose career has been dedicated to excellence in electronic testing and manufacturing.Robert's Info:Robert Boguskirboguski@datest.comDatesthttp://www.datest.com

Today, we're exploring a transformative topic: AI-based inspection technologies.  Artificial intelligence is revolutionizing how we detect, analyze, and address defects in the electronics assembly process, combining precision with unparalleled speed to unlock new possibilities for efficiency and reliability.Our guest today is a leading innovator in this field. Priyansha Bagaria is the founder and CEO of Loopr AI, a company at the forefront of AI-powered solutions for manufacturing inspection. Priyansha holds an MBA in International business and Global management, a bachelors of engineering degree in computer Science, and she held a fellowship in data science at Cornell University.Her academic background, coupled with her entrepreneurial spirit, has positioned her as a trailblazer in applying AI to manufacturing processes.In this episode, we'll explore the advancements Loopr AI is spearheading, how AI inspection technologies are reshaping traditional methods, and the tangible benefits AI offers to manufacturers striving for excellence. Loopr AI Website:https://www.loopr.ai

Today, we're diving into one of the most transformative innovations of our time: electric vehicles and the vast infrastructure needed to support their growth. Joining us is Brian O'Leary, Global Head of of e-Mobility & Infrastructure at Indium Corporation, a leading expert with deep insights into the electronic assembly industry and its critical role in the EV revolution.As electric vehicles continue to redefine the future of transportation, the reliability and scalability of the infrastructure that powers them—particularly public EV charging stations—have become pivotal challenges. The electronic assembly industry is at the heart of these systems, from the semiconductors enabling fast charging to the sensors ensuring safe and efficient operation. However, with nearly 26% of public EV charging stations estimated to be non-functional at any given time, reliability remains a significant hurdle.This episode will explore the major reliability issues plaguing public EV charging stations, including power instability, component failures, and environmental challenges.How innovations in electronics design and assembly can address these challenges, from improving thermal management to leveraging advanced materials like those developed by soldering materials manufacturers.The exciting opportunities for the electronics industry to lead the charge in building a more resilient, reliable, and efficient EV infrastructure.Brian O'Leary brings a wealth of knowledge on how advanced materials, smart assembly techniques, and innovative designs can solve these pressing issues and accelerate the adoption of electric vehicles. Together, we'll review the technical challenges, explore solutions, and look ahead to the bright future of electric mobility.Brian O'Leary's Contact Info:boleary@indium.comhttps://www.indium.com

Today we're celebrating the end of another incredible year. This isn't just any episode—it's a time to reflect on the journey we've been on together, highlight some milestones, and share a heartfelt thank you to everyone who has made this podcast such a success. Can you believe it? Reliability Matters has now released 159 episodes! It feels like just yesterday we started this podcast with the mission to explore how industry experts and their knowledge contribute to the reliability of electronics. And here we are—growing, learning, and making a real impact in our field.But here's what blows me away the most: over 85,000 downloads. That's not just a number—it's a testament to you, our amazing audience. Whether you're listening in your car or on your morning jog, or watching this on our YouTube channel, you've made this podcast part of your journey. And for that, I'm deeply grateful.This year alone, we've covered some fascinating topics. From ultra-high-density interconnects to post-reflow inspection, from thermal profiling to cutting-edge coating materials—we've explored it all. Along the way, I've had the privilege of sitting down with some of the brightest minds in the electronics industry.  Each guest has brought their unique insights, helping us all better understand the intricate science and art behind building reliable electronics.To my incredible guests—thank you. Your willingness to share your expertise, stories, and even a few laughs has been the lifeblood of this podcast. Every episode is a reflection of your generosity and brilliance.I also want to give a shout-out to you—yes, you. Whether you're a long-time listener or you just discovered us this year, you're the reason I do this.  The messages, the comments, the emails—it's all so inspiring. When you tell me how a particular episode helped solve a problem, spark a new idea, or simply make your day better, it reminds me why Reliability Matters matters.As we wrap up the year, I'm reminded of something I say often on this show: reliability isn't just a goal; it's a journey. It's a series of choices, processes, and innovations that, together, ensure the technology we rely on lives up to its promise. And this podcast? It's a part of that journey. It's a space where we can learn together, challenge assumptions, and stay ahead of the curve in an ever-evolving industry.Mike Konrad's Contact Info:mike@mikekonrad.comhttps://www.reliabilitymatterspodcast.com 

Today, I'm excited to introduce the hosts of the D-Code podcast, a dynamic trio of young professionals making waves in the electronics manufacturing industry. With experience rooted in contract manufacturing and stencil fabrication for electronic assemblies, they bring a fresh perspective to the table. Although they're at the start of their podcasting journey, D-Code has already begun to attract attention, tackling industry insights with a unique lens that up-and-coming voices can uniquely offer. My guests today are Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, a contract assembler located in Aurora, Nebraska, Sean Kincaid, President of K & F Electronics, located in Fraser Michigan, also a contract manufacturer, and Elias Malfavon, President of Metal Etch Services, a SMT stencil fabricator located in San Marcos California.I'll ask them about their experiences, challenges, and how they're setting out to decode the world of electronics manufacturing.Contact Information:The D-Code Podcasthttps://www.youtube.com/@The-D-CodeDaniel StanphillAurora Boardworksdaniel.stanphill@auroraboardworks.comhttps://auroraboardworks.comSean KincaidK & F Electronicssean@the-d-code.comhttps://www.circuitboards.comElias Malfavon Metal Etch Serviceselias@the-d-code.comhttps://metaletchservices.com

On today's episode, we'll be exploring the critical steps to avoid contamination on circuit assemblies during the rework process with our expert guest, Gayle Towell. Gayle is the Content Marketing Specialist at AIM Solder, a leading global manufacturer of solder assembly materials for the electronics industry. She holds master's degrees in both mathematics and physics from the University of Oregon and has nearly two decades of experience in higher education, technical writing, and creative writing. In her role at AIM Solder, Gayle is instrumental in producing technical and research-based materials, while also collaborating with industry partners on various projects.  She has contributed articles to industry publications, such as the Printed Circuit Engineering Association Magazine, where she discusses topics like solder paste powder sizes and mixing methods. Gayle has also participated in industry events, including the SMTA International conference, where she shared her expertise in sessions covering soldering technologies and solder paste advancements. Additionally, she has appeared on podcasts discussing the development of new solder products. Her extensive background in technical communication and her role at AIM Solder highlight her significant contributions to the electronics manufacturing industry, and today she'll be sharing her insights from a recent technical article "What's on Your Rework Bench."In this discussion, we'll review the rework station and the essential practices that can make or break circuit reliability. Gayle will walk us through the common pitfalls she's seen—from the dangers of unapproved fluxes to mismatched cleaning solvents—and explain how these mistakes lead to long-term failures in the field. She'll also share practical advice on maintaining a contamination-free bench, the importance of selecting compatible chemistries, and why regular audits and operator education are key to preventing unintended residues and contaminants.Gayle will help us prevent one problem, rework, while not creating another, contamination.Gayle's Contact InformationGayle Towellgtowell@aimsolder.comhttps://www.aimsolder.com

On today's episode, we're turning our focus to a pivotal innovation that has transformed design and manufacturing processes: flexible circuits.Flexible circuits have emerged as a game-changer in the manufacturing and design of electronic assemblies. With their unique ability to bend, twist, and conform to complex shapes, they offer unparalleled advantages in applications where space is at a premium and reliability is paramount. From wearable technology and medical devices to aerospace systems and consumer electronics, the use of flexible circuits has expanded rapidly, bringing with it both opportunities and challenges.In this episode, we'll explore the evolution of flexible circuit technology, discussing its key benefits, such as lightweight construction, enhanced durability, and improved design freedom. We'll also touch on the manufacturing complexities, material considerations, and the critical role that process control plays in ensuring reliability and performance.My guest today is Joseph Fjelstad. Joe is the founder of Verdant Electronics. Joseph Fjelstad has been active in electronics manufacturing since 1972 in various roles, including as a chemist, process engineer, and R&D manager. He holds nearly 190 U.S. Patents and numerous foreign ones. He is an internationally recognized expert, inventor and lecturer in the field of electronics interconnection technology and a veteran of several startup companies, including: Beta Phase, ELF Technologies, MetaRAM, Silicon Pipe, and Tessera (now the public company, Xperi).Some of Joe's innovative devices and novel reliability improving IC packaging structural features are found in nearly every electronic device made today. He is also an author, co-author or editor of several books on interconnection technology, including Flexible Circuit Technology 4th Edition, the most widely distributed reference book on the topic, Chip Scale Packaging for Modern Electronics, and Solderless Assembly For Electronics — The SAFE Approach. In addition, Fjelstad has written hundreds of articles, columns and commentaries for various industry magazines and journals over the last five decades. And today, he's the guest on my show.Here is a list of Joe's books:Flexible Circuit Technology 4th Editionhttps://iconnect007.com/my-i-connect007/books/flex-circuit-technologyChip Scale Packaging for Modern Electronicshttps://www.emerald.com/insight/content/doi/10.1108/cw.2004.21730bae.001/full/htmlSolderless Assembly for Electronics: The SAFE Approachhttps://iconnect007.com/my-i-connect007/books/solderless-assembly-electronics-safe-approach#:~:text=SAFE%20technology%20(Solderless%20Assembly%20For,design%20efficacy%2C%20reliability%20and%20security.Joe's Company:Verdant Electronicshttps://verdantelectronics.net Chapters:00:00:00 Importance of Flexible Circuits in Modern Electronics  00:02:42 Exploring the World of Flexible Circuits  00:05:30 Introduction to Flexible Circuits: A Historical Perspective00:08:43 Entrepreneurship Mindset: Naivety and Innovation00:11:08 The Value of Naivety in Engineering  00:13:43 Innovations in Bubble Printing Technology  00:16:47 Understanding Flex Circuits: Applications and Challenges00:19:58 The Lifespan and Failure of Torsion Bars  00:22:21 Evolution of Soldier Technology: From Heads-Up Displays to Wearables00:25:24 The Origins of the Integrated Circuit00:28:13 Advances in Microelectronics: From Printed Transistors to Modern Tech00:31:28 Challenges and Solutions in Flexible Circuit Design00:34:00 Collaborative Design for Efficient Manufacturing  00:36:49 Advances in Flexible HDI and the Upcoming Ultra HDI Conference  00:39:46 Evolution of Flexible Circuits: From 1903 to Present   00:42:40 Innovating Flexible Circuits  00:45:13 Evolution of Toll Road Technology00:48:08 The Future of Flexible and Stretchable Circuits00:51:53 Introduction to Verdant Electronics  00:54:46 The Military's Stance on Lead-Free Technology  00:56:27 Innovating Solderless Technology00:59:18 Insights on Persistence and Success in Entrepreneurship

Today, I'm in Rosemont Illinois at SMTAI, Surface Mount Technology International. I'm in the Ultra-HDI Pavilion on the trade show floor. And what are we going to talk about here in the Ultra-HDI pavilion? Ultra high density interconnects, of course.As the demand for smaller, faster, and more powerful devices grows, the need for innovative solutions in circuit design has never been greater. UHDI's represent a significant leap forward, allowing for more connections in a smaller space, pushing the boundaries of what's possible in electronic assemblies.But what exactly are UHDI's? Essentially, they refer to circuit boards with incredibly fine pitch interconnects, enabling higher functionality and complexity in much smaller form factors. This breakthrough is transforming industries like consumer electronics, aerospace, automotive, and medical devices, where space, weight, and performance are critical factors.In this episode, we'll explore the advantages UHDI's bring to the table, from increased design flexibility and performance to better thermal management. We'll also discuss how UHDI's are set to impact the assembly process. With tighter tolerances and more intricate layouts, UHDI assemblies will require new approaches to assembly, inspection, and reliability testing.To better explain UHDI technology, we've put together a panel of subject matter experts. Tara Dunn, Director of Training and Education at the Surface Mount Technology Association (SMTA), will moderate a panel discussion with other subject matter experts.In addition to Tara, our other experts are Anaya Vardya CEO of American Standard Circuits, Chrys Shea from Shea Engineering Services, Michael Sivigny, owner and General Manager of CeTaQ Americas, and Oren Manor, Op-Center Core Program Business Director at Siemens Digital Industries Software.Ultra-HDI is here! And if you haven't seen it on your assembly line yet, it's coming, so stay tuned as we unpack the future of Ultra High Density Interconnects and what it means for the next generation of technology.

One of the most critical aspects of manufacturing high-reliability circuit assemblies is thermal profiling during the reflow process. Whether you're designing, engineering, or troubleshooting circuit assemblies, understanding how temperatures during the reflow process influences the quality and performance of your assemblies is essential. In this episode, we'll break down what thermal profiling is, why it's important, and how it affects everything from solder joint integrity to component placement. We'll also explore the challenges and solutions involved in getting your thermal profile just right, ensuring your circuit assemblies are built to last in a competitive and demanding industry. Will review thermal profiling best practices, common mistakes, and the various capabilities of thermal profilers.I guest today is Mark Waterman. Mark is the Electronics division manager at ECD, a manufacturer of thermal profiling equipment founded in 1964. Mark began his career at ECD in 2006.I'll ask Mark all about thermal profiling best practices right after this.Mark Waterman's Contact Information:Mark Watermanmark.waterman@ecd.comhttps://ecd.com

If you're part of the electronics landscape, you've likely encountered the role contract manufacturers play — and it's a critical one. These specialized partners bridge the gap between design innovation and full-scale production, bringing efficiency, expertise, and flexibility to the table.As companies seek to meet growing demand for advanced electronic products, contract manufacturers are increasingly relied upon to provide cost-effective, high-quality assembly services. Whether it's managing supply chains, ensuring compliance with industry standards, or accelerating time to market, their contributions have become indispensable. In today's episode, we'll explore how contract manufacturing works, why it's so vital, and what trends are shaping the future of this essential industry.My guest today is Adrian Leal. Adrian serves as the USA Business Development Manager for Teltonika EMS and is the President of the Houston SMTA Chapter. With over 30 years of experience in the manufacturing industry, he has worked extensively as both an end user and a service provider. Throughout his career, he has held diverse roles including process engineer, manufacturing engineer, quality engineer, field engineer, and sales engineer.In 2003, Adrian became the first engineer from the oil and gas industry to earn the prestigious Process Engineer certification from the SMTA. From 2006 to 2015, he voluntarily took on the role of ESD Subject Matter Expert for SLB, where he developed an internal ESD program that remains in use today.If you're in Texas, you may know Adrian from his involvement in Cup of Joey networking events.I'll talk with Adrian about his transition from an OEM to a contract manufacturer and his recommendations on how to choose the most appropriate contract manufacturer for your needs.Adrian's contact information:Adrian Lealadrian.leal@teltonika-iot.comhttps://teltonika-iot-group.com

As the demand for more durable and dependable electronics continues to rise across industries, the choice of soldering materials, such as solder paste, plays a pivotal role in determining the reliability of these devices. We'll discuss how selecting the right solder paste can influence performance and longevity, and we'll hear from an industry expert about the latest advancements and best practices in soldering material technology. I guess today is Ebad Rehman, Regional Product Manager at MacDermid Alpha Electronics Solutions. He has a Master's degree in Technology from Illinois State University and has led multiple technical and strategic projects for MacDermid Alpha, including new product development and technology development projects, using lean and agile methodologies. He's also planned and developed processes for the Power Electronics group and the Aftermarket Enhancement group to drive efficiencies and effectiveness. Whether you're a seasoned engineer or someone new to the electronic assembly industry, this episode will equip you with the knowledge to make informed decisions that enhance the reliability of your electronic assemblies. Join us as we explore the critical intersection of materials science and electronics reliability.Ebad Rehman's Contact Info:ebad.rehman@macdermidalpha.comhttps://www.macdermidalpha.com

Two episodes ago, episode 149, we talked all about automated optical inspection. Today we're exploring the impact of less automated inspection Technology, that being optical microscopes.From commercial, class 1 electronics to high reliability class 3 electronics, the intricate electronic devices we rely on daily are assembled with astonishing precision. This precision wouldn't be possible without the aid of advanced optical microscopes. These remarkable instruments allow technicians and engineers to inspect, analyze, and ensure the quality of electronic components down to the minutest detail.In this episode, we'll uncover how optical microscopes have impacted electronic assembly, enhancing productivity, ensuring reliability, and driving innovation. One of the unique benefits microscopes provide, particularly in hand soldering applications, is the ability to view and solder the assembly under high magnification through the microscope. Obviously, this is not something any AOI system can perform.But microscopes are not limited to soldering applications. One of the most critical applications of optical microscopes in the electronic assembly industry is the inspection of circuit assemblies for quality assurance. Circuit assemblies are the heart of many products, comprising numerous, highly miniaturized components and connections that must be flawlessly integrated. Even the smallest defect, such as a microscopic crack or an improperly soldered joint, can lead to significant malfunctions or failures.Optical microscopes enable detailed inspection of these assemblies, allowing quality control professionals to identify and rectify issues that would be invisible to the naked eye. By providing high-resolution images and magnification, these microscopes help in detecting defects, ensuring correct alignment and polarity of components, and verifying the integrity of solder joints. This meticulous inspection process is crucial for maintaining the reliability and performance of electronic devices, ultimately ensuring customer satisfaction and, in many cases, safety.We'll hear from two industry experts who will share insights on the latest technological advancements and how these tools are indispensable in maintaining the high standards of modern electronics. Nili Walp is Marketing Manager at Vision Engineering, a manufacturer of microscopes design for various industries, including the Electronics assembly industry, where she has worked for over eight years. Nili earned a bachelors in communications from Boston University.Richard Nagel is Vice Pand Nili will share insights on the latest technological advancements and how these tools are indispensable in maintaining the high standards of modern electronics.Vision Engineering Contact Information:https://www.visioneng.usinfo@visioneng.us

Statistics, at its core, is the science of making sense of data. From predicting trends and making informed decisions to ensuring quality control and optimizing processes, the applications of statistics are vast and varied. In the electronic assembly industry, where precision and reliability are paramount, statistical techniques become indispensable tools for engineers, manufacturers, and quality assurance professionals alike.Join us as we unravel the complex yet captivating connections between statistics and the truth. We'll delve into real-world case studies, and uncover the statistical principles that ensure the decisions we make every day are based on facts, accurate data, and accurate statistics. In today's episode, we're also going to tackle some common myths associated with statistics and shed light on how misinterpretation of data can lead to false conclusions. Many people think of statistics as infallible, a definitive answer to every question posed by data. However, this couldn't be further from the truth. Statistics is a powerful tool, but its effectiveness hinges on proper application and interpretation.We'll discuss myths such as "Correlation equals causation," where the mere relationship between two variables is often mistaken for one causing the other. We'll also address the misconception that a larger sample size always guarantees accurate results, and how ignoring the context or the source of data can lead to misleading outcomes.Moreover, we'll explore real-world examples where statistical missteps have led to costly errors and how these pitfalls can be avoided through rigorous analysis and critical thinking. By understanding these common misconceptions and learning how to approach data critically, you'll be better equipped to harness the true power of statistics.My guest today, is Aaron Brown. Aaron teaches statistics at New York University and at the University of California at San Diego, and he writes regular columns for Bloomberg and Wilmott. In the late 1980s and early 1990s, he was a key participant in developing modern financial risk management and one of the original developers of Value-at-Risk. He also helped develop the rules that eventually became known as Basel II.Aaron holds an M.B.A. in Finance and Statistics from the University of Chicago and an BS in Applied Mathematics from Harvard.

In today's episode, we're exploring automated optical inspection (AOI) and x-ray inspection technology within the electronic assembly industry.Joining us are two experts who bring a wealth of knowledge and experience to the table.Joel Scutchfield is the General Manager of SMT and Semicon Business Operations & Director of Sales at Koh Young, manufacturers of automated inspection and precise measurement systems with its headquarters in Seoul South Korea and R&D centers around the world. Joel has been with Koh Young for just under 10 years.Jesper Lykke is the CEO at Viscom, a manufacturer of inspection technologies, in particular for automatic optical inspection (AOI) and X-ray inspection, with headquarters in Hanover, Germany and offices worldwide. Jesper has been with Viscom for 14 years.Both Joel and Jesper are widely considered to be subject matter experts on inspection technology.In this episode, we'll delve into the principles and applications of AOI and x-ray inspection, discussing how these technologies are revolutionizing the electronic assembly industry. We'll explore the latest trends, challenges, best practices, and future directions, providing you with a comprehensive understanding of how these inspection methods are critical to maintaining high standards in electronics manufacturing.Whether you're an industry professional, a tech enthusiast, or just curious about the intricacies of electronic assembly, this episode promises to offer valuable insights and expert perspectives on the inspection technologies that are driving both innovation and quality in the field. So, sit back, relax, and join us for an enlightening conversation about inspection Technology. Guest contact information:Joel ScutchfieldKoh Youngjoel.scutchfield@kohyoung.comJesper LykkeViscomjesper.lykke@viscomusa.com

Just like the famous line from the 1984 film, The Terminator, “I'll be back”, SMTAI is back. Back to the Chicago area.We're back in Rosemont, co-located with the Assembly Show, at the Donald E. Stephens Convention Center, October 20-24.Between SMTAI and the Assembly Show, there will be thousands of engineers and industry professionals in attendance.The exhibit floor features hundreds of exhibitors showing off the latest technology. But the topic we're discussing today is the Technical conference and other planned events taking place at this year's SMTAI.This year, there are 11 scheduled professional development courses, about 100 technical presentations across seven technical tracks.Joining me to discuss what's in store for attendees is Jason Keeping, member of the SMTA Global Board of Directors where he is Vice President of technical programs for SMTA. Jeff Kennedy, past SMTA President and Director of the Manufacturing Excellence Track, and Robert Boguski, member of the SMTA Global Board of Directors where he is VP of membership and Director of the Test and Inspection track.

Recorded live in Anaheim California during the IPC Apex Expo.This episode features three interviews including:• Kimberly Fagan from PVA• Taylor Wagan from CETEC ERP• Neil Hubble from Akrometrix

Recorded live in Anaheim California during the IPC Apex Expo.This episode features four interviews including:• David Chiu from Test Research, Inc.• Michael Dolan from South-Tek• Dalton Dodge from Brooks Automation • Michelle Ogihara from Seka Machinery, Inc.

Recorded live in Anaheim California during the IPC Apex Expo.This episode features three interviews including:• Gus Mavrou from Seho• Mark Stansfield from Solderstar• Jesper Lykke from Viscom

The challenging world of electronics becomes even more challenging when the end product is destined for harsh environments. For high reliability products operating in a harsh environment, the quest for reliability is not just a goal—it's an imperative. These are not your everyday gadgets; often they're critical components of systems designed to operate under extreme conditions, where failure is not an option. From the scorching heat of desert landscapes to the unyielding cold of arctic tundras, from the high-pressure depths of our oceans to the radiation-filled expanse of space, the demands on these electronic products are as varied as the environments themselves.While ocean depths, outer space, and frozen tundras are arguably harsh environments, we don't have to look too far for examples of product failures in less harsh environments. One example that comes to mind is the state of public EV charging stations. Government reports have concluded that up to 25% of public EV chargers are at any given time. While there are many reasons for this, one may conclude they are not designed and manufactured for the intended in climactic operating environment. On this episode, we'll uncover the numerous challenges that designers and engineers face in their quest for reliability, durability, and functionality of the final product.As we navigate through this complex landscape, we'll highlight the strategies that enable these products to not just survive, but excel in unforgiving conditions. Our navigator for this episode is my guest, Dr. Andre Kleyner. Dr. Kleyner has 30 years of engineering, research, consulting, and managerial experience specializing in reliability of electronic and mechanical systems designed to operate in severe environments. He received a doctorate in Mechanical Engineering from the University of Maryland, and a Masters of Business Administration from Ball State University. Dr. Kleyner is a Global Reliability Engineering Leader with Delphi Electronics & Safety and an adjunct professor at Purdue University. He is a Fellow of the American Society for Quality (ASQ), a Certified Reliability Engineer, Certified Quality Engineer, and a Six Sigma Black Belt. He also holds several US and foreign patents and authored multiple professional publications including two books on the topics of reliability, statistics, warranty management, and lifecycle cost analysis.

We're the best, we're number one, we're better than them, we've won more awards than our competitors, we've all seen those ads. While this form of advertising isn't unique, when's the last time it caused you to buy a product based on the ad. I think we all know that answer.There was a time when we relied heavily on print advertising to determine what products were available and from whom. The two primary methods to gain product awareness were print advertising and trade shows. While advertising and trade shows still exist, they are no longer the primary method of product awareness.31 years ago, beginning on April 30, 1993, all of that began to change. What happened on April 30, 1993? Public access to the Internet was born.Over the past 31 years, Internet technology propelled us into an age of self discovery. The older generation accuses the younger generation of always having their face in a screen. While that may be true, it's not always TikTok, Instagram, Facebook, or Snapchat. People today, particularly younger people, research products, technologies, and a host of other things online. Consumers today are far more educated on the products they wish to purchase them at any time in history.In what I find to be an exceptional irony, much of the industry responsible for building the technology behind Internet connectivity continues to advertise their products in a pre-Internet style.You may ask, what does this have to do with reliability? Building reliable products requires a net sum of a vast amount of best practices. One of those practices is insuring the right products, procedures, specifications, designs, and so many other factors are implemented.This goal cannot be accomplished by just reading advertisements from sellers. Frequently, engineers struggle to solve problems without a complete knowledge of the root cause of the problem. Particularly today, with so many in-house subject matter experts retiring, advertisements boasting the number of customers, time and business, and where they place in the hierarchy of competitive products do not assist the engineer and understanding the root cause of a potential problem, and certainly not the solution.Over the past several years, several companies in our industry have begun to change their advertising strategies from transactional, to transformational. That is to say they help to connect problems to solutions, more than merely hyping products.My guest today fully understands the value and effectiveness of what I like to call “Conscious Marketing “. Rick Short is Corporate Associate Vice President for Indium Corporation. Rick has been with the company since 1984 in capacities including Technical Service Manager, Marketing Director, International Sales Director, head of Technical Support, and head of Environmental, Health & Safety, in addition to his current role. He has an MBA from Ren-Se-Lere Polytechnic Institute, a bachelor's degree in business management from Utica College, and an associate degree from Mohawk Valley Community College.I talk with Rick about his company's unique approach to education and how that has helped to transform their customer base.

We've discussed the silver tsunami on the show numerous times, the unprecedented rate of which employees are retiring. When engineers and other employees retire from companies, they take with them more than a set of gold cufflinks or an engraved plaque. In many cases, they also take with them wisdom and knowledge.Perhaps this is never more true than in the case of my guest today. And who is that? My friend and colleague Doug Pauls.Doug Pauls holds a B.A. in chemistry and physics from Carthage College, Kenosha, Wisconsin, and a B.S. in electrical engineering from the University of Wisconsin, Madison. He worked nine years for the Navy, eight years as technical director of Contamination Studies Labs, and more than 20 years at Rockwell Collins (now Collins Aerospace), in the Advanced Operations Engineering group where he is a technical fellow and, a principal materials and process engineer. Doug was awarded the Rockwell Collins Arthur A. Collins Engineer of the Year Award in 2004 as well as numerous other awards.Doug is a long-time (and when I say long time I mean well over 30 years) IPC chairman and was awarded the IPC's Hall of Fame Award in 2017. Most notably, he is known for his expertise in surface insulation resistance testing, cleaning and cleanliness assessment, conformal coatings, and how to investigate and qualify manufacturing processes. He has been a U.S. representative to ISO and IEC working groups on SIR, electromigration, and cleanliness reliability standards. He has participated in numerous national and international consortia on electronics manufacturing materials and processes. He recently led a team of SMEs to redefine the cleanliness provisions of J-STD-001, culminating in what is presently J-STD-001H.To take liberties with a famous Mark Twain quote “rumors of my retirement have been greatly exaggerated”. For several years now, I've heard rumors of Doug Pauls retirement. Well, that day has finally come. I'll talk with Doug about his Long career within the electronic assembly industry. We'll talk about his triumphs and challenges, and his journey in this ever changing, dynamic, and challenging industry.If you're new to this industry, stick around because I plan on asking Doug for his advice to young people entering our world, the world of electronic assembly.

This episode was recorded at SMTA's Pan Pacific Strategic Electronics Symposium on the big island of Hawaii.My guests on this episode are Dr. Chuck Bower, founder of PanPac, Keith Bryant, and Dr. Ron Lasky.We discussed the history of PanPac, technologies introduced at PanPac, and what makes PanPac so unique. We also discuss Dartmouth College's unique engineering innovations program.

Optimization has become an important goal within the electronic assembly industry. While modern electronic assembly techniques utilize a variety of equipment, one specific type of equipment often consumes a disproportionate percentage of the overall equipment budget, that is the place machine. The cost of the machine, associated conveyors and feeders, require that the machine is running as often as possible.The airline Industry refers to this as “wheels up” time. Airlines make money when the aircraft is in the air “wheels up”. On the other hand, anytime the wheels are down, the aircraft is not making money for the airline.I listened to an interview a few years ago with the CEO of Southwest Airlines, a US discount carrier. Unlike most other airlines, Southwest does not charge its customers to check bags. The CEO was asked by the reporter why they have not joined the rest of the industry in charging for checked bags. The CEOs answer was genius. If Southwest Airlines began charging for check bags, it would actually slow down the boarding process as more and more passengers would drag their bags onto the aircraft most likely resulting in a number of those bags having to be checked at the gate. Southwest Airlines is famous for having the fastest aircraft gate turns in the industry, frequently under 30 minutes. Yes Southwest airlines charged for checked baggage, it would require more time at the gate before the next flight would be ready to depart. That would result in fewer flight segments per aircraft per day. In other words, allowing customers to check bags for free equates to more “wheels up” time and, subsequently, more profit for the airline.The same principal can apply to pick and place machines. When Pick and machines are running product, they are making presumably making money. When they sit idle, they are arguably costing money. What can assemblers do to improve the optimization or “wheels up” time on their pick and place machines?My guest today, Larry Welk believes he has an answer. Larry Welk, a.k.a. Professor spice is the co-owner of Smart Splice, a manufacturer of tape splicing tools.Larry will review tape splicing best practices and explain how tape splicing, when performed correctly, can lead to higher pick and place machine optimization.So, buckle your seatbelt this podcast episode is officially wheels up!Larry's Contact Information:Larry Welklwelk@smartsplice.comhttps://smartsplice.com/

This episode is a little different from our usual episodes. First of all, it's a dual-branded episode. It's both a Reliability Matters Podcast and an Ecosystem podcast episode. The Ecosystem podcast host Judy Warner will join me for an unusual topic, at least for The Reliability Matters Podcast. Most of my audience are assemblers of circuit assemblies. Our world begins with a bare board. I reminded of the biblical passage “the Wiseman built his house upon the rock”. Circuit boards are the foundation from which we build our products upon. There's so much that goes into the design and fabrication of a bare circuit board. Who designs these boards, what criteria were they given, what materials did they choose, where are they made, how much do they cost, and, perhaps most importantly in our world, how easy are they to assemble?To help answer these and so many other questions, Judy and I have assembled an expert panel of board designers.Our expert panel consists of Gerry Partida, Vice President of Technology at Summit Interconnect and Julie Ellis, Field applications engineering manager for TTM Technologies.Contact Information:Judy WarnerEEcosystem Podcastjudy.warner@impacttechmarketing.comJulie EllisTTM Technologiesjulie.ellis@ttm.comGerry PartidaSummit Interconnect gerry.partida@summitinterconnect.com

Today, we delve into an increasingly critical aspect of technology and electronics manufacturing - the pursuit of environmentally responsible electronics manufacturing. Our industry has witnessed many environmental revolutions.  The elimination of popular cleaning solvents brought on by the Montreal protocol in 1989, soon followed by strict VOC regulations pertaining to cleaning chemicals.The switch from lead-based solders to lead free alloys, led by the Restriction of Hazardous Substances directive, known as RoHS implemented within the EU in 2003 and adopted nearly worldwide, regulations regarding the disposal of electronic waste (e-waste) resulting in many countries mandating regulations and programs for the safe recycling and disposal of electronic products, and more.These regulations and others have inspired some companies to seek eco-friendly alternatives to traditional Printed Circuit Board (PCB) fabrication. The combination of numerous environmental regulations has resulted in many companies' implementation of sustainability programs.As our world becomes more connected, the demand for electronic devices continues to rise, and with it, the importance of mitigating the environmental impact of their production.On this episode of The Reliability Matters Podcast, I'll speak with Mark Edwards. Mark wrote an article entitled “Environmentally Responsible Alternatives to Traditional PCB Fabrication”, which of course, spurred my interest.Mark works as a Strategic Account Manager within MacDermid Alpha Electronics Solutions, on the global Business Development team for Circuitry Solutions. Mark has been involved in electronics manufacturing since the late 1980's and brings a passion for process automation, circuit assembly, solders/fluxes, adhesives, coatings and PCB fabrication – all with a focus on repeatability and reliability. Mark holds a B.S. degree in Mechanical Engineering Technology from Oklahoma State University and began his career at a defense electronics company in Dallas, Texas (that was later acquired by Raytheon). Mark has uncovered trends and synthesized customer needs for electronic hardware in the telecommunications, defense, automotive, industrial controls segments in the Americas, and now globally, in his newest role.Join me as we explore new materials and methodologies, and innovations that are shaping the electronic assembly industry towards a more eco-conscious future.Mark's Contact InformationMark Edwardsmarks.edwards@macdermidalpha.comhttps://www.macdermidalpha.com/circuitry-solutions

Today we're diving deep into the world of precision and craftsmanship—two crucial elements in the realm of hand soldering and rework of circuit assemblies.Whether you're a seasoned electronics enthusiast, a hobbyist, or just someone with a curious mind, this episode promises to demystify the art and science behind hand soldering and rework. We'll be exploring the latest tools, techniques, and trends that define this intricate process, shedding light on the unsung heroes who meticulously bring circuit assemblies to life, or in the case of rework, back to life.There is archaeological evidence that soldering was employed as early as 5,000 years ago in Mesopotamia. Soldering and brazing are thought to have originated very early in the history of metal-working, before 4000 BC. Sumerian swords from 3000 BC were assembled using hard soldering techniques.While soldering applications have morphed and expanded over the centuries, the basic “rules” of soldering have not. On this episode, we're going to talk about an obvious soldering application, at least to my audience, and that's soldering of electronic assemblies.From the evolution of hand soldering with numerous technological advancements to the challenges faced by DIYers and professionals alike, we've got it all covered, thanks to my subject matter expert guest, Debbie Wade. Debbie is the managing Director of ART A-R-T, Advanced Rework Technology, a fully independent training organization, which has been presenting various training courses for over thirty years. Debbie has been in the electronics industry for over 20 years with the last 15 of those years at Advanced Rework Technology. Debbie comes to us very well credentialed. She is the chairperson for the IPC-A-620 Training Committee and IPC European Training Committee, with her Master IPC Trainer status for IPC-A 600, 610, 620, 7711/21 and J-STD 001, she is an expert in the field of fabrication, assembly, process and acceptance of board and cable assemblies. Debbie has been presented with numerous awards from IPC in recognition of her contribution to IPC standards and training courses.So, grab your soldering iron (metaphorically speaking), get ready to dive into the flux, and join us as we unravel the secrets of successful hand soldering and rework. Stick around for valuable insights, practical tips, and maybe even a few stories from the trenches of hand soldering and re-work.Debbie's Contact Information:Debbie WadeMaster IPC TrainerAdvanced Rework Technology,debbie@rework.co.ukwww.rework.co.uk

Today, we delve into the crucial aspects of maintaining well-being on this journey—how to sidestep the notorious burnout, and perhaps more importantly, how to fuel and maintain your motivation. Because, let's face it, the road to creating a meaningful impact can be demanding, and it's essential to navigate it with resilience and purpose.Join me for a conversation with Rick Coulson. Rick recently retired from a 34 year career at Intel, most recently as a Senior Fellow in the Intel Optane Group. Rick is a passionate advocate for career sustainability and for servant leadership. Rick was awarded the Intel Achievement Award four times for his and his team's work on storage subsystems and SSD technology. He holds more than 90 Patents.Rick received his bachelor's degree in Electrical Engineering and Computer Science from the University of Colorado and his master's degree in Electrical Engineering from Stanford. He is currently a board member at Co-Serve International, a non-profit dedicated to teaching Servant Leadership around the world. With Co-Serve he has been to Kazakhstan 8 times. He's on the advisory board of Vooks, a company which produces award-winning books that are loved by parents and educators alike, and he's part of an additional stealth mode start-up (sounds mysterious). He enjoys mentoring and coaching, and today, he's my guest on the Reliability Matters podcast.Rick's Contact Information:rick.coulson99@gmail.com

We covered the topic of ultrathin conformal coatings back in November. We covered various conformal coating materials from traditional acrylics and silicones to ultrathin parylene coatings. What other coating materials are available? Where do these types of coatings fit within specific applications? Where do health and safety, environmental concerns, and sustainability programs fit in with a coating process?To answer these other questions, I invited Dr. Cassandra Zentner, VP of Health and environment at Actnano, a manufacturer of coating materials onto the program.Cassandra earned a BA from Oberlin College and a PhD in organic materials chemistry from MIT. Cassandra's Contact Information:Dr. Cassandra ZentnerVP of Health and EnvironmentActnanocassandra.zentner@actnano.comhttps://actnano.com

In today's increasingly connected and digital world, PCBs are the unsung heroes that power our devices, from smartphones to spacecraft. Yet, the art and science of designing these crucial components often go unnoticed. That's where this episode comes in. Today, I hope to shine a spotlight on the critical role PCBs play in modern technology and explore the best practices that drive innovation and reliability.In this episode, I hope to unravel the mysteries of PCB design, tackle complex challenges, and unlock the secrets to creating high-performance, efficient, and reliable circuit boards. Whether you're a seasoned PCB designer looking to sharpen your skills, a budding engineer eager to learn the ropes, or simply a tech enthusiast curious about the technology that shapes our lives, this episode has something for everyone.Today, I will be joined by Dr. Zach Peterson. Zach is a well-known researcher and electronics designer. In 2017, he founded Northwest Engineering Solutions as a technology consultancy and has since grown the company into an innovative design and manufacturing house for advanced electronic products.He conducted his Applied Physics Ph.D. research in ZnO random laser theory and stability and his M.Sc. Physics research in chemisorptive sensors for environmental monitoring at Portland State University. He also received his MBA (Leadership & Finance) from Adams State University. His work has been published in over a dozen peer-reviewed journals and conference proceedings, and he has written 2500+ technical articles on PCB design for a number of companies. He is a member of IEEE Photonics Society, IEEE Electronics Packaging Society, American Physical Society, and the Printed Circuit Engineering Association (PCEA). He previously served as a voting member on the INCITS Quantum Computing Technical Advisory Committee working on technical standards for quantum electronics, and he currently serves on the IEEE P31-86 Working Group focused on Port Interface Representing Photonic Signals Using SPICE-class Circuit Simulators.If Zack looks familiar, you may recognize him from the Altium On-Track and Altium Academy video series and Podcasts. Zach's Contact Information:Zachariah Petersoncontact@nwengineeringllc.comhttps://www.nwengineeringllc.com/

On this episode, I have no guests as this is the final episode of the Reliability Matters Podcast for the 2023 season. Instead, let's review what happened on the podcast this year.A special thanks to my guests and listeners/viewers for making this podcast so successful.

We are all aware of the damage electrostatic discharge can wreak on components and electronic products. We mitigate ESD damage through various forms of monitoring. We wear wrist and heel straps, stand on ESD-safe flooring, utilize ESD work stations, and more. We even have ESD testing locations that will test a human standing on a specialized testing station. But what happens the moment that person steps off the tester?My guests today are Dr. Daan Stevenson and Dr. Jonathan Tapson of IONA Tech, a manufacturer of a novel wearable ESD monitoring device that provides constant real time ESD monitoring.Normally, I don't talk about specific products on the show. We usually limit our conversations to best practices. This is a little bit of an exception to my normal rule. From time to time, a product is introduced that is so novel, it's worthy of a conversation. And that's the case here. Dr. Daan Stevenson is the Chief Executive Officer of IONA Tech. Daan has a background in mechanical and aerospace engineering. During his doctoral research, he studied the high voltage charging of spacecraft, which are electrical capacitors in the same way that the human body is. While working to design an automated ground station for UAVs, he frequently damaged electrical components from electrostatic shocks. This motivated the creation of IONA Tech, with the goal of advancing technology in ESD mitigation.My other guest is Dr. Jonathan Tapson, Chief Technology Officer of IONA Tech. Jonathan was Professor of Electrical Engineering at Western Sydney University before moving to Telluride Colorado in 2016. He spent his early career conducting sensor and instrumentation research, with a strong industrial focus. During this time he spun out three companies from his research, all of which are successful today. His specialties include low-noise circuits and systems design, mechatronic design and the integration of machine learning into real-time systems.Contact Information:Daan Stevensondaan@iona.techJonathan Tapsonjon@iona.techWebsite:https://www.iona.tech

Today we'll dive deep into the world of conformal coating. More and more assemblies are being subjected to conformal coating to protect the assembly from harsh environments. What's leading the drive to conformal coat electronic assemblies? What types of conformal coating options are available? What are the advantages and disadvantages of each type? For circuit assemblies, the protective embrace of conformal coatings ensures reliability, longevity, and performance. As technologies advance, so does the demand for innovative solutions to safeguard our electronic products. Whether you're a seasoned industry professional, a curious tech enthusiast, or just someone who's new to the world of conformal coatings, this episode is your go-to source for in-depth information on the growing trend of applying conformal coating to circuit assemblies.So, join us as we peel back the layers, and immerse ourselves in the world of electronics protection, and learn how conformal coatings play a pivotal role in keeping our devices humming, even in the harshest environments.To better understand conformal coating, I invited Lisa Rizzo to the show. Lisa is Senior Director of Strategy & Emerging Applications at HZO. HZO is a global leader & innovator in protective solutions that, according to them, “keep the world running”.They provide products to markets including consumer electronics as well as high-reliability markets including automotive, industrial, medical, and IoT to deliver a more resilient, reliable, and durable level of protection. HZO specializes in nanocoating solutions that safeguard electronics, electrical products & critical applications in an ever-changing market. Lisa Rizzo's Contact Information:lrizzo@hzo.comhttps://www.hzo.com/

We are all aware of the supply chain issues our industry has faced. Beginning with electronic components, it has spread to so many other types of parts are industry relies on. Fortunately, it looks like we are beginning to come out the other end of the supply chain shortage.But the supply chain problems have further spread to the labor market. If you are in a position to hire people for your company, you know firsthand how difficult that process can be today.Adding to the level of labor acquisition difficulties is the great “Silver Tsunami”, otherwise known as the great retirement.As I mentioned on our last episode, episode number 130, the fact is, baby boomers are entering retirement in greater numbers. According to government data, from now until 2030, 10,000 Baby Boomers each day will hit retirement age. Millions will begin to officially retire.Some of these retirees are designated subject matter experts within their companies. Not only are people retiring, they are taking with them a vault of valuable knowledge.This has created an even larger demand for consultants within our industry. I've had several industry consultants on my show over the last few years, including today's guest.And who is today's Guest? Legendary industry consultant, Bob Willis. If you've been in this industry longer than 18 seconds, there's a good chance you've at least heard his name. If you've been in this industry for virtually any length of time, there's a good chance you've seen his videos, read his books, or watched him present at numerous industry conferences and symposiums. If I reviewed Bob's complete professional biography, it would take an entire episode. Here's my conversation with my friend and colleague, Bob Willis.During our conversation, we discussed Bob's newest book, "Robotic Soldering Inspection and Defect Guide".Anyone who makes a donation to Bob's chosen charity will receive a download of his book as well as access to Bob's complete book collection: • Robotic Soldering Inspection and Defect Guide• Pin in Hole Intrusive Reflow Desing, Assembly & Defect Guide • Package On Package Assembly Inspection & Quality Control • Solder Paste Print Inspection & Defect Guide • Lead-Free Defect Guide 3 • Conformal Coating Inspection & Defect Guide • QFN LGA Assembly Inspection & Defect Guide • PCB Surface Finishes Inspection & Defect Guide • Cleaning & Contamination Defect Guide Click below for more information:https://www.justgiving.com/page/bob-willis-roboticsolderingbook

Some of you may recall episode 121 where I spoke with Dr. John Mitchell, president and CEO of IPC about his new book “fire your hiring habits”. During that episode, we talked about best practices for hiring the best people. I'd like to travel a little bit up the river to talk about where potential candidates for hiring come from. While most of the people we interview for positions within our companies come from other companies, more and more, we are seeing new people enter our industry. We've talked a lot about the “silver tsunami” affecting our industry.The fact is, baby boomers are entering retirement in greater numbers. From now until 2030, 10,000 Baby Boomers each day will hit retirement age. Millions will begin to officially retire. This is creating a terrific opportunity for young college graduates to enter our industry. Several years ago, I was a speaker at the SMTA, Pan Pacific strategic Electronics symposium in Hawaii. I shared my breakfast table with a longtime colleague, Dr. Ron Lasky, a professor at Dartmouth College. Over the course of breakfast, he asked me how I got into this industry and, more specifically, how I started my company. Dr. Lasky is an engineering professor at Dartmouth's Thayre school of engineering. He also teaches entrepreneurship to his soon to be engineers. Doctor lasky invited me to come to Dartmouth and speak to his students. I was more than happy to take him up on his offer, and I have spoken to his students on the subject of entrepreneurship every year for the past several years.I have been impressed by the emphasis on entrepreneurship within the Thayre school of engineering. We live in a time of marvelous evolution within the Electronics space. So many new and innovative electronic products are being introduced, fueled by IOT (Internet of things), the electrification of automobiles, advances in communication, and so much more.Education is the bedrock of our industry. It is the foundation for which much of our industry and the products we make are built upon. I've had Dr. Lasky on my show several times, and I thought it would be a great idea to invite his boss, the dean of Dartmouth's Thayre school of engineering onto the program.Dr. Alexis Abramson is the 13th dean of Thayer School of Engineering at Dartmouth. Prior to joining Dartmouth, she was the Milton and Tamar Maltz Professor of Energy Innovation at Case Western Reserve University and served as a director of the university's Great Lakes Energy Institute focused on creating sustainable energy technology solutions. During the Obama administration, Dr. Abramson served as chief scientist and manager of the Emerging Technologies Division at the US Department of Energy's Building Technologies Program. In 2018, she served as technical adviser for Breakthrough Energy Ventures, a $1 billion effort launched by Bill Gates to combat human-driven climate change. Abramson's research has focused on novel techniques for thermal characterization of nanostructures, the design and synthesis of unique nanomaterials for use in alternative energy applications, virtual energy audits for building energy efficiency, and strategies to accelerate technology commercialization at universities and research institutions.Dr. Abramson earned a BS and MS in Mechanical Engineering from Tufts University and a PhD in Mechanical Engineering at the University of California, Berkeley.https://engineering.dartmouth.edu

We talk almost exclusively about reliability on this show. Specifically, reliability of circuit assemblies. We discuss production best practices, design for manufacturing and reliability. Failure analysis, and more. We've reviewed the latest trends in industry 4.0, the connectivity of machine to machine and machine to management. We discussed big data and how to make all of our newly acquired data relevant and actionable. For all this to occur, our computers must function properly. They must perform the assigned tasks and communicate large sums of data. What happens to our production line if the computers stop functioning? What would happen if our network ceases to operate? We've all witnessed the airline industry grind to a halt recently due to computer failures and connectivity issues. The fact is, very few industries can function properly or even at all if the computer systems fail.I'm not referring to quality issues within the computer or network's internal circuit assemblies. I'm referring to malware, ransomware, and other nefarious actions brought on hackers with the intent to disrupt companies, industries, and governments, frequently with the goal of returning (or promising to return) your own data in exchange for an exorbitant payment.Our industry, like many others is completely dependent on computers and connectivity. Without ether, most production lines will simply sit idle. How can we avoid this terrifying scenario? How do hackers gain access to our computers and networks? How can we add reliability to our computer and network policies and procedures? To answer these and other related questions, I invited a network security expert on the show. Adrian Francoz, co-founder and CEO of Zeta Sky, a managed IT support and cyber security services company lives in the world of cyber security. He and his company protect their customer's networks through the implementation of security best practices and constant training, both for his customers, and for his own staff. After all, as I speak, hackers and other bad actors are hard at work searching for the next scam, vulnerability, and the opportunity to score a huge payday, all at our expense. In the Southern California area? Consider attending the inland Empire cyber security summit on Thursday, October 26 at the Chaffey College InTech Center, 9400 Cherry Ave, Bldg A Fontana, CA 92335.Register here:https://www.zetasky.com/inland-empire-cyber-security-summit-2023 Adrian's Contact Information:info@zetasky.comhttps://www.zetasky.com

Those of us in the electronic assembly space are no doubt aware of standards. In the simplest terms, standards tell us how to build products correctly. They differentiate correct from incorrect. They tell us what type of materials to use, how a solder joint is determined to be acceptable. Standards tell us how to test various parts of our assembly.How are the standards derived? Who determines what the standards are? How often are they updated?To answer these and other questions, I invited Leo Lambert onto the show.Leo is the author of several publications, including “Soldering for Electronic Assemblies”, published by Marcel Dekker in 1987. He has published and presented numerous papers relative to the subject of Soldering and Cleaning at various Technical Seminars and Exhibitions worldwide. Leo Developed, published, and conducted seminars entitled Deadline to Lead Free Seminars and Thriving in a RoHS/WEEE Environment.Leo received the IPC President's Award in 1989 for work conducted on solderable coatings for printed wiring boards.He is an IPC Hall of Fame recipient, Charter Member on UNEP (United Nation Environmental Program) Technical Solvent Options Committee, where he overseed the worldwide activities in reducing CFC's from use as cleaning material in Electronic Manufacturing resulting in the publication of the Montreal Protocol, an international treaty banning certain CFC-based materials.Leo is a Member of ICOLP (Industry Cooperative for Ozone Layer Protection). Leo is a recognized expert in standards and, he's my guest today on this episode of the Reliability Matters Podcast.Leo's Contact Information:Leo Lambertleo@eptac.comhttps://www.eptac.com

Welcome to another episode of the Reliability Matters podcast. For those of you keeping track, this is episode number 127.In recent episodes, we've covered high-level issues, such as hiring best practices, novel, training, methods, design for manufacturing, highly accelerated, life, testing, and more. On this episode, we're going to go back to the basics. What common problems are assemblers experiencing today? What are the basics of assembly best practices? Which problems seem to live in perpetuity?To answer these and other questions, I've invited two of my favorite experts on to the show. If you've been in the electronic assembly industry for some amount of time, there's little doubt you've heard of Phil Zarrow and Jim Hall. Phil has been involved with PCB fabrication and assembly for more than 36 years. Phil is the President and Principal Consultant of ITM Consulting. Jim Hall has been involved in the electronic assembly industry for the past 27 years. He's a principal consultant and resident Lean Six Sigma Master Black Belt with ITM Consulting. He's also an instructor in the Lean Six Sigma programs offered at Dartmouth College. Together with Dr. Ron Lasky, Phil and Jim designed the SMTA's SMT Processes Certification Course.A couple of years ago, Phil and Jim published a book in titled “troubleshooting electronic assemblies, tales from the board talk crypt”. I'll talk to them more about that book later in this broadcast.Phil and Jim host the popular audio series “Board Talk” a question and answer show hosted on the Circuit-Insight website. On their show, you'll hear serious questions, and often comical but real answers.Phil Zarrow's Contact Info:phil_zarrow@itmconsulting.comJim Hall's Contact Info:jim_hall@itmconsulting.comITM Consulting:https://itmconsulting.com

Moisture. The industrial world has been fighting moisture since the beginning of the industrial world. From a general point of view, moisture leads to issues such as • Mold and mildew • Rust • Wood rot • Damage to building materials • Microbial growth • And so much more.In the electronics world, moisture creates a host of reliability problems including: • Popcorning • Delamination of conformal coating • Corrosion • Electrochemical migration • Adhesion degradation (such as on labels and glues) • And moreI wanted to dive into moisture mitigation, so I invited two guests onto my show to discuss this very topic.Dan Jenkins is sales manager and partner of the Steel Camel, an industrial solutions company specializing in corrosion and water intrusion control for fuel systems and industrial equipment. Prior to Steel Camel, Dan worked as consultant and instructor in the crane accident prevention industry. He has consulted to large organizations such as Shell Oil, and the United States Department of Interior.Dan earned an MBA from the University of South Florida and earned his BA in Industrial Arts / Technology from Cal St. University Chico and his Post Secondary Teaching Credential from San Francisco State University.Bob Lowry has both BS and MS degrees in Chemistry. His experience includes 31 years as Sr. Scientist and Lab Manager for three integrated circuit manufacturing companies, where measurement of moisture and moisture control activities were a major part of services he provided.Dan has 20 years of experience consulting to the microelectronics industry on a wide variety of topics including materials analysis and measurements and methods of moisture control for electronic components. Bob is also the co-author of the book Hermeticity of Electronic Packages.Dan Jenkins' Contact Info:djenkins@steelcamel.comhttps://www.steelcamel.com/Bob Lowry's Contact Info:rlowry98@aol.com

As all of you are well aware, this show is all about reliability, specifically reliability of circuit assemblies. One challenge that seems to be persistent within our space is design for manufacturability or DFM. If you're a contract manufacturer, I have no doubt that you've had the experience of being asked to build a product that seems unbuildable. One example that rings true in my world was the introduction of bottom terminated components or BTC's. BTC's are marvelous components.Because all the lead terminations are below the part, they allow for highly dense component placement and highly miniaturized assemblies. They also presented a number of unique challenges in reflow, in many cases voiding, cleaning, and inspection. Like many other industries, we are not immune to the introduction of new technologies that may lack implementation knowledge. We then spend the next several years at technical conferences and symposiums learning us how to implement these new technologies. There are many acronyms in our industry that begin with DF… Design for testability, mechanical assembly, serviceability, reliability, and so many more. So many in fact, that there is a placeholder acronym for all of the various design fours refer to as DFx. Perhaps the holy grail of DFx is DFM, Design for Manufacturability as it encompasses so many aspects of assembly.To help us understand what exactly is DFM, I invited Andrew Williams to be my guest on this episode. Andrew Williams is the Engineering Manager for Electronics Manufacturing at PRIDE Industries. He has more than 30 years of experience in manufacturing and design and holds an SMT Process Engineer certification from SMTA and an IPC Certified Electronics Program Manager. Andrew is a guest lecturer at UC Davis and Cal State University Sacramento for Supply Chain Management, Operations, and TQM courses, and speaks frequently on DFM, DFS, and other DFX topics and today, he's my guest on the Reliability Matters Podcast.Andrew's Contact Information: Pride Industrieshttps://www.prideindustries.comandrew.williams@prideindustries.com

Industry icon Dave Hillman completed a 3,600 mile solo kayak journey down the Missouri River. I spoke with Dave about the inspiration for the journey, insights gained over his four-month expedition, and how his experience as an engineer helped him prepare for this epic experience.

We all strive to build products that are reliable. If you're listening to our watching this podcast, chances are you are concerned about or at least interested in reliability. Where does reliability start? Who is responsible for reliability? What types of reliability testing can be performed? My guest on this episode will help answer these and other reliability-based questions.My guest today is Dr. Christopher Jackson. Dr Chris Jackson is a leader, engineer and logistic specialist who has helped many organizations work towards realizing business goals through improving the reliability of their products and processes. He is cofounder of online training company IS4, founder of Acuitis Reliability, established the Center for the Safety and Reliability of Autonomous Systems (SARAS) at UCLA after retiring as a lieutenant colonel having served 17 years in the Australian Army, where he was the Senior Reliability Engineer. Dr Jackson completed his PhD in Reliability Engineering at the University of Maryland in 2011.Dr Jackson authored multiple reliability and management textbooks and teaches both professional education courses and post-graduate courses. Industries he has helped range from small satellites through to military vehicles. Dr Jackson is a Certified Reliability Engineer (CRE) through the American Society of Quality (ASQ), a member of the Institute of Engineers, Australia (MIEAust) and a Chartered Professional Engineer (CPEng).Chris was a guest on this podcast back in June of 2020 (episide 45) and I'm thrilled to have him back as my guest today.Dr. Jackson's Contact Information:chris.jackson@acuitas.comhttps://www.acuitas.com

When it comes to circuit assemblies, there are defects, which result in one of two situations. The preferred result of a defect is to capture it on your factory floor and repair it before it ships to the customer. The second scenario is referred to as an escape. That's when the board ships to the customer and fails in the field. This is a scenario, all assemblers dread and strive to prevent. One way to prevent escapes is through the use of automated inspection or AOI systems.My guests today are Arif Virani, Chief Operating Officer and co-founder of Darwin AI, and Bart Piwowar, CTO of Darwin AI, a manufacturer of innovative inspection systems.Arif Virani is a technology leader with over 20 years of experience in the industry. As Co-founder and Chief Operating Officer of DarwinAI, he spearheads the company's mission to transform manufacturing with a new standard for quality inspection using AI. DarwinAI's solutions have been implemented at the top Electronics Manufacturers to increase quality and efficiency, while reducing waste. DarwinAI was selected by CBInsights for its AI 100 annual list of the 100 most promising private AI companies in the world in both 2020 and 2021.Before founding DarwinAI, Arif had a successful career in management consulting at McKinsey & Company, where he advised F500 enterprises on technology investments and transformation. He led several technology-enabled programs, including building and commercializing data and analytics capabilities. Arif started his career working as a software developer at various technology companies. In addition to his work at DarwinAI, Arif is an Advisory Board Member of NGEN Canada's AI for Manufacturing Initiative. He has a Master's in Business Administration from the University of Pennsylvania's Wharton School and a Bachelor's in Applied Science (Computer Engineering) from the University of Waterloo.Bart Piwowar is an experienced Product Leader, leading high performing product teams driven by data to deliver solutions that solve customer's problems. He has spent many years leading data science teams, applying Innovation methodologies, and working with emerging technologies to bring solutions in many disciplines. He graduated from University of Waterloo with a degree in Physics and Computing and later followed with an MBA from Wilfrid Laurier University.Bart's career interests range from AI product development, decision science and entrepreneurship. I met Arif earlier this year at the IPC APEX Expo in San Diego California when he introduced me to his company's automated inspection system. Needless to say, I was truly impressed with their technology and I'm thrilled to have him as my guest on this episode of the podcast.Contact Information:Arif Viraniarif@darwinai.cahttps://darwinai.com/Darwin AI's YouTube Channel:https://www.youtube.com/@DarwinAI

Most of us are well aware of the supply chain shortages, both within our industry and well beyond. Some of us are also keenly aware of labor shortages. This show is all about reliability of circuit assemblies. While reliability is often referred to as a process, it is also rooted in culture.Reliability begins with people. So, instead of talking about common reliability, subjects, such as voiding, soldering materials, assembly, best practices, and the plethora of other usual suspect topics, I thought it would be a good idea to talk about people. After all, as I said, reliability begins with people.My guest today is Dr. John Mitchell. Many of you know John as the president and CEO of IPC, one of our industries largest trade associations. John has recently written a book, entitled fire your hiring habits. I have to admit, the title is quite intriguing.Here's a little background on John. Since 2012, Dr. John Mitchell has served as president and CEO of IPC, a not-for-profit trade association driving competitive advantage for more than 3,000 companies across the globe. Leading the global operations and staff, John manages the creation and execution of the Board of Director's goals.Under his leadership, IPC has essentially doubled the total company membership globally as well increased the acceptance of standards by over 50 percent. John led the charge for IPC's Online Certification Portal and the company's overhaul of it Member Success department. His efforts served to improve relations with members and helped move the needle on positive regulatory change.Prior to IPC, John was an engineer with General Electric Aerospace and was a founding member of Alpine Electronic's research company—which pioneered modern navigation systems in the U.S. OEM market. John himself holds a patent in GPS navigation systems. John then served as general manager/director of the largest product development initiative in Bose Corporation's history. He went on to become CEO of Golden Key International Society, the noted collegiate honor society serving over two-million members.John earned his doctorate in higher education management from University of Georgia's Institute of Higher Education, a Master of Business Administration from Pepperdine University, and a Bachelor of Science in electrical and computer engineering from Brigham Young University. In addition to his work with IPC, John is an in-demand speaker and the author of two books so far (sounds like more books may be in the works… I need to ask him about that!).Fire Your Hiring Habits is available at most book sellers including Amazon:https://tinyurl.com/fire-your-hiring-habits

Can reliability training the both entertaining and effective? The Manufacturing Game's Michelle Ledet Henley has a different approach to traditional training methods.Michelle Ledet Henley has worked with The Manufacturing Game since 1998 as a developer of new simulations and training material. She has traveled worldwide in her capacity as a facilitator and trainer for The Manufacturing Game and other simulations developed by Ledet Enterprises, Inc. Michelle has been instrumental in developing simulations with a focus on reliability, project management and distribution.She began her career with KPMG Peat Marwick in San Francisco, CA, and then worked for a real estate management and development firm in the Washington, D.C. area. Before joining The Manufacturing Game®, Michelle formed her own company, Innovative Interfaces, which provides computer programming services around the United States.Michelle has a bachelors of business administration degree from the University of Texas - Austin in Accounting and Information Services.Michelle's Contact Information:mrledet@manufacturinggame.comhttp://manufacturinggame.comlinkedin.com/in/michelleledethenleyThe following books were recommended on this episode:Don't Just Fix It, Improve Ithttps://a.co/d/gYvMKdIThe Story Telling Code by Dana Norris https://a.co/d/cCgTWNb

I first met my guest at the SMTA Pan Pacific Symposium in Hawaii this past January. He was presenting a paper entitled Quantum Technology, A Theoretical Overview of the Possibilities. The more I listened to and watched his presentation, the more I wanted to learn about quantum physics and mechanics. So I selfishly invited him onto my show today so I could learn more, and perhaps you can too.My guest today is Dr. James Whitfield. Dr. Whitfield is an associate professor of physics at Dartmouth. He earned his Bachelor's of science and chemistry and mathematics from Morehouse University and his PhD in chemical physics from Harvard University. He was a postdoctoral fellow at Columbia University in New York, Vienna Center for Quantum Science and Technology in Vienna and Gant University and Belgium, and he is currently an Amazon visiting academic and even better than all that, he's my guest today on the Reliability Matters Podcast.

The subjects of Industry 4.0 and Big Data have been widely discussed on this podcast. What is Industry 4.0? What data is our industry collecting? And, perhaps more importantly, how can we sift through all of that data to make it useful and actionable?To help answer these and other data-related questions, I invited Ryan Gamble, CEO and Founder of Intraratio on this episode. Intraratio Corporation is a company that provides on-premise and cloud hybrid software with platforms to track, manage, control, and automate the manufacture of advanced electronics. Intraratio serves the semiconductor, SMT, space/military, medical device and EV markets. Ryan earned a dual Electrical and Computer Engineering degree and spent many years in the semiconductor industry. He's responsible for improving product manufacturing and testing of commercial and space/military product lines including multi-core DSP, RF and Silicon Photonics devices. During this period he developed software systems to automate and manage quality and reliability of complex electronics, extending this to hyperscale web based platforms that interconnect factories globally.His passion is working with all levels, to identify and recommend solutions to business problems, based on a deep technical understanding of operational processes and product complexities.Ryan's Contact Info:rgamble@intraratio.comhttps://www.intraratio.com