1. © 2014 Mentor Graphics Corp.
www.mentor.com1
The Lean NPI Flow:
Seamless Integration of PCB Design
& Manufacturing Processes
Better for Design, Better for Manufacturing
David Wiens & Michael Ford
Mentor Graphics
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Mentor Graphics
2
 Electronic design automation (EDA) industry pioneer and global
innovator of advanced design solutions
 Founded in 1981
 Revenue ~$1.15B; 7% CAGR
 Market share ~23% of worldwide EDA market; ~45% of PCB
Source: EDAC Market Statistics

2. © 2014 Mentor Graphics Corp.
www.mentor.com2
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
The New Product Introduction (NPI) Process
PCB Design
Define the Product
NPI
 Optimize Product to Processes
 Prepare Process Instructions
Executing PCB Fabrication
Execute Manufacturing Process
Executing PCB Assembly
Execute Assembly Process
Design-Through-Manufacturing
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Why NPI Matters
4

3. © 2014 Mentor Graphics Corp.
www.mentor.com3
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Product Costs Are Committed In The Design Phase
$
70%
Design Manufacturing/Execution/Realization
Design NPI Ramp to
volume
Volume Sustain – End-of-Life
Cost incurred
Cost committed
Reduce costs by left shifting towards design
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Traditional NPI Process
 Where is the waste in the NPI flow?
– Call-backs from manufacturing
– Data reconstruction, misunderstandings & mistakes
 How many design revision spins during the NPI phase?
– Industry average: 2.8 design revision spins, per design
– (Aberdeen Research, Printed Circuit Design Integrity)

4. © 2014 Mentor Graphics Corp.
www.mentor.com4
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Best Practice NPI Flow Until Today – Putting Pieces Together
DFM verification at the design level:
– Based on manufacturing rules
– Reduced cost and first-pass yield
– With fewer design revision spins
Manufacturing-level product-data:
– Control over what is manufactured
– Eliminates data reconstruction & guesswork
Consistency in manufacturing:
– Multiple vendors, fabrication and assembly, from the same model
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Valor NPI
Lean NPI Flow 2014 - Let’s Look At How This Works

5. © 2014 Mentor Graphics Corp.
www.mentor.com5
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
DFM Left-Shifted - Now Embedded Into Design
 Valor DFM technology embedded in Xpedition:
– DFM in the context of the layout process
– Rules managed centrally for all
designers on the network
– Designer need not have
manufacturing domain knowledge
– Improve manufacturability at source
– Good news for manufacturing!
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Valor NPI
Intelligent, Integrated Product-Model Hand-Off

6. © 2014 Mentor Graphics Corp.
www.mentor.com6
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
ODB++ v8 in the Xpedition Lean NPI Flow
 Complete product-model
 Links product-NPI and process-NPI
 De-facto standard
 Structured, integrated
 No need for drawings
– Direct load into software-driven processes
– High automation
– High repeatability
– High quality
– Reduced supply-chain risk
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Process-NPI: Fabrication

7. © 2014 Mentor Graphics Corp.
www.mentor.com7
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Process-NPI: Assembly & Test
Valor Process
Preparation
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
Enterprise Global Build Process Preparation
14
 NPI once, not NPI again, over and over
 Central engineering libraries
 Auto-generation & simulation
 Product portability
 Integrated NPI & process
preparation, for EMS

8. © 2014 Mentor Graphics Corp.
www.mentor.com8
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
 We started with a complicated problem:
– A major bottleneck to business innovation & success
Summary
www.mentor.com
© 2014 Mentor Graphics Corp. Company Confidential
 We started with a complicated problem:
– A major bottleneck to business innovation & success
Summary
 We have achieved an industry first:
– A complete lean NPI flow
– DFM fully embedded into design
– Enhanced manufacturing product-model hand-off
– Immediate process preparation, globally
– Better for design, better for manufacturing

9. © 2014 Mentor Graphics Corp.
www.mentor.com9