IPC Smart Factory Standards

Powering Industry 4.0

David Bergman VP Standards & Training, IPC

Manufuture October
2017
 Our Mission

IPC is an industry association supporting electronics

manufacturing globally and dedicated to the competitive
excellence and financial success of its member
companies worldwide.
History

Founded in 1957
as the Institute of
Printed Circuits

Six Founding Member

Companies were
dedicated to growing the
Printed Circuit Market
Who Do We Serve? 4300+ Global members
 Worldwide Locations

Europe (2004)
Brussels, Tallinn China (2002)
Stockholm, Moscow Qingdao, Shanghai,
Shenzhen,Beijing,
Suzhou, Chengdu

India (2010) SE Asia (2012)

USA (1957) Bangalore
Bangkok
Bannockburn, IL (headquarters)
Atlanta Georgia
Taos, NM
Washington DC
Members Blanket Electronic Manufacturing Supply Chain

9% 10% PCB Manufacturers

23% EMS Companies

34%
Suppliers

25% OEMs

Government/Academia
How Does IPC
Strengthen
the Industry?

• Coordinates global collaboration on the

development of industry standards
• Provides standards training
• Conducts and shares market research
Standards
How do you communicate with your
customers?
With your suppliers?
 Supply Chain Management
9850
SMEMA 9853 NEW!
Assy Mtrls AOI
Assembly J-STD-004
J-STD-005
materials IPC-HDBK-005
J-STD-006
Solder
IPC-SM-817 Flux IPC-4101, 4104,
IPC-CC-830
Cleaner
4202, 4203,
HDBK-830 4204
……
Third-party
LAB

IPC-TM650
Components
Components J-STD-020
J-STD-032
Compo IPC-9691

J-STD-033
IPC- 9501
nents IPC-1751
IPC-1752
IPC- 9502
……

J-STD-001

laminates PCB EMS OEM

Subtrates
IPC-4101, 4104, IPC-6011, 6012, IPC-A-610
4202, 4203, 6013, 6017
4204

IPC-A-620 IPC-7711/21
IPC-A-600
History of IPC in Intelligent Manufacturing

11
 Printed Circuit Board Intelligent Data

IPC-D-350 Printed Board Description in Rev D 7/92

Digital Form; Technical Rev C 10/85
Content Identical to IEC- Rev B 8/77
61182-1 Rev A 2/75
Orig. 8/72

12
 Factory Automation
Merged with Surface Mount Equipment Manufacturers Association 1998

• SMEMA 1.2. The purpose of this standard is to provide an equipment interface

specification for board transfer manufacturing systems of surface-mounted printed
circuit boards.
• IPC-2531 Standard Recipe File Format Specification, originally published in 1999. The
intent of this specification is to provide a standard method for developing process
control files used by electronics manufacturing equipment. Process control files
(often referred to as recipes) provide the instruction sets used by assembly
equipment to accomplish specified tasks.
• CAM-X IPC-2541 Generic Requirements for Electronic Manufacturing Shop Floor
Equipment Communication Orig. 10/01. This standard establishes requirements and
other considerations for the interchange of information between electronic
manufacturing software equipment and factory information systems.
13 IPC Confidential
14 IPC Confidential
 What Is “CFX”?
Trigger: A Critical Mass of “Pain”
• Challenges of Industry 4.0 / smart / digital factories
• Difficulties to acquire live manufacturing data
• Multiple redundancy of effort of data capture
• Time for “IoT” style communication vs. acquisition!
 What Is “CFX”?

• Task Group is named: “Connected Factory Initiative”

• Standard will be named “Connected Factory Exchange” (CFX)

• Committee Chairs:

Software Provider Tier-One Manufacturer Machine Vendor

Jason Spera Mahi Duggirala Marc Peo
CEO Director Enterprise Solutions, IT President
Aegis Software Flextronics Heller Industries
What Is “CFX”? Connected Factory Initiative: Task Group
• Aegis Software - Horsham PA
• Aegis Software – UK
• ASM Assembly Systems - Suwanee GA
• ASYS - Dornstadt Germany
• AT&T - Park Ridge IL
• AT&T Services, Inc - Durham NC
• Cimetrix Inc. - Midvale UT
• Cogiscan Inc. - Bromont QC Canada
• CYTIot, Inc. - San Mateo CA
• Essemtec AG - Aesch Switzerland
• Europlacer North America - Tampa FL
• FlexLink Systems, Inc. - Allentown PA
• Flextronics International - San Jose CA
• Fuji America Corporation - Vernon Hills IL
• Fujitsu Network Communications - Richardson TX
• Heller Industries Inc. - Florham Park NJ
• Jabil Circuit, Inc. (HQ) - Saint Petersburg FL
• Juki Automation Systems, Inc. - Morrisville NC
• Juki Corporation - Tokyo Japan
• Keysight Technologies - Loveland CO
• Keysight Technologies - Singapore Singapore
• KIC
• Mentor Graphics (Ireland) Ltd - Shannon Ireland
• Mentor Graphics-Valor Divison - Rancho Santa Margarita
• Microscan Systems Inc. - Renton WA
• MIRTEC Corporation - Oxford CT
• Miyachi Unitek Corporation - Monrovia CA
• Mycronic Technologies AB – Taby
• Northrop Grumman Corporation - Baltimore MD
• Omron Electronics LLC - Hoffman Estates IL
• Samsung C&T Automation, Inc. - Irvine CA
• Samsung/Hanwha - Seongsan-gu South Korea
• Trans-Tec America - Chandler AZ
• Universal Instruments Corporation - Conklin NY
• Viscom Inc. - Duluth GA
 What Is “CFX”?

CFX Mission:

• Create a single, common standard for data exchange (plug & play)
• Enable modern, smart, digital, computerized Industry 4.0 solutions
• Eliminate waste & enable value creation throughout the industry
• Be accessible to companies in all sizes and sectors

CFX is the IoT standard for assembly manufacturing

 What Is “CFX”?

CFX Mandate:
• “Plug and play” IoT communication standard
Plug
Bi-directional
• Bi-directional exchange of information and play

• Connect every process, automated,

semi automated & manual Connected Inclusive Adaptable
• Inclusive of bespoke processes, such as
functional test

• Adaptable for new automation and robotics

Introduction to
The IPC CFX Standard
 CFX Architectural Overview

CFX Principles: The search for modern IoT technology

Communication
Content is Encoded and
Protocol
sent using the Protocol

Language
Content
 CFX Architectural Overview: Communication Protocol
• Baseline Transport Protocol:
• Research:
• Months were spent to find the best
protocol solution considering
different viewpoints used:
(scalability, failsafe, mission-critical
data, IT friendly)
• Decision: AMQP v1.0
• Event data needs to be sent reliably
to potentially many users (broadcast)
• Minimize the communication
overhead for machines and
processes
• Slight delays are not seen as critical
• Suitable also for point to point data
(e.g. commands, requests)
 AMQP 1.0 Flexible Message Transfer Protocol

Enterprise Highlights:
Software Systems

• Established standard with built-in security

• Omni-directional

• Open source brokers available

Host or
Broker • Equipment vendors are insulated from the
Test Equipment
Automated
Material Handlers complexities of routing etc.

• Ease of development / implementation

Process &
Assembly Machines
 Encoding By JSON

Highlights:

• Very light encoding format

• Easy “upgrade” from XML

• Libraries available in all development

platforms

• Simple to use

• Modern & popular

CFX Content Definition
 CFX Content – The “Lego Brick” Approach
The Challenge:
• There are a wide range of complex processes:
• Assembly, placement, test, printing, marking, routing, soldering, bending,
repairing, programming, packing etc.
• Many “hybrid” processes exist:
• e.g. Placement machine with optical inspection
• Who knows what new processes will come…
 CFX Content – The “Lego Brick” Approach
The Solution:
• Break every process down into distinct components (bricks)
• Every process / operation can then be “built” by the
combination of appropriate bricks
• New processes can be defined without the need to update
the standard
• Applies to many types of assembly and other processes, including
business, transactional, robotics, electro-mechanical etc.
 CFX “Brick” Culture

= CFX Example
Applications

PCB Arrives
Product Tracking
Stop / Start
Asset Utilization
Material Trace
Material Traceability

Visual Check AOI Closed Loop Application

PCB Leaves

Broken-down Process Constituents

 IPC CFX Standard & Industry 4.0
• IPC CFX:
• Designed for IoT Manufacturing, for everyone
• Electronics assembly, mechatronics, and beyond
• Secure, simple, standard

• Industry 4.0:
• The business case of manufacturing
• Computerizations control automation
• Connected machines, lines, factory, enterprise

What we learned:
1. CFX: The Connected Factory Exchange
2. How to be a part of the Smart Factory, Industry 4.0
 IPC CFX standard timeline

Q3 IPC meetings APEX Meetings

Sept 2017 Feb 2018
• Review content / • Results / examples of
structure to date trials

APEX Meetings Productronica Voting

Feb 2017 Nov 2017 Expected by Summer
• Decide transport • Initial demos (planning) 2018
mechanism

Developer Toolkit to be donated as Open Source software Q4 2017

 IPC CFX Standard & Industry 4.0
Thank-you!

Next Steps:
• Please contact IPC if you have any comments or questions

David W. Bergman
Vice President Standards & Training
IPC - Association Connecting Electronics Industries
3000 Lakeside Drive Suite 105N
Bannockburn, IL 60015-1249 USA
DavidBergman@ipc.org
www.ipc.org
 Backup slides

32 IPC Confidential
 What is Industry 4.0?

What is

INDUSTRY
 What is Industry 4.0?

Business Perspective: Technical Perspective:

• German Government Inspiration • Computerization of automated processes

• Small / medium enterprise initiative • Computerized, live decision-making, not just

a single solution
• Manufacturing close to the market
• Use of live data in computerizations
• No distribution chain business case
• Many sources, many consumers
• Flexible “build to order”, but mass
production efficiency
 What is Industry 4.0?

Values & Benefits:

• For Manufacturers: • For Solution Suppliers & IT:

• Lower-cost, flexible manufacturing • Computerized decision-making solutions of many

• Re-shoring opportunity to reduce global risk types

• Focus on added value software development

• For Machine Vendors:
• More efficient “connected” automation

• Reduce the number of “MES Interfaces”, to one

• Value creation opportunity for Industry 4.0

 CFX Message Name Architecture

Root Level 1 (Topic) Level 2 (Sub-Topic) Level 3 (Sub-Sub Topic)

SMT Assembly
Assembly
THT Assembly
PCB Paste Inspection
Test and Inspection
PCB Inspection
Solder Paste Dispensing
Application Solder Dispensing
Coating
CFX Production
Thermal Processing
Processing
Cleaning
Casting and Molding
Machining
Forming
Loading and Unloading
Packing
 CFX Message Name Architecture

Root Level 1 (Topic) Level 2 (Sub-Topic) Level 3 (Sub-Sub Topic)

SMT Placement Performance

THT Inserter Performance
ResourcePerformance Solder Paste Printer Performance
Dispenser Performance
Reflow Oven Performance
Sensor Identification
Storage Automated Storage
CFX
Management MSD Management
Materials
Consumption
Transport
Unit Validation
Work Order Management
Information
Production Scheduling
Quality Management
Examples Of CFX Message “Brick” Mapping

Example 1: Simple SMT Placement Machine

Color Coding:

Green: Publish

Yellow: Consume

Blue: Publish & Consume

Examples Of CFX Message “Brick” Mapping

Example 2: Intelligent SMT Process

Color Coding:

Green: Publish

Yellow: Consume

Blue: Publish & Consume

Examples Of CFX Message “Brick” Mapping

Example 3: Stencil Printer with SPI

Color Coding:

Green: Publish

Yellow: Consume

Blue: Publish & Consume

Examples Of CFX Message “Brick” Mapping

Example 4: MES System

Color Coding:

Green: Publish

Yellow: Consume

Blue: Publish & Consume

 CFX Message Types

Type Flow Recipient

Event Publish / Emit (Outbound Flow) Any Number of Recipients

Request Source -> Destination 1 Targeted Recipient

Response Destination -> Source Originator of Request

Broadcast Request Source -> Destination(s) Any Number of Recipients

Broadcast Response Destination(s) -> Source(s) Any Number of Recipients

Message Clarity: Different types of messages applicable for different purposes

 CFX Message Envelope

Field Description

Name of the CFX message contained within the transmission

MessageName
(e.g.CFX.Production.WorkStarted)

Version The version number (revision) of this published standard

Timestamp The date and time when the occurrence of the event took place (ISO-8601)

UniqueID A globally unique ID identifying the “conversation” of messages

Source The CFX identification of the creator / publisher of this message

RequestID For Response type messages, it is the conversation ID of the Request

Message Integrity: Ability to keep track of discrete conversations, requests, commands

 Structure of CFX Messages

• The messaging structure is based on a hierarchy of levels of “bricks”

• Each CFX message is named so as to know where in the structure it lies

Root: “CFX”

Level 1: “Topic” e.g. Materials

Level 2: Message e.g. Consumption

Example message looks like “CFX.Materials.Consumption.MessageName”

 Level 1 CFX Message Names - Topics

• CFX: • CFX.Sensor:
• Root level - connection status, identification etc.
• ID readers, temperature / humidity sensors etc.
• CFX.Production:
• Affect or impact units of production as part of the • CFX.Materials:
production process
• Consumption, spoilage, setup verification, storage
• CFX.ResourcePerformance:
and movement
• Activity of the production resource / production process

• CFX.Information:
• Factory control and management (routing,
schedule, quality) etc.
 Application & Value Examples
• CFX Is a Key Ingredient For:
• Machine to machine data exchange
• Machines & processes to factory
• Factory systems to machines & processes
• Transactional events
 Application & Value Examples: Machine - Machine
• Closed Loop Feedback:
• Dynamically change operation “A” using feedback “B”
• For example: AOI to SMD placement adjustment

• Machine Vendor / Lean Process Enhancement:

• Machine vendors provide closed-loop Industry 4.0 solutions
• Works with any other in-line equipment “off the shelf”

• Machine Vendor / Lean Process Enhancement:

4.0
• Lean Six Sigma live computerizations

INDUSTRY
• Enables control of any process, based on measurement

Applies to all processes,

not just machines…
 Application & Value Examples: Processes - Factory

• “Big Data” Collection:

• Many different types and sources of data
• Collected, contextualized and analyzed
• Local & enterprise Business Intelligence

• Applications:
• Productivity, efficiency and OEE
• Reports, dashboards, alerts, opportunities to improve
• Planning, including capacity planning, flexibility
• Supply-chain control, JIT material delivery, resource management
• Traceability (IPC-1782)
Industrial Engineering & MES
taken to the next level
 Application & Value Examples: Factory - Processes
• Operational Data:
• Engineering data (programs, documents etc.)
• “Poke-Yoke” control
• Material information (supply-form, vendor exception)
• Product data (production unit information) POKA YOKE
• Applications:
• Automated changeover preparation
• Setup optimization
• Active quality management
(MISTAKE PROOFING)

Live & Real-time Process

optimization / Factory Control
 Application & Value Examples: Transactional

• Automated Transactions:
• Stock purchase / material movement /
back-flush
• Tool and machine maintenance
• Program / document setup
• Applications:
• Enhanced ERP / MRP
• Resource reservation & management
Error proofing critical
dependent transactions