A printed circuit board (pcb) mechanically supports and electrically connects electronic components using conductive tracks, pads and other features etched from copper sheets laminated onto a non-conductive substrate. pcb's can be single sided (one copper layer), double sided (two copper layers) or multi-layer. Conductor on different layers are connected with plated-through holes called vias. Advanced PCB's may contain components - capacitors, resistors or active devices - embedded in the substrate.
Almost all electronics factory procurement staff have varied prices for the PCB confused too, even though some have many years experience in PCB procurement staff has also not all understand there is a world going on, in fact, PCB prices are set by a variety of factors consisting of the following:
Frist, PCB materials used diversity caused by different price
Ordinary double panel, for example, sheet metal generally FR-4, CEM-3, etc., thickness ranging from 0.6mm to 3.0mm, copper thickness from ½ Oz to 3 Oz is different, all of these on a sheet caused a huge price difference; in solder inks, oils and common photosensitive thermosetting there are some green oil price difference, which caused the price of different materials diversity.
Second, different production processes, PCB cause the price of Diversity adopted
Different production processes will result in different costs. If gold plate and spray tin plate, making the shape of the gong (milling) plate and beer (red) plates, using screen printing lines and dry lines, etc. will form different costs, causing prices to diversity.
Third, PCB itself diversity of different difficulty caused prices
Even if the same material, the same process, but can also cause difficulty in itself a different PCB different costs. If there are two kinds of circuit board 1000 holes, one board aperture greater than 0.6mm and the other one is less than 0.6mm aperture plate will form different drilling costs; same as the other two kinds of circuit boards, but the line width type A were greater than 0.2mm, less than a 0.2mm, will result in different production costs because of the high scrap rate difficulty plate inevitably increase the cost and cause the price diversity.
Fourth, different customer requirements will result in different prices
Customer requirements will directly affect the level of mill yield, as one kind of board by IPC-A-600E, class1 required 98% pass rate, but may be required by class3 pass rate of 90%, resulting in different costs MILL , leading to changing product prices.
Fifth, PCB manufacturers prices caused by different diversity
Even the same product, but because of technology and equipment from different manufacturers, different skill levels, will form a different cost, like many manufacturers nowadays produce gold plate, because the process is simple, low cost, but some manufacturers gold plate, scrap that rise, resulting in higher costs, so they prefer to produce spray tin plate, tin plate so they spray quote but lower than gold plate.
Sixth, the payment price differences caused by different
Currently PCB mill will generally be adjusted according to the different ways of payment PCB prices, ranges from 5% -10% range, which also caused the price difference.
Seventh, regional diversity caused by different price
Currently Geographically speaking, from south to north, prices showed an increasing trend, there are some differences in prices in different regions, and thus also caused the prices of different regional diversity of how to calculate the PCB quote!
1, plate costs (costs of different sheet type)
2, drilling costs (pore size and number of holes drilled impact fee)
3, process cost (different process requirements of the board of difficulty lead to different processes, as well as the price will vary)
4, artificial hydro plus management fees (this fee depends on the cost of each plant's control, relatively speaking, Taiwan-funded plants is low multinational)
These basic components, as the prices of raw materials Well, now basically stable, the possibility of a price increase is unlikely.
Here I come to be added more:
On the plate in terms of: the impact of price mainly to the following points:
1, sheet material: FR-4, CEM-3, which is our common-sided and multilayer boards, his price and intermediate plate thickness and the thickness of copper foil, whereas FR-I, CEM-1 of these The board is our single common material, and this material prices than the above-sided, multilayer big difference.
2, is the sheet thickness, the thickness of which is our common: 0.4,0.6,0.8,1.0,1.2,1.5,1.6,2.0,2.4,3.0,3.4, and our conventional plate thickness is not a big price difference.
3, is a copper thickness will affect the price of platinum, copper and platinum thickness is generally divided into: 18 (2/1OZ), 35 (1OZ) 70 (2OZ), 105 (3OZ), 140 (4OZ) and so on.
4, raw material suppliers, we have a common and commonly used to: Health benefits \ Jian Tao \ International etc.
Process costs:
1, depending on the PCB above the line, such as fine lines dense lines (in 4/4mm) below, the price will be another operator
2, there is a board there BGA, so the cost will be relatively increased in some places is how much money a BGA another operator
3, depends on what surface treatment, our common are: spray tin (HASL), OSP (green board), sprayed pure tin, tin, silver, gold, and of course different surface craft, the price will be different.
4, depends on technology standards; we used are: IPC2 level, but there will be higher customer requirements, (such as Japanese) Our common are: IPC2, IPC3, enterprise standard, military standard, and of course the higher standard , the price will be higher.
Each piece of PCB PCB industry are customers sell customized, so you need to quote the PCB costing, but also need to refer to the automatic imposition PCB computer calculations on a standard-sized CCL typeset material utilization to make Comprehensive quotes.
Costing PCB industry is the most special of all industries, the most complex, from a material, plate, forming, until FQC, packaging, warehousing completion, according to every process requires input material costs, labor costs, manufacturing costs, etc. stepwise accounting, and then based on the accumulated costs Order Product Code batches. And different types of products, which processes standard rates will differ. For some products, such as blind buried plate, gold plate, pressed copper base plate, because all processes or special materials, special requirements must be calculated using this method for the same reason, the drilling process will be used Drill Size affect the cost of the product, which directly affect the WIP costs, retirement calculation and assessment costs.
In addition, PCB factories belong Customer OEM products, different customized products are not the same, there is little sharing of products. On the other hand, considerations of quality, some customers may also specify a vendor substrate, ink, etc., in order to achieve the quality and cost control requirements.
Fast fish eat slow fish, only to respond quickly to change in order to survive
ECN (Engineering Change Notice) changes.
PCB industry production process often ECN engineering change, and there is often internal and external ECN ECN change (client project file changes) simultaneously. ECN frequent changes in product design, if not properly managed, resulting in scrap inventories will be very alarming. So, how to plan ECN product design changes in the application of ERP system is a very critical and important things.
If the matter ECN big change or small changes are expected to change the number of products and semi-finished products, will allow the staff of various departments have been unable to figure out whether each different version is compatible with other products, whether the number of different materials can be delivered, which will cause many WIP inventory or unnecessary in the event of retirement ECN product design changes.
Planning and establishment of BOM data.
BOM data base for the planning and establishment of PCB industry, foundations like the construction of a building as important foundations play well, the building must build it up, this is the inevitable truth.
Basic engineering data consists of two parts:
Basic materials data management.
Product Structure
BOM management. The PCB industry is the rapid development of the industry, the amount of materials and processes will be changed because of advances in technology, some materials and processes after a year or two years longer in use, because some of the materials and processes of production technology and R & D technology advances increased. Thus, in terms of the underlying data, PCB industry will have a lot of changes.
PCB industry is also characterized, for reasons of quality, some customers will clearly specify only accept a one or a few manufacturers of raw materials.
How to ensure delivery?
PCB industry, short delivery cycle, require the production of a single management control by the order to complete the production of the entire production process, which requires ERP system can provide production scheduling plan and manage work in progress, in order to ensure that the production delivery and customer responsiveness. Therefore, PCB's most critical competitive advantages: engineering research and development, production management, the material control, manufacturing, processing and other aspects of outsourcing, especially in the field of production management of WIP (work in progress) control. If WIP control properly, it will happen a lot of mixed version, lost, stagnation spin, allowed WIP quantity, feeding delays, increased the number of setups, delivery and other mismanagement unknown phenomenon.
PCB industry wide range of products, is generally based on the number of layers to distinguish, single sided, double sided, four-layer board, eight boards, 10 laminates, etc. PCB products, processed materials, process, process parameters, testing methods, quality requirements, etc., will be produced by the preparation instructions (MI) approach, issuing and processing instructions to the production department and outsourcing units.
For the four-layer board and the following products, the process is relatively simple, the production process the card can be done from scratch, tail, midway replacement process does not require the conversion process or card. As more than six boards blind buried plate products, because of the different inner and outer layers have different wiring diagrams, process or process parameters, but also the use of a different mold, film and other auxiliary equipment, you need to use different production instructions and related documents, the production process will produce different types of card production process, inner layer to control the type, the number of manufacturing process and the outer layer.
In the production process, the inner layer of plywood have different coding in the production process must be distinguished by different coding by different production processes card to control its production schedule. PCB production volume by card (LotCard) Migration handover ancillary products, commonly known several. As the production line product quantity, model complex, thus requiring several operations, scrap operations, repair operations must be simple, fast and fault tolerance. In the implementation process, I deeply felt universal ERP product is essentially unable to deal with this inner and outer encode, respectively, several were scrapped were feeding operations.
In general, the more detailed production planning, the more it gives a wealth of information, the more valuable it is also more difficult to calculate the corresponding. Production planning more rough, the less information, the lower the value. The PCB related to the process is often more complex, a complex process engineering data and MI multilayer PCB production often takes a long time to complete, and customer delivery is often very tight. For the PCB manufacturing industry production management operations are process-based manufacturing methods, it will be using a small schedule (Run Card schedule) management techniques. Therefore, it must be scheduled for the following PCB production process characteristics:
Reflow processing
PCB is more representative of the processing flow of the processing, the processing mode is different from the mechanical assembly, which is mainly composed of a main raw material input, the subsequent inputs materials, processing of raw materials are around the main processing. And as a result of multilayer technology, PCB industry reflux production (ie repeated one or a period of processing operations) situation is more and more common.
Cutting and lamination
Whether it is a part of the PCB or substrate processing the output of the preceding paragraph, must be experienced is the constant cutting. Front investment is substantial original cloth, in order to continue to meet the needs of the processing of subsequent processing, will continue cutting its size in order to become a reasonable follow-up treatment. Another step is press fit, either anterior or posterior segment processed substrate processing plywood, laminated work need to be, coming two areas of the same shape as a piece of laminated boards, laminated plywood case is particularly evident .
Cutting and lamination of this characteristic, that the finished product requires a certain amount of processing what quantity of raw materials, the number is converted to a large number of small plates plates, thereby calculating the number of raw material inputs. Circumstances scrap / waste but appears, and then combined with the use of materials and his son work order of proportion, sometimes resulting in an increase in workload and PCB factory processing flow is not smooth incoherent.
Monolithic scrapped
Different industries and assembly scrap, PCB's retirement in addition to retirement (excluding the discarded products) in addition there are the so-called monolithic scrapped. The reason is that lamination process is usually carried out for the big board, a large number of plates is generally the final output ranging from single products. When defects occur before the lamination process, resulting in poor quality of a point on a single panel A or B, the production staff could not simply discarded the big board, but continue to use the material, but will be recorded for the single panel a single scrap quantity.
For example, a large plate A can eventually cut into 16 small PCB board, and the current processing steps due process issues, resulting in corrupted at some point the board, so the results of the batch processing of large plate scrap is 0 ( No scrap the entire piece), but as a single scrap. This number will be back with the cumulative flow processes, as well as the production of the final product output statistical purposes. This time should be noted that the number of single scrap of cooperation in the industry through the pressure is inherited double plate. Because the single panel A and panel B single nip, the dead pixels in the projection panel A B will cause dead pixels, the resulting double sheet will not be used at this point to form the same number of single scrapped number.
Finally, PCB industry is a foundry industry, product design changes very frequently, often change versions. Once the customer to change the version, manufacturer instructions and process card must meet to change, and even some changes, some cases may occur without changes.
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