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Features Articles

5G has great potential, but brings power challenges at the infrastructure and board levels.

5G network capacity is predicted to increase as much as 1000-fold by 2030. That's a stunning increase that can be attributed to effects such as our digital lifestyles and digital business transformation. Clearly, our dependence on online services that are available anytime, anywhere and at full speed shows no sign of abating. The effect on global energy demand could be even more stunning. The information & communications technology (ICT) industry currently consumes about 4% of the world's electricity, and this could increase to an amazing 20% with the growth of 5G networks. In absolute terms, that's equivalent to 150 quadrillion BTU per year.

Of course, 5G is huge, in scope as well as deployment. It covers low frequency bands, up to about 1GHz, although the main benefits of 5G are its ability to carry richer services that by their nature require faster data rates. These will push the limits of Frequency Range 1 (FR1) as defined by 5G standards, up to 6GHz in the FR1 range, and even higher in FR2 that extends into the millimeter-wave bands at 60-70GHz and even beyond. While services in the FR1 bands can support data rates of about 1-2Gbit/s, the higher bands are needed to support multi-gigabit data rates and latency of less than a few milliseconds.

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Don't be afraid to drop bad fit customers.

Since tax season is upon us, I recently had a chat with my CPA. She is co-owner of one of the largest accounting firms in my area and I've done business with her for over two decades, so we discuss business strategy in addition to going over the numbers. This year, she mentioned they were planning to rationalize their customer base, eliminating those who tended to provide incomplete records right before critical deadlines. She saw these clients as problematic to her business for two reasons: they overloaded resources and their behavior increased the probability her team would make a mistake.

There is a parallel in the electronics manufacturing services (EMS) industry. Ask any longtime industry CEO and they will say 80% of their issues come from 20% of their customer base. Why do EMS companies keep bad fit customers? There are a number of reasons:

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What’s best for your design may not be what’s best for assembly.

Printed circuit board assemblies animate a collection of components designed to do something useful. Joining those components on a board that completes the connections with a circuit pattern is the best solution we have to create modern electronic devices. The performance and reliability of the device is largely determined by interconnections on the PCB assembly.

The placement itself is a function of the signal connectivity on a local scale and voltage domains on a macro scale. More chips equal more voltage domains. Each IC requires dedicated support consisting of some or all of the following:

  • Passive components that do the grunt work of supplying and filtering power
  • External clocks for optimizing data flow
  • Local power supplies
  • Test points, connectors, etc.
  • Wherever the I/O pins take you in terms of neighboring components.
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Returning to a focus on soft skills will help industry find responsible employees.

For well over a decade, the number one question, complaint and concern I hear from businesspersons, regardless of industry or company size is: "Where is industry – any and every industry – going to find all the people necessary to actually build stuff?" And yet despite this serious workforce void, businesses continue to plan on a combination of reshoring product from distant lands or growing organically – which requires expanding their workforce. But how can you expand your manufacturing when the most critical ingredient – employees – is nowhere to be found?

Academia, from the earliest contact in elementary school to high school and right through university, has become misaligned with the real-world skills and education needed for a balanced and thriving economy. Yes, society needs doctors, lawyers, engineers and other more academically focused professions, but society also needs people with the interest and skill to touch and build product. In addition, there are real skills, education and training that together enable a worker to operate the complex and simple machinery and processes that successfully produce a multitude of technologically advanced, viable and sought after products. Maybe it is time to recalibrate our focus to some of the traits and skills that lead to success regardless of profession but appear to be currently missing in the workforce.

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Quality management systems will not work without engaged personnel.

It was just a few bolts. What could possibly go wrong?

In industry, but especially in the electronics industry, nothing has changed more over the past several decades than the concept and implementation of quality management. In the early 1980s it was inspect, inspect and inspect again. In the late 1980s and through much of the 1990s, the concept of Total Quality Management, or TQM, became the rage. Manage the process and involve all the shop floor employees and stakeholders and better quality will result – requiring less inspection.

During the 1990s and continuing into the new millennium, TQM became overshadowed by Six Sigma. Applying Six Sigma, including certifying employees as green or black belts, enabled greatly improved quality. To be Six Sigma meant 3.4 (or less) defects per 1 million parts. Achieving this level was impressive for sure.

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Making a board producible is entirely in your hands.

The goal of a good documentation package is that it is complete and coherent enough to proceed with the job without any explanations, waivers, errata or feedback of any kind. It doesn't always work that way, particularly when more than one vendor is involved. The fab drawing is more of a baseline from which they will all deviate to one degree or another. Even using the same vendor all the time is no guarantee that the DfM data come back immaculate.

The foundational aspect of PCB fabrication is a plausible phototool. That final imagery is derived from the artwork that you sent their way. What we know as global micro editing is where the phototool is crafted from the ECAD data. The artwork is more like a starting point.

Etch compensation – pre-distorting the artwork.The first item on the CAM operator's list is dealing with etch compensation. The traces and other geometry that appear on the board are what's left behind after the etch process. First, they must drill and plate the holes with copper. That's done prior to etching and adds a measure of copper to the entire panel. Only then do they mask off the circuit pattern that is not to be removed.

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