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National Aeronautics and Space AdministrationAutomotive Specifications/ElectronicPartsLower Cost and Acceptable Performance?NEPP Class D Workshop, September 24, 2013Michael J. Sampsonmichael.j.sampson@nasa.gov301-614-6233NASA GSFC Safety and Mission Assurance DirectorateNEPP Co-managerhttp://nepp.nasa.govDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.
Overview The Concept The Pluses, Minuses, Challenges, Questions andSurprises Preliminary ConclusionsDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.2
The Concept First a Premise: automotive parts (AEC) liesomewhere between Commercial-Off-The Shelf(COTS) and military (MIL) for:– Robustness– Quality– Reliability– Performance– Size– Information Availableto the gear-space-shuttle-3000lb-gorilla.htmlDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.3
So ? Use Automotive Parts (AEC) and:– Buy in Bulk – Use Price Breaks– Test Large Sample (10%?)– Characterize and Test Extensively with Maximum DataCapture to Allow Intense Statistical Analysis– Screening Only For: Removal of Outlying Populations: Rejection of Anomalous Lots– Maximize Stress and Time for Board-level TestingDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.4
However, What is an AEC Part? This is a Complex Question, One We are Still LearningAbout (and probably will be for years)Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.5
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AEC Council ber Company Tier1 AutolivSustaining Member2 Continental AGSustaining Member3 Delphi Automotive Sustaining Member4 Gentex CorpSustaining Member5 HarmanSustaining Member6 Johnson Controls7 TRW8 VisteonSustaining MemberSustaining MemberSustaining MemberFounded Current HQ1953 SwedenRevenuesProducts 8.3B (US 2011)Seatbelts, airbags, steeringwheels, safety electronics,active safety productsTires, brake systems,automotive 30.5B (Euro 2011) safety and communicationssystemsVehicle Electronics, systems,1994 USA (Michigan) 16B (US 2011)modules and componentsautomatic‐dimming rearviewmirrors and camera‐based,1974 USA (Michigan) 1B (US 2011)lighting‐assist and driver‐assistfeatures to the globalautomotive industryaudio, electronic, andinfotainment systems forautomotive OEM's, home andcomputer1980 USA (Connecticut) 3.8B (US 2011)systems,loudspeakers andelectronics for audioprofessionals1871 Germany1885 USA (Wisconsin)1901 USA (Michigan)1999 USA (Michigan)# of Employees # of Countries4800029Considered a Swedish/American company after mergerof Autoliv AB and Morton Automotive Safety 6http://en.wikipedia.org/wiki/Continental AG146,60032http://en.wikipedia.org/wiki/Delphi rg/wiki/Harman International Industries#Automotive systems100001996 Acquired Prince Automotive and greatly expandedits automotive interior systems businesshttp://en.wikipedia.org/wiki/Johnson Controls 42B (US 2012)automotive interiors, carseats,batteries, climatecontrol, facility management 16.2B (US 2011)Steering systems, Foundationbrakes, ABS, Electronic stabilitycontrol, Driver assist systems,Chassis electronics, Powertrainelectronics, RF products, Airbags,Seat belts, Steering es/FINAL 2012 TRW Profile Presentation Feb 24.pdf 13.8B (US 2012)audio and infotainment,instrument panels, driver info,displays, control panels,powertrain/engine y/profile.htmlDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.1700008
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Minimal coverage of radiation effectsDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.13
Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.14
Scope of AEC Q100 Integrated CircuitsDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.15
Automotive Part Grades e‐40 C to 150 C‐40 C to 125 C‐40 C to 105 C‐40 C to 85 C‐0 C to 70 CAEC 100MicrocircuitsXXXXXAEC 101 Discrete SemiconductorsDiscretes except LEDsLEDs‐‐X‐‐‐‐X‐‐Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.AEC 200PassivesXXXXX16
Quality System Automotive Quality System utilizes ISO 16949 Process approach to Quality System Required audits:– Internal audits utilizing trained auditors be performed on aperiodic basis.– External audit certification by 3rd party organization as perparagraph 7.4.1.2– External audits performed on a 2-3 year cycleDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.17
Audits ISO 16949 and ISO 9000:2008 audits– Process based audits– Internal audits– External audits Manufacturers (Ford, Delphi, Toyota etc) typicallyperform supplier audits for the following:– Process based audits– Initial qualification– Candidate suppliers– Component failures?Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.18
AEC Certified Products Component Supplier successfully completesqualification test requirements of AEC-Q100, 101,200 etc. Supplier claims AEC certified based on selfcertification using AEC Q101 test results. May be certified to ISO 16949 “QualityManagement Systems – Particular requirementsfor the application of ISO 9001:2008 forautomotive production and relevant service partorganizations”.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.19
AEC Compliant Products AEC Compliant is defined as:– Automotive product meets the intent andrequirements of the AEC specifications,– NO Self certification– No ISO 16949 certification, but typically certifiedto ISO9000:2008 Can’t be certified to ISO-16949 if the supplier does not own allprocesses from start to finish (i.e. wafer fab, packaging etc.)– Does not supply sufficient product volume to themajor auto manufacturers– Typically not a supplier to an automotive Tier 1 orTier 2 userDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.20
AEC Certified versus AEC CompliantProducts Not all automotive electronic component suppliers’components are AEC Certified, some are only AECCompliant!Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.21
Qualification Testing: Automotive versusMilitary Automotive Qualification testing consists of:– Basic Electricals 100%– Qualification tests for electrical and environmental testsperformed on sample sizes ranging from 5 to 77 devicesdepending on test method.– ESD testing utilized human body model, machine model, andcharged device model Qualification for Military product consists of:– Electrical and environmental screening is 100%– Conformance inspection done on sample basis ranging from22 to 116 devices.– 1000 hour life test completed.– ESD testing utilizes human body model onlyDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.22
Screening: Automotive versus Military Automotive screening (not a requirement) consists of:– Basic Electricals 100%, perhaps not all parts or all vendors– Part specific electrical tests may be on a sample basis– Environmental testing typically not part of screening other thanqualification Screening for Military product consists of:–––––Screening completed on every inspection lotElectricals done 100%Burn-in and life testEnvironmental testing done 100%Exception is ‘JAN’ grade devices which is similar to theautomotive grade devices.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.23
Automotive EEE Part Origins Automotive grade discrete semiconductor partsare typically not manufactured in the UnitedStates– Typical wafer fabrication facility is in China or Taiwan– Assembly facility typically in ChinaDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.24
Comments NASA and Government Space in Total is aDifficult Customer:–––––Low Quantity Procurement and Thereby DollarsVery DemandingDoes Lots of TestingIntense Follow-up for ANY Non ConformancesCarefully Regulated Procurement NASA’s Low Procurements Afford MinimalInfluence in a Process Designed Around CloseRelationships Between Suppliers and Users – FAR/Legal IssueA Few Manufacturers Provide Hermetic Automotive GradeDevices.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.25
So How Could NASA Benefit? Three Advantages Typically Claimed for “COTS”– Lower Cost– Greater Performance– Faster Delivery A Following Chart Shows Cost Comparison for TwoExamples Similar Analysis Required for More Popular PartsActive and Passive A NEPP Study to Provide a More Thorough Analysisis UnderwayDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.26
Some Cost Comparisons100 piece orderPart0.1 uF/50 VCeramic ChipCapacitor2N2222ATransistorGradePackageUnit Cost ( ary18120.68Space1808 taryTO-185.02SpaceUA38.00Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.27
Concerns Automotive grade EEE parts are rated for automobileenvironment (in cabin or under hood) – not space!Not all automotive grade EEE discrete semiconductor partsare constructed to the same reliability levels:– A few manufacturers design for a 25 year life, other suppliersdesign for a lower design life.Automotive grade EEE discrete semiconductor parts are amixture of AEC certified and AEC compliant devices. Not allautomotive electronic component suppliers components areAEC Certified, some are only AEC Compliant!The user has to understand what they are buying!!!The close ties and interdependency between the supplier andthe user that is integral to the AEC process is a challenge forgovernment users, perhaps insurmountable– FAR?– Procurement quantities far too small to attract the supplier’s interestDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.28
Acknowledgements Mr. Jeff Jarvis, US Army AMRDEChttp://elsmar.com/Forums/showpost.php?p 142002&postcount 41http://www.ehow.com/about 5031167 t.aspx?page rg/source/Orders/index.cfm?title 2companies-25430.htmlMr. Pat Sanchez and Mr. Chris Velador, Semtech CorporationMr. Daniel Revilla and Ms. Kelley Price, International RectifierCorporationMr. Ronan Dillon, Microsemi istors-Discretes noaudio/Automotive-TransistorsDiscretes noaudio.swfDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.29
BACK-UPDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.30
Automotive Definitions Tier 1 Supplier – Manufacturer to the vehicleassemblers who are responsible for delivery ofthe finished assembly, product development andcontinued technology renewal. Tier 2 Supplier – Producer of parts providingvalue-added to minor sub-assembly. Tier 3 Supplier – Supplier of engineered materialsand special services such as rolls of sheet steel,bars, and heat treating surface treatments. Tier 4 Supplier – Supplier of basic raw materialsto higher Tier suppliers.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.31
Production Part Approval Process(PPAP) What is PPAP?– History:– The Auto Industry Action Group (AIAG) was founded byFord Motors, Chrysler, and General Motors in 1982. Thisgroup created the Advanced Product Quality Planning &Control Plan (APQP) and created the PPAP as a subset ofAPQP requirements. The basic premise of the PPAP is that:the supplier and customer understand and agree on theproduct specification requirements to produce product thatconsistently meet those requirements for a givenproduction run of an electronic component. The end goal isfor the supplier to ship a zero defects part to the customer.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.32
Production Part Approval Process(PPAP) PPAP required per ISO 16949 paragraph 7.3.6.3– Subset of the advanced product quality planning process– Additional customer specific requirements may be imposedon by particular auto manufacturers– PPAP approval is required from auto manufacturers when anew or modified component is proposed, or when amanufacturing process is proposed.– Usually has an agreed upon Failure In Time (FIT) ratebetween the component supplier and end user.Current AIAG PPAP document revision level is 4th edition –June 2006– 4th edition revision modified customer notification to berequired for ALL proposed changesDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.33
Production Part Approval Process(PPAP) PPAP Levels 1 to 5– End user determines required supplier PPAP level Typical PPAP level used is Level 3PPAP Levels PPAP Submission Requirements1Product Submission Warrant only (and for designated appearance items, an AppearanceApproval Report) submitted to customer2Product Submission Warrant with product samples and limited supporting datasubmitted to customer3Product Submission Warrant with product samples and complete supporting datasubmitted to customer.4Product Submission Warrant and other requirements as defined by customer.5Product Submission Warrant with product samples and complete supporting datareviewed at organization’s manufacturing location.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.34
PPAP Elements PPAP consists of 18 elements to ensure that thedesign meets customer requirements.– Design records – Documentation detailing the design andconstruction– Engineering Change Documents – typical engineeringchange notices– Engineering Approval – An engineering trial usingproduction parts at the customer plant– Design Failure Modes and Effect Analysis (DFMEA) – Afailure mode effects analysis based on the componentdesign requirements listing potential failure modes.– Process Flow Diagram – Process flow chart showing allmanufacturing test steps or sequences.– Process Failure Modes Effect Analysis (PFMEA) – Copy ofan approved PFMEA listing all manufacturing steps andindicate potential problems during the assembly orinspection processes of finish products.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.35
PPAP Elements Cont’d.– Control Plan – A copy of an approved control plan listingthe PFMEA steps and how potential concerns are resolvedat different stages of the manufacturing process.– Measurement Systems Analysis Studies – Contains GageRead and Record studies for critical characteristics.– Dimensional Results – Comparison and verification ofdimensions to the component drawings.– Records of Material/Performance Test – Summary report oftests performed on the part.– Initial Process Studies – Documentation containsStatistical Process Control charts that affect criticalcomponent characteristics.– Qualified Laboratory Documentation – Documentation oflaboratory certifications of the laboratory facilities used forRecords of Material/Performance Tests.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.36
PPAP Elements Cont’d.– Appearance Approval Report – Documentation containing theAppearance Approval form approved and signed off by the customer.– Sample Production Parts – A sample of production parts from samelot of initial production run. PPAP package typically contains aphotograph of the sample and where it is maintained (customer orsupplier).– Master Sample – A sample signed off by the customer and supplier ,that is typically used to train operators on subjective inspectionssuch as visual or noise.– Checking Aids – In the case where specific tools are required forchecking part, this documentation contains a photograph of the toooland calibration records including dimensional report of the tool.– Customer-specific requirements – Some customers may have specificrequirements to be included in the PPAP package in addition to theAEC requirements.– Parts Submission Warrant (PSW) – This is a form that summarizes theinformation contained in the PPAP, includes reason for submissionand level of documents submitted to the customer.Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.37
Electronic Parts - MicrocircuitsAEC-Q100 vs QML/QPLSummary: As can be seen from below, all applicable tests of AEC-Q100 are covered byQML/QPL ionQML/QPL-08-09ELFRSpecifiedElectrical distribution Specified-10-11-12Solder ball shearESD CDMPower devicesWire bond shearSpecifiedESD HBMSpecifiedESD MMNot specified, characterized for sensitive productsLatch upSpecifiedData retention, OLT SpecifiedGate leakageNot specified, plastic package specific testFault SimulationSpecifiedBeing addedNot specified, characterized for sensitive devicesSpecifiedDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.38
AEC Q100 Qualification Sample SizeDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.39
Scope of AEC Q101 DiscreteSemiconductorsDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.40
AEC Q101 Qualification Sample SizeDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.41
AEC Q101 Qualification Sample SizeDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.42
AEC Q101 Qualification Sample SizeDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.43
AEC Q101 Qualification Sample SizeDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.44
Scope of AEC Q200 PassivesDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.45
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Purchase Price Comparison of Commercial, Automotive, MIL and Space Grade Ceramic Chip Capacitors0.1 uF, 50 V RatingCompiled by Jay Brusse/Dell at NASA GSFCPart Number4/11/2013Cap Value Voltage RatingSource(uF)(V)GradeSizeUnit 104KAT2General CommercialGeneral CommercialGeneral CommercialGeneral VXAVXAVX 0.1100.0350.0250.0201pc order100pc order500pc order1000pc 4KAT208055C104KAT208055C104KAT2General CommercialGeneral CommercialGeneral CommercialGeneral VXAVXAVX 0.100.0220.0160.0121pc order100pc order500pc order1000pc 0505050AVXAVXAVXAVX 0.450.140.00950.00751pc order100pc order500pc order1000pc 0505050AVXAVXAVXAVX 0.390.140.100.0651pc order100pc order500pc order1000pc .1505050Kemet Kemet QPL 1.020.680.600.40Order Qty1pc order100pc order500pc order1000pc order45.70 1pc order29.59 1pc order35.10 1pc orderDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.Cost Estimate Source Notes:0603 is smallest chip size available forCOTS 0.1uF/50V capacitor0603 is smallest chip size available forAutomotive 0.1uF/50V ‐stocked.Non‐stocked.Non‐stocked.Call for PriceCall for PriceCall for PriceCall for PriceMouserMouserMouserMouser1210 is smallest chip size available forMIL grade 0.1uF/50V capacitorGSFC Stock Database1808 is smallest chip size available forGSFC Stock DatabaseSpace grade 0.1uF/50V capacitorGSFC Stock Database52
Purchase Price Comparison of Commercial, Automotive, MIL and Space GradeTransistors2N2222A TransistorCompiled by Benny Damron/Jacobs Engineering at NASA MSFCPart 511‐2N2222AGeneral CommercialGeneral CommercialGeneral CommercialGeneral ND2SD2675TLCT-NDMinimum Collector‐ Collector‐Max CollectorPowergainEmitterBasePkg TransistorDissipationCurrent ICVoltage VoltageHfestyle Polarity(mW)PD(mA)VCE (V)VCB eAutomotiveAutomotiveSourceUnit PriceOrder TMicroelectronicsSTMicroelectronics 1.100.7680.5980.4731pc order100pc order500pc order1000pc 05005001000100010001000RohmRohmRohmRohm 0.550.330.25000.19001pc order100pc order500pc order1000pc order1pc order100pc order500pc order1000pc 0500500800800800800On SemiconductorOn SemiconductorOn SemiconductorOn Semiconductor 307575757550505050500500500500800800800800On SemiconductorOn SemiconductorOn SemiconductorOn Semiconductor 4.840 1pc order4.840 100pc order500pc order1000pc 0404040500500500500800800800800On SemiconductorOn SemiconductorOn SemiconductorOn Semiconductor 6.125.024.073.431pc order100pc order500pc order1000pc coa 2.7145.0038.0033.0029.003pc order1pc order100pc order500pc order1000pc AJANS2N2222ADeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.53
Part Submission WarrantDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.54
Customer Support Automotive grade EEE parts suppliersprovide the following support to customers:– Application Support by Field Application Engineers– Return Material Authorization/Failure Analysiscapability Preliminary FA Report – 7 days Final FA Report - 14 days or less– Warranty Waiting on input for this – best guess is a year replacementDeliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.55
http://nepp.nasa.gov56Deliverable to NASA Electronic Parts and Packaging (NEPP) Program to be published on nepp.nasa.gov.
automotive electronic component suppliers components are AEC Certified, some are only AEC Compliant! The user has to understand what they are buying!!! The close ties and interdependency between the supplier and the user that is integral to the AEC process is a chal
