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Last updated on 2024年7月19日

How do you document and report PCB failures and repairs?

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When you work with printed circuit boards (PCBs), you may encounter various types of failures and defects that affect their functionality and performance. Whether you are testing, debugging, or repairing PCBs, you need to document and report the issues and solutions in a clear and consistent way. This will help you track the root causes, improve the quality, and communicate with your team and clients. In this article, you will learn how to document and report PCB failures and repairs using some best practices and tools.

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1 Identify the failure

The first step is to identify the failure and its symptoms. You can use visual inspection, multimeter, oscilloscope, logic analyzer, or other test equipment to check the PCB for physical damage, shorts, opens, incorrect voltages, signals, or logic. You should also compare the PCB with the schematic, layout, and bill of materials to verify the components, connections, and values. You should document the failure by taking notes, photos, screenshots, or videos of the test results and the PCB condition.

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Jim Villalvazo

Director at IDTG
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Data is critical, NPI information is the intent of the production flow. Most of these failures occur in the printer. But that doesnt mean the printer is at fault. This process as simple as it seems is quite complex. The real data needs to be measured vs the NPI introduction of the process. Not all fails are mechanical, therefore my best source is ICT and Xrays.

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Presanna Govindaraj
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Documenting and reporting PCB failures and repairs is crucial for quality control. Create detailed failure reports outlining the issue, observed symptoms, and affected components. Include high-quality images and schematics to provide comprehensive documentation. Specify the repair process, including replacement components and soldering techniques used. Utilize standardized reporting templates for consistency and clarity in communication. Establish a systematic approach to categorize and prioritize failures for efficient reporting. Regularly update failure and repair documentation based on continuous improvement initiatives, ensuring comprehensive and reliable reporting in PCB manufacturing processes.

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Hamidreza Abbasi

As an accomplished electrical engineer with 7 years of experience in the field of electrical engineering, I have a proven track record of designing and implementing innovative solutions to complex problems.
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Documenting and reporting PCB (Printed Circuit Board) failures and repairs is essential for maintaining proper records, analyzing trends, and improving processes. In my opinion, they should include : Failure Documentation: a. Identify the Failure b. Record Observations c. Capture Relevant Data d. Photographic Documentation: e. Diagnostic Test Results: Repair Documentation: a. Repair Process b. Materials and Tools c. Technician Information d. Quality Control Checks Reporting: a. Failure Report: b. Repair Report c. Root Cause Analysis d. Trend Analysis Storage and Accessibility: a. Centralized Database b. Version Control c. Security and Confidentiality

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2 Analyze the cause

The next step is to analyze the cause of the failure and determine the possible solutions. You can use a systematic approach, such as the 5 Whys, fault tree analysis, or fishbone diagram, to trace the failure to its source and identify the contributing factors. You can also consult the datasheets, manuals, design rules, or online resources to find out the specifications, tolerances, and best practices for the PCB and its components. You should document the cause by writing a clear and concise problem statement that summarizes the failure and its context.

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Sergio Pedro Ilescas Hernández

PCA Manufacturing Engineering SPV
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CFX connection between equipments, do more easy and accurate data analysis. To identify factors with variation and implement more robust contra measures.

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Sean Kincaid

President @ K & F Electronics | Electronic Manufacturing Services (EMS)
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Electrical testing done on a flying probe will tell you where the short or open occurred. You could always use a meter and beep out pad to pad or hole to hole. This gets more difficult in multilayer designs.

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Jim Villalvazo

Director at IDTG
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Auditing the process is a start to find the process failure. Data is great but it wont necesarily tell you if a printers process was changed during the particular production run.

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3 Perform the repair

The third step is to perform the repair and verify the outcome. You can use soldering tools, desoldering tools, jumper wires, or replacement components to fix the PCB according to the solution you have chosen. You should follow the safety precautions, quality standards, and ESD protection measures to avoid further damage or injury. You should also test the PCB again after the repair to ensure that it works as expected and meets the requirements. You should document the repair by recording the steps, tools, materials, and time you have used for the repair.

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Sean Kincaid

President @ K & F Electronics | Electronic Manufacturing Services (EMS)
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Cut out shorts and reapply solder mask. For opens. If the trace is still available, you can add gold wire or in a pinch use a jumper.

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Jim Villalvazo

Director at IDTG
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Repairs, this is a sore subject, we have made businesses of this option. I realize that not all processes will be perfect but I believe that the repair, even though required, is the final step to recovery, but not the optimum results of a production run. Root cause analysis is the real solution to help understand what is happening.

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4 Report the results

The final step is to report the results and share the feedback. You can use a standard format, such as a failure analysis report, a repair report, or a test report, to present the information in an organized and professional way. You should include the following elements in your report: a title, a summary, a problem statement, a failure description, a cause analysis, a repair description, a verification description, a conclusion, and a recommendation. You should also attach any relevant documents, such as photos, screenshots, videos, or test data, to support your report.

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Mike Wang

Business Development Director at MV Circuit Technology(trademark PCBMay)?Focusing on PCB Manufacturing and Assembly for 18 Years? Help 300+Customers All Around the World.
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We prepare for one 8-D report(Corrective & Preventive Action Report) to report the results. We will put up the problem pictures on the wall, informing relevant personnel of the problem, attention to control this problem in subsequent production, and completely eradicating this problem appear again.

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5 Use software tools

Making documentation and reporting simpler and more efficient can be done by utilizing software tools. These tools can be used to capture, store, organize, and share data. For example, PCB design software is used to create and edit schematics, layouts, and bills of materials. It can be utilized to compare the PCB with the original design and detect any discrepancies or errors. Additionally, it allows the user to export or print the design files for reference or reporting. Test software is used to control and monitor test equipment such as multimeters, oscilloscopes, logic analyzers, or other devices. This software can measure and record voltages, signals, logic, or other parameters of your PCB. It also allows users to save or export test data for analysis or reporting. Documentation software is used to create and edit documents such as notes, reports, or feedback. It provides users with the ability to write and format text, insert images, tables, charts, or other elements; as well as add comments or annotations. Furthermore, it permits users to save or export documents in different formats such as PDFs, Word documents, or Excel spreadsheets.

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Jim Villalvazo

Director at IDTG
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We have to remember that the stencil is cut to the customers approval. The stencil mfg house only does what the production engineers request. This is typically established at the production NPI stage. I ask how is the stencil technology selected, all too many times a price tag is the only defining factor, this has always been a process limitation.....then there is the price wars between the Stencil mfg companies. There are many factors that directly affect this process. I dont recall any software that really goes into the printer and sees all the parameters that affect this process directly, this is to create real dialog to help observe and create solutions.

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6 Follow best practices

To ensure that your documentation and reporting are effective and useful, you should adhere to certain best practices. Accuracy is key; double-check your spelling, grammar, and calculations for errors. Additionally, clarity is essential; use consistent terminology, abbreviations, and units for understanding. Conciseness is also important; avoid unnecessary details, repetitions, or filler words. Furthermore, completeness is a must; cover all aspects, stages, and outcomes of the failure and repair. Finally, timeliness is essential; update documents and reports as needed for currency.

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Keesjan (Case) Engelen

CEO Titoma, Electr. Design & Mfg Colombia & China. On-Time & On-Budget since 2001
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Clear documentation and reporting help keep information accessible and useful: - Document details of the analysis. - Take photos of defects from different angles before and after adjustments. - Record images and measurements. - Record test configurations and procedures. - Arrange findings and evidence in a report. - Summarize conclusions and what needs fixing. - Share with stakeholders and get their input. Detailed records help identify the main problem and improve processes.

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Mike Wang

Business Development Director at MV Circuit Technology(trademark PCBMay)?Focusing on PCB Manufacturing and Assembly for 18 Years? Help 300+Customers All Around the World.
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All production and quality departments often do some training and practices from time to time and understanding every detail, no mistake to happen!

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Sean Kincaid

President @ K & F Electronics | Electronic Manufacturing Services (EMS)
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You blame the stencil manufacturer... Doesn't even matter if you used one or not just blame them their used to it. It's like anything else the more you track the more you can find your root cause. You cannot make a design better without failing sometimes. It can be a great learning experience.

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Jim Villalvazo

Director at IDTG
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The stencil is a key factor, but so is the human running the operations. All too many times I see these errors repeated. Thx

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How do you document and report PCB failures and repairs?

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3

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1 Identify the failure

2 Analyze the cause

3 Perform the repair

4 Report the results

5 Use software tools

6 Follow best practices

7 Here’s what else to consider

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