Printed Circuit Board Development Automation Project Plan Date Submitted: February 11, 2003 Project/Team Number: Dec 03-09 Team Members Colin Burnett Advisor Client Khawaja-Shahzad Butt Christopher Rieck Dr. Gary Tuttle Senior Design Christopher Sosnowski
Table of Contents TABLE OF CONTENTS 1 LIST OF FIGURES 2 LIST OF TABLES 3 DEFINITIONS 4 ABSTRACT 5 ACKNOWLEDGEMENT 5 INTRODUCTION 5 PROBLEM STATEMENT 5 OPERATING ENVIRONMENT 5 INTENDED USERS AND USES 5 ASSUMPTIONS AND LIMITATIONS 5 EXPECTED END PRODUCT AND DELIVERABLES 6 PROJECT PROPOSAL 6 PROPOSED APPROACH 6 Functional Requirements 6 Constraint Considerations 6 Technology Considerations 7 Technical Approach Considerations 7 Testing Requirements Considerations 7 Security Considerations 7 Intellectual Property Considerations 7 Commercialization Considerations 7 Possible Risk and Risk Management 8 Project Proposed Milestones and Evaluation Criteria 8 Project Tracking Procedure 9 STATEMENT OF WORK 9 Problem Definition 9 Technology and Implementation Consideration and Selection 9 Process Design 10 Process Testing 10 Process Demonstration 11 Project Reporting 11 ESTIMATED RESOURCES AND TIMELINE 12 ESTIMATED RESOURCES 12 TIMELINE 13 TEAM INFORMATION 14 SUMMARY 15 REFERENCES 15 APPENDICES 15 1
List of Figures Figure 1: EE 491 Gantt Chart... 13 Figure 2: EE 492 Gantt Chart... 14 2
List of Tables Table 1: Personal Effort Requirements... 12 Table 2: Estimated Resources... 12 Table 3: Estimated Project Costs... 13 3
Definitions ASP ECpE EE GUI HTML ISU MRC PHP PCB XML Active Server Pages Electrical and Computer Engineering Electrical Engineering Graphical User Interface Hypertext Markup Language Iowa State University Microelectronics Research Center Personal Home Page Printed Circuit Board Extensible Markup Language 4
Abstract Many ECpE senior design projects require the fabrication of a circuit board. To aid these projects, the focus of this project is to provide documentation on the available choices to obtain a circuit board by means of do-it-yourself methods or out-sourcing to a commercial company. Acknowledgement No acknowledgements at this time. Introduction Problem Statement Circuit board fabrication is not a simple process and as such it can take large amounts of time to research and develop criteria for evaluating which option is best for a given project. The focus of senior design projects, that require a circuit board, is in the application and not the means to obtaining or producing a circuit board due to time and financial constraints. To facilitate these groups, a process decision flow chart will be developed. The flow chart will take into account the various factors such as board size, number of components, component size, number of holes, trace widths, turn-around requirements, financial support, and quantity. The ultimate goal is to provide a suggestion of which option is best suited for the given circuit board requirements. Operating Environment Not applicable for a process project. Intended Users and Uses The intended users are ECpE senior design students with projects that require the fabrication of a circuit board. Future possible users would be others that seek to fabricate a circuit board. The intended uses are to guide in obtaining or producing a circuit board; or inform the various processes for producing a circuit board. Assumptions and Limitations 5
Assumptions: Server to host web site is sufficient Students have access to web site via the Internet Students are capable of generating a board layout Materials and facilities are available for fabrication No limitations. Expected End Product and Deliverables The primary end product will be a document containing a flow chart and instructions for either obtaining or producing a circuit board. In supplement to the document, an interactive web site will be made to guide the user and defer to the document. Project Proposal Proposed Approach Functional Requirements The following functional requirements pertain to the primary end product document: Given a set of factors and requirements a decision to obtain a circuit board by outsourcing or not should be answered If it is decided to not out-source then a specific process shall be given If it is decided to out-source then a list of companies and their capabilities shall be given Shall give a general description of what each process involves Shall detail the preparations, facility selection, and steps in performing each process Will contain multimedia of the process steps The following function requirements pertain to the interactive website: Mimics the functionality of the flowchart in the primary end product document Shall be a GUI that accepts user input Constraint Considerations The following constraint considerations pertain to the primary end product document: Adequate length as to not deter its usage The following constraint considerations pertain to the interactive website: Allocated server space 6
Technology Considerations No technology considerations for the primary end product document. The following technology considerations for the interactive website: Static or dynamic pages For static pages, use HTML or XML or another language For dynamic pages, use PHP or ASP or another language Technical Approach Considerations No technical approach considerations for the primary end product document. The following technical approach considerations pertain to the interactive website: Determination of using static or dynamic web pages shall be determined by the available software of the hosting server Determination of which static language will be dependent on browser capabilities, sufficient functionality of the language, and licensing agreements & fees Determination of which dynamic language will be dependent on server capabilities, sufficient functionality of the language, and licensing agreements & fees Testing Requirements Considerations The following testing requirements pertain to the primary end product document: Generation of scenarios to test flow chart and process instructions for accuracy and correctness Use previous senior design projects as other scenarios (possibly as reference) The following testing requirements pertain to the interactive website: Matches flow chart outcomes for all scenarios Security Considerations No security issues because there is no provided proprietary information. Intellectual Property Considerations No intellectual property issues because there is no provided proprietary information and the process is public knowledge. Commercialization Considerations No commercialization considerations because this project is for the improvement of senior design and has no commercial backing. 7
Possible Risk and Risk Management Possible risks: 1. Loss of access to the MRC lab through Dr. Tuttle 2. Loss of a team member Risk Management: 1. Possible access through other ECpE faculty & staff 2. Distribute project work equally Project Proposed Milestones and Evaluation Criteria Milestones: 1. Fully research processes Obtain a full understanding of the requirements to perform each process in addition to knowing how to complete each process 2. Clean up MRC PCB fabrication lab Find lab; determine available equipment; and remove unnecessary items 3. Set up MRC PCB fabrication lab Familiarizing team with equipment and locating materials & resources needed for circuit board fabrication to the point of being able to fabricate a circuit board 4. Preliminary process instructions and flow chart Rough draft of process decision tree (flow chart) and process instructions to be used in testing and documentation 5. Perform scenario testing Test generated scenarios and previous senior design project decisions for correctness of flow chart 6. Perform circuit board fabrication and document results Test all available processes for instruction correctness & accuracy and document steps & results with a digital camera 7. Interactive website completed Website implementation of flow chart done and tested for correctness 8. Primary end product document completed Corrections from testing scenarios and fabrication testing are applied to document and document is finalized Evaluation criteria: 1. Each team member is capable of describing all processes. 2. Lab is accessible to team members and all non-necessary equipment is removed. 3. All equipment present is in working order and needed materials & resources are present in the lab. 4. Rough draft is done and is capable of being used in testing without external input (i.e. from team members knowledge or experience). 5. A sufficient number of scenarios have been generated and applied to the flow chart that yields the best process for the scenario. 6. All available processes are tested and yield a circuit board of satisfactory quality. At least six digital pictures of each tested process should be done. 7. Website is available and yields identical results as the primary end product document. 8
Project Tracking Procedure At each meeting with Dr. Tuttle the milestones and Gantt chart shall be checked and determined if the team is on track. If the team is behind schedule, the team will need to apply more effort. The amount of effort will be determined by how far the team is behind and when the next task/milestone needs to be completed. If an unexpected cost arises, it will likely need to be funded externally due to the high cost of the equipment needed for circuit board fabrication. The only other unexpected cost will be materials needed to perform circuit board fabrication. However, no financial over-budgeting is foreseeable. Statement of Work Problem Definition Task 1a: Problem Definition Completed Objective: Define the problem Approach: Talk with Dr. Lamont, Dr. Patterson, and Dr. Tuttle to clarify desired outcome and purpose of project Result: A full understanding of what is expected of the project Task 1b: End User(s) and End Use(s) Identification Objective: Determine end user(s) and end use(s) Approach: Use problem definition to determine end user(s) and end use(s) Result: End users: ECpE senior design project students requiring a circuit board End use: Guide in obtaining or producing a circuit board Task 1c: Constraint Identification Objective: Identify constraints Approach: Determine the constraints from the applications from the end use Result: Primary end product document shall be of adequate length as to not deter its usage and the interactive website shall fit into allocated server space Technology and Implementation Consideration and Selection Task 2a: Static Language for the Interactive Website Objective: Determine the best suited static language Approach: Look at the static languages with the highest implementation to ensure the website can be used in the highest number of locations since the end destination is unknown Result: HTML shall be used since all browsers are capable of displaying it and HTML has no licensing 9
Task 2b: Dynamic Language for the Interactive Website Objective: Determine the best suited dynamic language Approach: Look at the dynamic languages with the highest implementation to ensure the website can be used in the highest number of locations since the end destination is unknown Result: PHP shall be used since it s use is free and works will all of the most popular web servers Task 2c: Static vs. Dynamic Language Selection for the Interactive Website Objective: Determine if a static or a dynamic language should be used Approach: The most likely location for the interactive website to be hosted will be on the senior design or ISU public web servers Result: The static language shall be used because the dynamic language support of both the senior design and ISU public web servers is unknown Process Design Task 3a: Identification of Process Requirements Objective: Identify all of the material and resource requirements for each process Approach: Research each process Result: A list of materials and resources needed for each process Task 3b: Fabrication Process Defining Objective: Determine a list of steps to perform each process Approach: Research each process Result: A list of steps needed to perform each process Task 3c: Documentation of Process Instruction Objective: Compile task information from 3a & 3b Approach: Write a rough draft of the primary end product document Result: A document that can be used in testing Task 3d: Perform Circuit Board Fabrication and Process Documentation Objective: Physically perform each available fabrication process and obtain digital multimedia of each performed process Approach: Use MRC PCB lab to carry out and document each available process Result: Completed circuit board(s) with each step documented with a digital camera Process Testing Task 4a: Scenario Generation Objective: Test correctness and accuracy of flow chart Approach: Randomly generate circuit board requirements and numbers and apply to the flow chart Result: Whether or not the process decision is correct 10
Task 4b: Former Senior Design Project Information Gathering Objective: To see if this project yields a better solution than what previous projects decided Approach: Gather information about previous senior design projects, that required a circuit board, and analyze the results Result: Whether or not the process decision is correct as made by the flow chart and the previous senior design team Task 4c: Evaluate Test Results Objective: Determine if the test results from 4a & 4b warrants a change in the flow chart Approach: Look at the results from 4a & 4b and if the results show the flow chart is inaccurate or missing important decision factors Result: A modified or unmodified flow chart Process Demonstration Task 5a: Demonstration Planning Objective: Finding a good plan to demonstrate project Approach: Finishing the project and decide if demonstrations will accurately convey the project and its results Result: Having a good plan for demonstrating our project successfully Task 5b: Faculty Advisor Demonstration Objective: Determine if project met Dr. Tuttle s expectations Approach: Apply demonstration plan Result: Success of project Task 5c: Industrial Review Panel Demonstration Objective: Determine if project is of high quality Approach: Apply demonstration plan Result: Success of project Project Reporting Task 6a: Project Plan Objective: To carefully plan and conduct the project Approach: Writing this document Result: A well-understood plan to successfully complete project Task 6b: Project Poster Objective: To display project to other individuals Approach: Summarize project plan into an appealing poster Result: An appealing and an informative poster 11
Task 6c: Design Report Objective: Fully document the details of our end product design Approach: Document the design of the end product Result: Details the functional requirements, design constraints, and that the end product is intended for the end user for appropriate end uses Task 6d: Final Report Objective: Provide a complete record of the project Approach: Combine all documented data and team members logs Result: A document that fully encompasses the entire project Task 6e: Weekly Email Reporting Objective: Used as a means to inform the advisor and client Approach: Keep accurate documentation of each week s activities Result: An informed advisor and client Estimated Resources and Timeline Estimated Resources Personal Effort Requirements Name Problem Definition Tech. Consideration & Selection Process Design Process Testing Process Demonstration Project Reporting Total per Person Burnett, Colin 9 0.5 37 6 12 44 108.5 Butt, Khawaja-Shahzad 2.5 0.5 40 6 12 44 105 Rieck, Chris 8 0.5 38 6 12 44 108.5 Sosnowski, Chris 8 0.5 37 6 12 44 107.5 Total per Task 27.5 2 152 24 48 176 429.5 Table 1: Personal Effort Requirements Estimated Resources Item Cost Time (Hrs) Printing Poster $45.00 Misc Printing $10.00 Lab time with Dr. Tuttle 10 Total $55.00 10 Table 2: Estimated Resources 12
Estimated Project Costs Item Cost (w/o Labor) Cost (w/labor) Printing Poster $45.00 $45.00 Misc Printing $10.00 $10.00 Labor @ $10.50 per hour Burnett, Colin $1,139.25 Butt, Khawaja-Shahzad $1,102.50 Rieck, Chris $1,139.25 Sosnowski, Chris $1,128.75 Total $55.00 $4,564.75 Table 3: Estimated Project Costs Timeline February March April May Task Description 3 10 17 24 3 10 17 24 31 7 14 21 28 5 12 19 26 1 Problem Definition 1a Problem Definition Completed 1b End User and End Use Identifcation 1c Constraint Identification 2 Technology and Implementation Consideration and Selection 2a 2b 2c Static Language Dynamic Language Static vs. Dynamic 3 Process Design 3a 3b 3c 3d Identification of Process Requirements Fabrication Process Defining Documentation of Process Instruction Perform Circuit Board Fabrication and Process Documentation 4 Process Testing 4a 4b 4c Scenario Generation Former Senior Design Project Information Gathering Evaluate Test Results 5 Process Demonstration 5a 5b 5c Demonstration Planning Faculty Advisor Demonstration Industrial Review Panel Demonstration 6 Project Reporting 6a 6b 6c 6d 6e Project Plan Project Poster Design Report Final Report Weekly Email Reporting Figure 1: EE 491 Gantt Chart 13
August September October November December Task Description 4 11 18 25 1 8 15 22 29 6 13 20 27 3 10 17 24 1 8 15 1 Problem Definition 1a Problem Definition Completed 1b End User and End Use Identifcation 1c Constraint Identification 2 Technology and Implementation Consideration and Selection 2a 2b 2c Static Language Dynamic Language Static vs. Dynamic 3 Process Design 3a 3b 3c 3d Identification of Process Requirements Fabrication Process Defining Documentation of Process Instruction Perform Circuit Board Fabrication and Process Documentation 4 Process Testing 4a 4b 4c Scenario Generation Former Senior Design Project Information Gathering Evaluate Test Results 5 Process Demonstration 5a 5b 5c Demonstration Planning Faculty Advisor Demonstration Industrial Review Panel Demonstration 6 Project Reporting 6a 6b 6c 6d 6e Project Plan Project Poster Design Report Final Report Weekly Email Reporting Figure 2: EE 492 Gantt Chart Team Information Client Senior Design Faculty Advisor Dr. Gary Tuttle Address: 2126 Coover, Ames, IA 50011-3025 Address: 247 ASC I, Ames, IA 50011-3060 Phone: (515) 294-1814 Fax: (515) 294-9584 Email: gtuttle@iastate.edu 14
Team Members Colin Burnett Computer & Electrical Engineering Address: 2113 Frederiksen Court, Ames, IA 50010 Phone: (515) 572-7708 Email: cburnett@iastate.edu Khawaja-Shahzad Butt Computer Engineering Address: 246 N Hyland Avenue #2, Ames, IA 50014 Phone: (515) 292-3701 Email: shahzad@iastate.edu Christopher Rieck Electrical Engineering Address: 1134 Frederiksen Court, Ames, IA 50010 Phone: (515) 572-7704 Email: crieck@iastate.edu Christopher Sosnowski Electrical Engineering Address: 4405 Castlewood #1, Ames, IA 50014 Phone: (515) 292-2203 Email: csos@iastate.edu Summary Many ECpE senior design projects have the need for a circuit board. To save these projects time, effort, and money this project will guide the user to the best decision for their project s requirements and specifics. To accomplish this important task we will: Research the numerous available methods Document the steps Set up the MRC PCB lab Design & implement an interactive website Provide a document containing full instructions and images to perform each process The interactive website will compliment the document by being more readily accessible and usable. Through this project other senior design projects will be able to focus on their designs and not have to worry about obtaining or producing a circuit board. References No references at this time. Appendices No appendices at this time. 15