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June 2004

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Subject:
From:
"Kasprzak, Bill (sys) USX" <[log in to unmask]>
Reply To:
TechNet E-Mail Forum.
Date:
Sat, 19 Jun 2004 08:17:00 -0400
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Bruce,

I'm very familiar with the various reasons why your board was never
upgraded. (In the military business, it's typically, ".... because we
qualified the system with the 'dead bug'.")

I'll still contend that a board redesign and a delta qual would still be
cheaper than installing the 'dead bug' 800 times and counting.

Tell me you're not attaching wires to the resistor pak. This is nuts.

'Dead Bugs' should only be intended for development, prototypes and small
production orders (<50 pcs).

Bill Kasprzak
Moog Inc., Systems Group, Process Engineer


-----Original Message-----
From: [log in to unmask] [mailto:[log in to unmask]]
Sent: Saturday, June 19, 2004 6:38 AM
To: TechNet E-Mail Forum.; Kasprzak, Bill (sys) USX
Subject: Re: [TN] Dead Bugs



We have been installing one dead bug SMT resistor pak on one of the main
electronic control boxes for the M1A1 SEP tanks since the beginning of the
production cycle.  In this case a change was needed to make the board
functional, yet no one was willing to spring for an entire board layout.
This card and the box it goes into has passed all levels of military qual
testing including ballistic shock, vibe and all environmental scenarios
(these occur every 100 units).  In addition, I have yet to see a card
returned from the field (whether it be the US or Iraq) where this part has
been called into question.  We have built a total of about 800 of these
cards and are continuing to outfit the M!A1 with this box (card).  So the
reliability factor, if installed correctly, is a none issue.  That being
said, myself and well as the assemblers hate the fact that we have to
install the part in this fashion.  So good reliability can easily be
achieved, but a price is definitely paid in assembly time.

Bruce Stilmack
GDLS-TO Manufacturing Engineer
(850) 574-4773
[log in to unmask]




                    "Kasprzak,

                    Bill (sys)           To:     [log in to unmask]

                    USX"                 cc:

                    <bkasprzak@MOO       Subject:     Re: [TN] Dead Bugs

                    G.COM>

                    Sent by:

                    TechNet

                    <[log in to unmask]

                    RG>





                    06/18/2004

                    11:05 AM

                    Please respond

                    to "TechNet

                    E-Mail

                    Forum.";

                    Please respond

                    to "Kasprzak,

                    Bill (sys)

                    USX"









Joe,

A couple of obvious things.

1) If you have a customer that wants to disallow this for production, then
he's willing to foot the bill for new board layouts. That's good.

2) If it's on the print, that takes precedence over any general rules or
other edicts. Whether allowed or not, you're obligated to make the parts to
print.

If "dead bugs" are part of "Production", gosh, I hope the order is very
small. "Dead Bugs" should be limited to development maybe even prototype
work. Otherwise, new board layout is needed.

You might want to know why they're suggesting this? I'd be curious.

Good Luck.

Bill Kasprzak
Moog Inc., Systems Group, Process Engineer


-----Original Message-----
From: Kane, Joseph E [mailto:[log in to unmask]]
Sent: Friday, June 18, 2004 10:27 AM
To: [log in to unmask]
Subject: [TN] Dead Bugs


We've talked before about implementing design changes with "dead
bug" components, where you turn the part upside down, bond
it to the board surface, and solder wires to the pins.

Of course, this takes more labor, but sometimes it's useful to
implement a change for a short time while artwork is being updated.

Now we have a customer talking about disallowing this practice for
production.  Anyone have a good reason why dead bugs should be
outlawed?  Are there any specs that prohibit this?

Joe Kane
BAE SYSTEMS Controls
Johnson City, NY

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