I would be interested in assisting you in your investigation. However I think to be useful you must define ppm more closely. Ideally the metric must: 1)take into account the complexity/density of interconects per unit area. 2) Define the causes of failure to be included. EG: Misplaced components should not be counted as having dry's or shorts, but measured separately. 3) Be realistic. You cannot count the exact number of opens/shorts from failed PCBs at ICT, merely the event and it's cause. A component with a quantity of shorts or drys on a single IC will inevitably be recorded as simply Dry IC? or Short IC? I will be happy to provide you with our ICT results. Regards Mike Fugl Snr Prod Eng Psion. ______________________________ Reply Separator _________________________________ Subject: PWB Solder defect rates Author: [log in to unmask] at INTERNET Date: 7/12/95 8:38 AM I am interested in actual soldering defect rates found "out there". While visiting a main customer, I was shocked to hear that the number of open circuits detected at "in-circuit testing" was running around 25 ppm. Apparently this problem is due to insufficient solder during surface mount assembly and is due to many different causes. This value of 25 ppm was stated as "above average" but at the same time was considered "okay" due to the complexity and large number of interconnects on the pcb's. I would like to ask the following questions: 1) Can anyone share their actual "solder open" defects rates and provide how they compare with the industry average? (I would attempt to establish the distribution curve of responses and publish later) Can you include bare board finish (ie HASL, reflow tin-lead, OSP etc...)? 2) Is this considered normal??? 3) Is there a repair procedure recommended by IPC to repair these types of defects and is there a reference IPC document? 4) How are the defect rates normalized based upon assembly complexity, board size and SMD pad geometries? 5) Has this defect rate been "self-inflicted" with the advent of no-clean fluxes and solder paste? Thanks Dave Rooke - Circo Craft [log in to unmask]