As the complexity of electronic systems grows, the traditional design practice, a sequential process, is replaced by concurrent design methodologies. A major advantage of concurrent design is that the feedback from software and manufacturing engineers can be easily incorporated into the design. The implementation of concurrent engineering methodologies is greatly facilitated by employing the latest Electronic Design Automation (EDA) tools. These tools offer integrated simulation of the electrical, mechanical, and manufacturing functions and support virtual prototyping, rapid prototyping, and hardware-software co-design. This report presents recommendations for enhancing the electronic design and manufacturing capabilities and procedures at JSC based on a concurrent design methodology that employs EDA tools

Bachnak, Rafic

Salkowski, Charles

English

NASA Technical Reports Server

ELECTRONIC DESIGN AUTOMATION: INTEGRATING
THE DESIGN AND MANUFACTURING FUNCTIONS
_,_ 1¸
t. _/
Ray Bachnak
Franklin University
EM3
August 2, 1996
Charles Salkowski
Manufacturing & Process Development Branch
Manufacturing, Materials, and Process Technology Division
Engineering Directorate
https://ntrs.nasa.gov/search.jsp?R=19970025437 2020-06-18T00:19:14+00:00Z

ELECTRONICDESIGNAUTOMATION: INTEGRATING
THE DESIGNAND MANUFACTURING FUNCTIONS
Final Report
NASA/ASEE Summer Faculty Fellowship Program -- 1996
Johnson Space Center
Prepared by:
Academic Rank:
University & Department:
NASA/JSC
Directorate:
Division:
Branch:
JSC Colleague:
Date Submitted:
Contract Number:
Rafic Bachnak, Ph.D.
Professor
Franklin University
Electronics Department
201 S. Grant Ave.
Columbus, Ohio 43215
Engineering
Manufacturing, Materials,
& Process Technology
Manufacturing & Process
Development
Charles Salkowski
August 2, 1996
NAG 9-867
2-1
ABSTRACT
As the complexity of electronicsystemsgrows,the traditionaldesignpractice,a
sequentialprocess,is replaced by concurrent design methodologies. A major advantage
of concurrent design is that the feedback from software and manufacturing engineers can
be easily incorporated into the design. The implementation of concurrent engineering
methodologies is greatly facilitated by employing the latest Electronic Design
Automation (EDA) tools. These tools offer integrated simulation of the electrical,
mechanical, and manufacturing functions and support virtual prototyping, rapid
prototyping, and hardware-software co-design. This report presents recommendations for
enhancing the electronic design and manufacturing capabilities and procedures at JSC
based on a concurrent design methodology that employs EDA tools.
2-2
INTRODUCTION
Thecontinuousincreasein complexityof electronicsystemsis making the design
and manufacturingof suchsystemsmore challengingthan ever before. As a result,
designershavebeenmovingfrom thetraditionaldesignapproach,a sequentialprocess,to
concurrentmethodologieswheretheelectronicdesignerbecomesawareof the physical
layoutprocessandthe manufacturingandassemblyissues. This integratedenvironment
improves communicationsamongthe various design teams and reducesthe rise of
multiple timeiterations.
With designcapacitiesexceedingamillion gatesandclock ratesof morethan300
MHz, systemanalysisandverificationbecomethe major obstaclesin the designphase.
This is especiallytrue becauseof signalintegrity problemssuchastiming delays,level
distortions, and noise. Furthermore,as technologiesevolve, designers will find it
impossibleto designefficient systemswithouttheuseof sophisticatedtools. Since1989,
manycompanieshavebeensuccessfullyusingEDA tools. Thesetools provide integrated
simulation of the electrical, mechanical,and manufacturingfunctions and lead to a
correctby designapproach[1-11].
Adopting concurrentdesignmethodologiesand employing EDA tools basedon
processesthat supportvirtual prototypingandhardware-softwareco-designhaveproven
to reducecost,decreasetime to market,and improveproduct quality. The rest of this
report is organizedas follows. First, the benefitsof using concurrentengineeringand
EDA tools are described. Second,industry designand manufacturing practicesare
summarized.Third, the resultsof evaluatingthe designcapabilitiesand proceduresat
JSC are listed. Finally, recommendationsto improve the electronic design and
manufacturingfunctionsat JSCarepresented.
CONCURRENTDESIGN
Designershaverealizedthatto achievehighproductivity theprocessesusedareas
importantasthetoolsemployed.In recentyears,thetrendhasbeena move towardmore
concurrentdesignmethodologies. A major advantageof concurrentdesign is that it
bringstogetherteammembersfrom differentdisciplines.Thisresultsin early detectionof
designflawsandleadsto fewerdesignchanges,a reduction in time to market, andthe
improvementin overall quality. Accordingto a study cited in [12], concurrentdesign
techniquescanreduceproductdevelopmenttimeby up to 70%andimprove quality by up
to 600%. Figure 1 showsthe relationshipsbetweenvarious processesin an integrated
design and manufacturingenvironmentthat employs concurrent engineering. This
environment facilitates hardware-softwareco-design, virtual prototyping, and rapid
2-3
prototyping. It also allows for the interaction betweenelectrical,mechanical,and
manufacturingengineers.
System ]• ............................. Requirements
Rapid
• l Virtual Software: Prototyping Developm nt
AlgorithmicDescription ]
Prototyping
Hardware
Design Packaging ]
PCB Layout _Manufacturing ]
Figure 1.- Integrated Design and Manufacturing Environment
In general, testing hardware and software independently does not lead to complete
verification since some problems occur only from the interaction of hardware and
software. Delaying integration until the hardware design is complete may impact the cost
and time schedule. In addition, if testing is delayed until the board is manufactured, the
pressure will be on the software developer to resolve the problems. Concurrent design
supports hardware-software co-design and allows for interaction between software and
hardware engineers. In this environment, problems can be diagnosed and corrected at the
earliest possible phase of the design cycle when the software and hardware engineers can
coordinate their efforts so that problems are fixed either in hardware or software
depending on the best solution.
While hardware prototyping may still be necessary at some point in the
development cycle, taking full advantage of software simulation can significantly
improve the overall process. A relatively new technique, virtual prototyping, is used to
graphically simulate the operation of a system using a model that best matches reality. In
addition to detecting design flaws, virtual prototyping guarantees that the system's
operation and performance meet the initial system requirements. Although this approach
leads to an increase in the time invested at the beginning of the design process, it reduces
the time required for software and hardware integration.
2-4
Another important feature of concurrentdesign is that it facilitates Rapid
Prototyping(RP). RPis bestachievedby workingat a high level of designautomation
using HardwareDescriptionLanguages(HDLs). HDLs takethe hardwarearchitecture
descriptionand automaticallytranslateit into a physicalimplementationusing various
devicessuchas Application SpecificIntegratedCircuits (ASICs), programmablelogic
devices(PLDs), customIntegratedCircuits (ICs), andField ProgrammableGateArrays
(FPGAs). Gatearraysareusedfor fast turnaroundprototypingwhenthe designrequires
betterperformancethancanbeachievedwith PLDs. CustomICs canbe optimized for
performanceand functionality but they are time consumingand costly for normal
prototyping. While theadvantagesaremany,accordingto [4] less than 20 percent of the
electronic designers in the US have adopted HDLs for RP.
ELECTRONIC DESIGN AUTOMATION
EDA tools provide an effective environment to integrate the design and
manufacturing processes. A state of the art EDA system is able to:
• Perform electrical, mechanical, and manufacturing simulation.
• Analyze various design levels, from IC to complete systems.
• Perform mixed-signal (analog and digital) simulation.
• Perform high-level synthesis (behavioral and HDL).
• Support hardware-software co-design, virtual prototyping, and rapid prototyping.
• Provide a centralized database of files accessed by all software modules.
• Offer simultaneous access to all teams.
• Automate data exchanges and provide a standard format for information to be
communicated both within the organization and with customers and vendors.
Some EDA companies such as Cadence, Mentor Graphics, Synopsys, and
Viewlogic, offer a wide range of software tools that support most of the design functions
listed above. The user, however, must recognize that each step of the design process has
its own specialized set of tools. Therefore, an organization must carefully determine its
design needs and identify those tools that'satisfy them. The elements of an EDA system
may be grouped as follows:
• Entry tools (Include schematic capture, block diagram and state diagram entry tools,
and hardware description language editors).
• Simulation tools (Include analog and digital simulators, timing simulators, HDL
simulators, and signal integrity analysis, electromagnetic interference, thermal,
vibration, and fatigue analysis, and faults analysis).
• Synthesis tools (Include HDL entry and simulation and behavioral languages).
• PCB tools (Include layout editors, routing tools, and design rule checkers).
2-5
INDUSTRY DESIGN AND MANUFACTURING PRACTICES
EDA tools have been successfully used by many companies representing a wide
range of industries including automotive_ communications, semi-conductors, aerospace,
and computers. A review of articles reporting the results of using EDA tools by more
than 23 different companies revealed that in addition to handling complex designs, the
use of EDA tools reduces development time by up to 75%, decreases cost by up to 50%,
and improves product quality significantly.
In spite of the many advantages of EDA tools, it is estimated that only 35% of all
designers use them. Furthermore, a 1996 survey by Integrated System Design Magazine
[13], completed by 140 EDA users, revealed that not all users take full advantage of the
capabilities of EDA tools. The results of the survey are shown in Figure 2. As can be
seen in the Figure, schematic entry is still used in twice as many design groups as HDL
entry.
Other --
Signal
mmm
Integrity
Faults
HDL Entry
IC Layout
Logic
Synthesis
Analog
Timing
PCB Layout
Logic
Simulation
Schematics
0%
I I I I |
20% 40% 60% 80% 100%
Figure 2.- Percentage Use of EDA Tools for Various Design Functions
Data from the same survey (see Figure 3) indicate that schematic entry is the most
time-consuming task. While HDL entry and logic synthesis combined required only 10%
of the design cycle, schematic entry requires 23%. This implies that HDL-based design
implementations are more efficient than schematic entry approaches.
2-6
Other
Signal
Integrity
Faults
HDL Entry
IC Layout
Logic
Synthesis
Analog
Timing
PCB Layout
Logic
Simulation
Schematics
0%
m
I
m
m
m
m
I I I I I
5% 10% 15% 20% 25%
Figure 3.- Percentage of Total Design Time Used for Each Process
As electronic equipment becomes more complex, the capital and technical
requirements of electronics manufacturing increase. As a result, many original
equipment manufacturers are focusing on product development and using contractors for
manufacturing [14]. The Institute for Interconnecting and Packaging of Electronic
Circuits (IPC) forecasts that contract manufacturing will grow 20% annually through the
year 2000. It is anticipated that by 1997, about 30% of all expenditures for PCB
assembly will go to contract manufacturers. To decide whether to create manufacturing
capability in-house or outsource, a number of business and technical issues must be
assessed to ensure that the allocation of assets best matches the goals established for the
organization. The financial ability to invest in manufacturing and the anticipated returns
on investment are two major factors that should be considered.
DESIGN AND MANUFACTURING CAPABILITIES AT JSC
To assess the current JSC electronic design and manufacturing procedures and
capabilities, I interviewed designers working on different projects in EM, EV, and ER.
All the individuals I met were very helpful and exhibited a high level of dedication and
professionalism. It was obvious however, that there are some weaknesses in the design
capabilities and procedures. The following is a list of observations:
• There is lack of communication and coordination between different design groups.
• There are no standard manufacturing procedures.
2-7
• There is no standard software package (Software used include OrCAD, AutoCAD,
VIEWlogic, Protel, CADSTAR).
• There are no electrical or mechanical simulation capabilities of complete systems --
Soflrware is used mainly for schematic entry.
• There is duplication of work.
• The majority of individuals support the consolidation of the electronic design
functions.
• The majority of individuals prefer in-house PCB rapid prototyping capabilities.
• Some individuals prefer in-house electronic manufacturing capabilities.
CONCLUSION AND RECOMMENDATIONS
The use of EDA tools based on concurrent engineering methodologies that
support sottware-hardware co-design, virtual prototyping, and rapid prototyping is
essential for a successful electronics design and manufacturing operation. To improve
the current design and manufacturing functions at JSC, the following actions should be
implemented:
• Form an overseeing committee that coordinates efforts regarding planning, training,
software, hardware, etc. The committee must be derived from all major design
groups at JSC to guarantee competent planning and effective communication.
• Acquire EDA tools that offer simultaneous access to all design teams (electrical,
mechanical, manufacturing, etc.) and have the following capabilities: Schematic
capture, HDL, electrical and mechanical simulations, PCB layout and simulation.
• Establish an EDA support center responsible for processes/procedures, training,
technical support, integration of design tools, network administration, library
development, equipment upgrading, licenses, etc.
• Consolidate the electronic manufacturing operations -- All orders are submitted to a
centralized facility.
• Provide proper training for all technical personnel -- This is very crucial for a smooth
and successful transition to the new environment.
• Maintain PCB rapid prototyping capabilities -- Communicate information to all
customers and provide quality products.
• Postpone the decision regarding establishing in-house manufacturing capabilities until
the electronic design functions are consolidated
The transition from the current structure to an integrated design environment can
be completed within two years. This aggressive schedule assumes the support and
commitment of everyone involved in the process. Acquiring EDA tools, developing
procedures, and providing training may be carried out in five phases as follows:
2-8
I° Pre-Planning (1 month)
• Identify individuals who should be involved in the planning phase -- Project
managers, design engineers, software specialists, etc.
II. Planning (4 months)
• Identify JSC design and manufacturing needs -- Survey designers, managers,
technicians, and other appropriate technical personnel.
• Specify required design capabilities (software and hardware).
• Select software and hardware that satisfy the required design capabilities.
• Order hardware and software.
• Develop some design procedures based on concurrent design methodologies.
• Identify a pilot project and select the first group of individuals for training.
III. Equipment Procurement and Installation (1 month)
IV. Initial Training (3 months)
• Provide proper training to a group of 12 individuals including those who will
constitute the support group.
V. Pilot Project (6 to 12 months)
• Implement design procedures and processes.
• Develop library.
• Refine processes and procedures.
VI. Full Conversion to the New Environment (12 months -- Start 3 months after pilot
project begins) -- 40 to 50 people
• Provide proper training to groups of eight to ten designers at a time.
• Provide support at all levels in the design process.
• Continue developing library and revising processes and procedures.
2-9
REFERENCES
[1] K. Lai, "A New Dawning in EDA," Integrated System Design Magazine, June
1996.
[2] G. Zach and J. Wilson, "An Evolution in System Design and Verification," ISD
Magazine, March 1996.
[3] S. Schulz, "Trends in Simulation and Synthesis," ISD Magazine, September 1995
[4] P. Clemente, R. Crevier, and P. Runstadl, "RTL and Behavioral Synthesis: A
Case Study," VHDL Times, Vol. 5, No. 1, 1996.
[5] B. Barrera and T. Feist, "FPGAs Streamline Design Process," EE Times, April
22, 1996.
[6] E. King, "Virtual Prototype Finds Design Flaws," ISD Magazine, May 1996.
[7] R. T. Maniwa, "Putting it Together: Prototyping Methods," ISD Magazine,
September 1995.
[8] A. Borrione and A. Pincetti, "Virtual Prototyping Proves Real Asset," EET
Times, January 22, 1996.
[9] S. Gilbrech, "FPGA Flexibility Enables Concurrent Board Design and Layout,"
ISD Magazine, March 1996.
[10] R. Maniwa, "Focus Report: Formal Verification, Cycle-Based Simulation, Timing
Analysis, and ESL Entry," ISD Magazine, June 1996.
[11] N. Barkus and G. Hinde, "EDA's Impact on the Design Process," Printed Circuit
Design, pp. 26-29, June 1995.
[12] J. Smith, R. Tomasek, M. Jin, and P. Wang, "Integrated System Simulation,"
Printed Circuit Design, February 1995.
[13] S. Schulz, "Results of the 1996 USE/DA Survey on EDA Business Practices,"
ISD Magazine, June 1996.
[14] G. Derman, "Manufacturing Technologies Interconnects Packaging," EE Times,
June 13, 1994.
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Electronic Design Automation: Integrating the Design and Manufacturing Functions

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