Software development methodology of structural-parametric description of low-temperature co-fired ceramics-technology for the production of microwave components

Abstract

The article discusses the production of microwave components based on the technology of low-temperature co-fired ceramics (LTCC). A set of standards Continuous Acquisition and Life cycle Support (CALS) and International Organization for Standardization (ISO) and business process models in these standards are considered. Based on the basic models of the ISO and CALS standards, a structural-parametric description model (SPD) has been developed, in which the structure of ISO-9000 is preserved, and specific parameters of LTCC technology are added. The methodology of the (SPD) of this technology is proposed. Open source software for processes, resources, results, production operations, control and management has been developed for each technological operation (TO), workplace and area. The methodology for creating information support and Microsoft Access Database Management System (DBMS) of SPD is proposed. Recommendations for the development of a software-methodological complex of information support for SPD of LTCC technology are proposed.

Keywords

Low-temperature co-fired ceramics ISO-9000 CALS method of structural parametric description information support structural-parametric description model of low-temperature co-fired ceramics Microsoft Access Database Management System

1 Introduction

For the manufacture of high-frequency and ultra-high-frequency modules and microcircuits of low and medium degree of integration, the technology of LTCC is currently used [1].

LTCC technology provides a low-cost solution for mass production of electronic devices in the telecommunications, medical, automotive, military and other industries.

During the implementation of LTCC technology, problems were identified related to the mutual influence of a large number of technological processes parameters at each stage of production on the quality of products [2 –5].

Variable parameters of LTCC technology (sheet sizes, names of pastes, time, equipment setup, etc.) are scattered throughout the documentation. The number of documents and procedures for production, control and management is rather large [6 –8].

In turn, the documentation is poorly formalized, fragmented, often redundant and/or insufficient to extract the necessary data from it. It is necessary to monitor that each employee fulfills the requirements of the documents and is responsible for their violation.

A key feature of the technology implementation is the difficulty of analyzing a significant number of parameters distributed according to the documentation. Currently, the existing quality standards ISO-9000 and CALS-technologies do not provide specific ways to improve quality, but are recommended.

To improve the quality of production of microwave components, a method of SPD is proposed.

Here there is the structure and brief description of the sections.

The first section provides the article structure.

The second section discusses CALS set of standards, as well as the theoretical foundations for the development of SPD.

In the third section, the main SPD models are developed and finalized in relation to LTCC technology, and ISO and CALS are taken as the basic model.

The fourth section shows how to create a database in MS Access.

The fifth section presents the results of the development of the software and methodological complex, the advantages and disadvantages of MS Access.

The sixth section summarizes the results of the development.

2 Theoretical basis

2.1 Setting research and development objectives

An important problem in the formation of information support is the choice of the optimal composition of objects of informatization in the subject area. It is known that the significance of any object in the system often changes depending on the situation at the moment. Therefore, often the indicators of informatization objects include the quality of products and production and their non-compliance with the requirements of working documentation(WD).

The main problems of forming information support include increasing the efficiency and reducing the complexity of solving the problem of diagnosing the non-compliance of control object (NCO) with the requirements of WD.

Monitoring, marketing and management systems developed within the framework of ISO-9000 and the International CALS program are focused on solving these problems. Due to the complexity and multifaceted nature of this program, a large number of performers from different countries, including Russia, take part in it.

In addition to regulating the design of technical, software and language tools for various information systems, CALS standards describe the rules for the electronic submission of data about products, environment and processes, as well as the rules for exchanging this data. Conditionally normative WD in the field of CALS can be divided into three main groups:

standards of general principles of electronic exchange of databases defining organizational and technical aspects of interaction;

database security standards, their encryption, use of electronic digital signature, etc.;

technical standards for data formats and models, technologies for presenting, accessing and using data about products, processes and environment of the product life cycle.

Here it is appropriate to further emphasize that all three groups of CALS standards, although they solve the problems of describing and developing regulations for the interaction of life cycle participants within the framework of a paperless workflow, they consider the database as a pre-prepared initial information support.

The novelty of CALS concept is as follows:

breadth of coverage and systematic approach (we are talking not only about production or design, but also about supporting all processes in life cycle: from conception to product disposal);

Integration is achieved by standardizing the presentation of information (or results) in the processes of design, procurement, production, repair, after-sales service, etc. This ensures the rapid transfer of functions from one contractor to another, which, in turn, can benefit from the results already work.

The main advantages of applying CALS concept are the following:

reducing the time to market for a product (reducing time costs);

reduction in the cost of the life cycle (reduction of material costs);

product quality improvement.

The development and implementation of CALS standards in Russia is carried out by organizations of the Ministry of Economy and Gosstandart within the framework of the federal target program for restructuring the defense industry and civil industries. More information can be found at www.cals.com.

The methods of SPD systems and technologies proposed in this paper differ from CALS standards in terms of the description of the database by their simplicity, clarity and logical relation with the current WD.

However, in the article, SPD methods are considered not as an alternative to traditional ones (ISO, CALS, etc.), but as one of the possible options for describing objects.

At the same time, SPD method can be included in a new methodology for displaying, modeling and optimizing complex nested (hierarchical) systems, including all types of industrial technologies, enterprises of any form of ownership and organizations.

The main objectives of the development of SPD enterprises and electronics technologies are the following:

implementation of a modern efficiency management strategy (quality and nomenclature of production, organization and economic efficiency, analysis and synthesis of measures to eliminate identified NCO);

solving information problems at all stages of the life cycle of products with an immediate response of personnel to manifestations of non-conformities in products and the work of the enterprise, establishing the causes of NCO and taking measures to eliminate them.

Using the example of LTCC, we consider the application of SPD methodology to a section of LTCC technology.

2.2 LTCC technological process and its parameters

Here we will assume that technology is staff activity, regulated by technological documentation. In turn, the documentation contains a processes description with indication of measured parameters [9].

The object of research is the technological process LTCC. It consists of TO. Each TO is performed at its own workplace. TO has input resources X, technological processes Y and results Z [10, 11].

Also in TO there are control operations (control V) (checking for compliance of the obtained results with the indicated ones) and corrective action (management U) (Table 1).

Table 1
LTCC production technology parameters

SPD LTCC

TO Resource X Process Y Results Z Control V Management U

Production and cutting of blanks Chemical composition, mass of components (grams) Production of blanks Ceramic sheets: geometric size (X, Y), thickness of sheets (h), mechanical damage Control of time, sintering temperature, geometric dimensions of sheets, mechanical damage, chemical composition and mass of components Changing installation settings, replacing original components, changing component ratios

Formation of transition holes Ceramic sheets: geometric size (X, Y), thickness of sheets (h), mechanical damage Formation of transition holes Sheets with holes: (X holes, Y holes) Control of the accuracy of punching holes (Xpun, Ypun), hole sizes (a, b . . .), mechanical damage Adjustment of settings and verification of installation, adjustment of execution program, replacement of matrices and punches

Filling holes, screen printing Sheets with holes: (X holes, Y holes) Screen printing Sheets with drawing topology (X, Y, h) Control of geometry and accuracy of drawing, mechanical damage Setting positioning accuracy, adjusting stencils, changing the number of passes and types of squeegees, their rigidity, type of use of pastes

Assembling layers into a package Sheets with drawing topology (X, Y, h) Assembling layers into a package Ready stack (X, Y, h) Control of position, sequence of arrangement of sheets, pressure, compression time Changing installation settings, positioning accuracy, changing the sequence of ceramic sheets, the sides of the installation of sheets, pressure and compression time

Package stump Ready stack (X, Y, h) Package stump Individual elements (X, Y, h) Control of cutting accuracy, mechanical damage Changing installation settings, sheet positioning accuracy, setting the cutting accuracy

Firing Individual elements (X, Y, h) Firing LTCC firing components Control of temperature, firing time Changing installation settings, temperature, firing time

SPD LTCC
TO	Resource X	Process Y	Results Z	Control V	Management U
Production and cutting of blanks	Chemical composition, mass of components (grams)	Production of blanks	Ceramic sheets: geometric size (X, Y), thickness of sheets (h), mechanical damage	Control of time, sintering temperature, geometric dimensions of sheets, mechanical damage, chemical composition and mass of components	Changing installation settings, replacing original components, changing component ratios
Formation of transition holes	Ceramic sheets: geometric size (X, Y), thickness of sheets (h), mechanical damage	Formation of transition holes	Sheets with holes: (X holes, Y holes)	Control of the accuracy of punching holes (Xpun, Ypun), hole sizes (a, b . . .), mechanical damage	Adjustment of settings and verification of installation, adjustment of execution program, replacement of matrices and punches
Filling holes, screen printing	Sheets with holes: (X holes, Y holes)	Screen printing	Sheets with drawing topology (X, Y, h)	Control of geometry and accuracy of drawing, mechanical damage	Setting positioning accuracy, adjusting stencils, changing the number of passes and types of squeegees, their rigidity, type of use of pastes
Assembling layers into a package	Sheets with drawing topology (X, Y, h)	Assembling layers into a package	Ready stack (X, Y, h)	Control of position, sequence of arrangement of sheets, pressure, compression time	Changing installation settings, positioning accuracy, changing the sequence of ceramic sheets, the sides of the installation of sheets, pressure and compression time
Package stump	Ready stack (X, Y, h)	Package stump	Individual elements (X, Y, h)	Control of cutting accuracy, mechanical damage	Changing installation settings, sheet positioning accuracy, setting the cutting accuracy
Firing	Individual elements (X, Y, h)	Firing	LTCC firing components	Control of temperature, firing time	Changing installation settings, temperature, firing time

As we can see from the Table 1, at each stage of production, there are more variable parameters, depending on used components, time of technological process and accuracy of equipment setting.

In a real life, there is no system that would collect all of the above-mentioned parameters together, compare them and issue recommendations for improving the quality.

In this paper, a method for creating, describing and modeling parameters in the form of information support, based on SPD according to the data of regulatory documentation, is proposed to improve the quality of production of microwave components [7].

As an information support, a set of planned and monitored performance indicators of an enterprise, its divisions and staff are used, provided for by the regulatory documentation for an objective assessment of the quality and efficiency of used resources, processes and results [8].

3 Methodology

3.1 Mathematical model of SPD

ISO, CALS and GOST R standards recommend that when describing information support, both the traditional object and the new process approach be used to describe business processes and all stages of the life cycle of products.

With the object description of the database, an object is any object, process, property and value that has its own name. The disadvantage of this initial position is that it does not reduce or indicate the way to limit the power of the set of databaseobjects.

It is based on a conceptual model for describing business processes, represented by “black box” (Fig. 1), which rarely allows finding an unambiguous solution due to the fuzzy regulation of the process description “from top to bottom”.

Fig. 1

Business process model according to ISO and CALS standards (“black box”).

Representation of technological processes is in the form of analyzed and comparable data with the possibility of aggregation. Thus, hierarchy of indicators is built. The implementation of this model in the form of a database will be discussed later.

This paper proposes the structure of the information model (Fig. 2) of the workplace as an “atomic” cell of an open source enterprise, which has all the properties of nested hierarchical systems.

Fig. 2

Model of SPD of TO.

Each nested system is characterized by a structure containing a certain number of subsystems, the functions of each subsystem and the interconnections of the subsystems.

With the process approach to the description of the system, the main functions (processes) are distinguished in it: ensuring and fulfilling the planned tasks U; monitoring the solution of tasks W and analysis of non-compliance of NCO; decision making V to eliminate and prevent NCO. This closed control loop (U, W, V) is formally described by tuples of functions U, W, V in relation to a given workplace by a set of the form (1).

To solve the problem related to the complexity of LTCC data analysis, a mathematical model of SPD of this technology is proposed. This technology retains ISO-9000 structure and includes specific LTCC parameters (Fig. 2). $\begin{matrix} S_{WP} {= {[U}_{WP} {(X}_{WP} {, Y}_{WP} {, Z}_{WP})], \\ {[W}_{WP} {(X}_{WP} {, Y}_{WP} {, Z}_{WP})], \\ {[V}_{WP} {(X}_{WP} {, Y}_{WP} {, Z}_{WP})]}, \end{matrix}$ (1)

Expression (1) uses the following notation:

U_WP (X_WP, Y_WP, Z_WP) is TO U_WP, where X_WP (x₁, x₂, … x_N) is a relational list of resource names required to perform a given U_WP operation;

Z_TO (z₁₁, z₁₂, … z_1B) is a relational list of product indicators compiled according to the requirements of the documentation.

W_WP [X_WP (x₁, x₂, … x_D), Y_WP (y₁, y₂, … y_F), Z_WP (z₁, z₁, … z_G)] is W_PM monitoring data tuple, where X_WP, Y_WP and Z_WP are relational lists of corresponding resources, processes and products, compiled according to the requirements of the documentation in relation to the performance of control and analysis operations;

V_WP [X_WP (x₁, x₂, … x_Q), Y_WP (y₁, y₂, … y_W), Z_WP (z₁, z₂, … z_R)] is V_WP monitoring data tuple, where X_WP, Y_WP and Z_WP are relational lists of resources, processes and products, compiled according to the requirements of documentation in relation to the performance of management operations.

Since TO is usually performed at one workplace for several products and production routes S(j) (where j = (1, 2, . . . n); n is the number of product items manufactured by this workplace, the total load of this work-place is determined by summing resources, processes and results for each T-route in accordance with expression (2): $\begin{matrix} S_{WP} = {\sum Sj [Uj (Xj, Yj, Zj), Wj (Xj, Yj, Zj), \\ Vj (Xj, Yj, Zj)]}, \end{matrix}$ (2)

where j = (1, 2, . . . n); n is the number of product items manufactured by this WP; Uj(Xj,Yj,Zj), Wj(Xj,Yj,Zj), Vj(Xj,Yj,Zj) are workflow, monitoring and management functions, respectively; Xj, Yj and Zj are relational lists of resources, processes and products, respectively.

Based on SPD model of the workplace, we will compose SPD model of LTCC area, shown in the Fig. 3.

Fig. 3

SPD model of LTCC area.

For example, the technological process for the production of LTCC component consists of six technological steps.

Each TO is performed at its own workplace. Moreover, the result of one operation is a resource for the next one. This model of open source can be extended to each workplace (1. Production and cutting of blanks, 2. Formation of transition holes. 3. Filling holes, screen printing, 4. Assembling layers into a package, 5. Package stump, 6. Firing).

The unit of SPD or the atomic cell is TO. One or more TO can be performed at one workplace [12 –18].

At the same time, the functions of management and control (feedback) apply to each maintenance and to the workplace and the area as a whole.

Based on SPD of the workplace and SPD of the area, a layout diagram of the enterprise was drawn up. In this case, the management function hierarchically consists of branch management, plant management, shop management, area management and workplace management. Control is also hierarchical (Fig. 4).

Fig. 4

Hierarchical structure of enterprise.

The sequential transition from consideration and description of a real object (in this case, WP) to its documentary (textual) description, from text to a structural-functional model, and from the latter to a tuple and a parametric portrait (PP) leads to the final as a result, to a compact mathematical representation of the workplace in terms of set theory.

So, as a result of successive transformations of textual, structural-functional and functional-parametric descriptions of a typical workplace model, a compact formal description of the workplace was obtained by the functions of the workflow U, monitoring W and management V.

Based on the data of these functions, mathematical expressions (2) are obtained. Having carried out similar transformations of the descriptions of the S_SUBD2 subdivision (Fig. 2) and the S_ENTERP3 enterprise (Fig. 3), it is easy to obtain their mathematical representation at three levels:

Level I - workplace displays SPD S_WP1 data at the lower level according to expression (2);

Level II - subdivision displays SPD S_SUBD2 data according to expression (3): $\begin{matrix} S_{SUBD 2} = {\sum \sum Sji [Uji (Xji, Yji, Zji), \\ Wji (Xji, Yji, Zji), \\ Vji (Xji, Yji, Zji)]}, \end{matrix}$ (3)

where j = (1, 2, . . . n), n is the number of product items manufactured by this division, and i = (1, 2, . . . d), d is the number of workplaces of this division involved in the production of n items products.

Level III - enterprise level displays S_ENTERP3 data according to expression (4): $\begin{matrix} S_{IS 3} = {\sum \sum \sum Sjik [Ujik (Xjik, Yjik, Zjik), \\ Wjik (Xjik, Yjik, Zjik), \\ Vjik (Xjik, Yjik, Zjik)]}, \end{matrix}$ (4)

where j = (1, 2, . . . n), n is the number of product items manufactured by this enterprise; i = (1, 2, . . . d), d is the number of enterprise divisions involved in the release of this product; k = (1, 2, . . . R), R is the number of workplaces in each subdivision that participated in the production of products.

The concept of information support is proposed based on the models discussed above.

3.2 Information support and database

Information support is a set of planned and controlled performance indicators of enterprise, its divisions and staff, provided for by the regulatory documentation for an objective assessment of the quality and efficiency of used resources, processes and results.

As it was shown above, information support SPD is a database.

The proposed concept of information support SPD meets the requirements:

there is a set of independent materials, systematized in a certain way, so that these materials can be found and processed using a computer;

there is a set of data (parameters) stored in accordance with SPD, which are manipulated in accordance with the rules of data modeling tools (SPD models of portraits and tuples).

Database types, also called database models or database families, are templates and structures used to organize data in a database management system. The choice of the type will affect what operations the application can perform, how the data is presented, and the functions of databases for development.

We have a collection of data, organized according to the conceptual structure of open source software, describing the characteristics of this data and the relation between them; it supports one or more areas of application (production LTCC).

4 Results

4.1 LTCC database in Microsoft Access DBMS

Microsoft Access package is included in Microsoft Office. On the one hand, it is a complete database, on the other hand, it has a simple and intuitive interface that facilitates the rapid creation of a database prototype. The created database prototype can be integrated into more serious tools such as ADO.NET and Qt SQLite. The papers [19, 20] describe the development of this database using the Client-Server technology.

The work on creating a database in Microsoft Access DBMS begins with the definition of relational tables and fields intended for storing data characterizing IO. In the database of SPD LTCC, the relation of the tables in which the data is stored is visible. The way of data aggregation into enlarged indicators and portraits is shown in the Fig. 5.

Fig. 5

Data structure in microsoft access.

The Fig. 5 shows the schema of the database tables, their fields and relation, as well as the aggregation path into coarse tuples and portraits (from left to right).

In the left column, there are three sections with different types of parameters that participate in the description of “Indicator” (next column) in a one-to-many relation, i.e. the same types of parameters can participate in the description of several indicators.

“Indicator” can be included in “Resource”, “Process” or “Result”. Further, “Tuple” is formed from these three components, which will be included in “Production”, “Management” or “Control”. Based on these three things, “Portrait” is formed as the top and abstract level of the hierarchy.

Since the information support description model includes the functions of production U, control W and management V, and these same functions can apply to different levels of management –WP, division, enterprise, question arises of introducing additional identifiers that uniquely determine the relation as to the level of management and to the object and control subject [21 –23].

The importance of indexing and identification here also increases due to the aggregation of indicators, which allows the use of the same data in archives belonging to different levels of government.

To avoid mixing of data over long periods of time, and especially when processing statistical data, identifiers must clearly correspond to structured and integrated data [24].

To fulfill this condition, it is necessary to use the standard formats of the original SPD and mark all operations on it during structuring and integration, as it is shown in the Fig. 4. when adding identifying indicators.

For the convenience of data management, a database was created in Microsoft Access DBMS, in which the above indicators were introduced. The metrics are stored in the table. To add something, we use the input form shown in the Fig. 6.

Fig. 6

Form for entering indicators.

In the column “Name” we enter the name of the indicator and select the type of parameter. The column “Type of portrait parameter” indicates what type the portrait of this operation belongs to. The types are described in the table. The metric data is presented in a metric tree. There is a possibility of adding, deleting and editing indicators.

SPD implies a transition from a real enterprise to a virtual structure, where all workplaces, divisions of the enterprise and connections between them are displayed.

Thus, on the one hand, we get real (controlled) parametric portraits, and on the other hand, we have reference (planned) portraits. A comparison is made through the acts of workplaces, as a result of which a discrepancy with the objects of control is established.

IO SPD in electronic form will be called a “virtual” enterprise.

The statement of SPD in Microsoft Access DBMS allows using the wide capabilities of this system for preliminary processing of initial data (aggregation, structuring, distribution by management levels) and for operational and statistical processing of technological process data.

Since the data of Microsoft Access DBMS is easily converted into all modern databases, it can be argued that SPD Microsoft Access DBMS can be easily integrated into other databases.

5 Discussion

There are the results of the development of the software and methodological complex below:

The tables of parameters of a portrait and a tuple in Microsoft Access DBMS were created, and the lists of entities were filled with source data;

For the types of parameters of portraits and tuples, visualization (display) was provided. This can be done using ComboBox or ListView;

It is possible to edit the display of indicators of portraits and tuples. There is a possibility to change (add and remove) the type of the indicator of the portrait and the tuple.

The result is shown in the Fig. 7.

Fig. 7

Form of displaying indicators.

Thus, the given example of extracting initial data from documentation, structuring, coding and identifying indicators shows the feasibility and convenience of using SPD for mathematical modeling of TO.

A classification of parameters has also been introduced (Tables 2, 3).

The type of the portrait parameter indicates what type the portrait of this operation belongs to. The types are described in the Table 2.

Table 2

Parameter_type_portrait

Code_parameter_type_portrait	Parameter_type_portrait
U	Production
V	Control
W	Management

The type of the indicator parameter describes what type the given indicator belongs to in the tuple. The types are described in the Table 3.

Table 3

Parameter type tuple

Code_parameter_type_tuple	Parameter_type_tuple
X	Resource
Y	Process
Z	Result

The data on tuples is presented in the form of a format (Fig. 8), in which there are following fields: field with a tree of tuples; three fields, where the indicators are grouped by the type of the tuple indicator; fields corresponding to “Resources”, “Processes” and “Results”.

There are buttons for deleting and adding a tuple to the tree.

The advantages of Microsoft Access DBMS are the following:

Translation of SPD into Microsoft Access DBMS does not require preliminary labor-intensive and complex procedures for checking the correctness, consistency and integrity of IO data.

Setting SPD data in Microsoft Access DBMS allows using the wide capabilities of this system for preliminary processing of initial data (aggregation, structuring, distribution by control levels) and for operational and statistical processing of technological process data.

Since Microsoft Access DBMS data is easily converted into all modern DBMS, it can be argued that SPD and TO portrait description can be easily ported (embedded) into other DBMS.

Availability of funds for designing a database application without knowledge of the programming language.

The disadvantage of Microsoft Access DBMS is the following:

Access technology does not allow making multi-user systems. To solve this problem, it is proposed to use ADO.NET, SQLite and PHP with MySQL in the future [25].

Fig. 8

Tuple display form.

Coding LTCC technology in Access database using SPD methodology made it possible to increase production efficiency by identifying NCO.

With the help of real indicators (real databases), we find NCO that we can eliminate and, therefore, improve the quality of the output.

6 Conclusion

The article proposes methodology to the development software of information support for the production of microwave components based on the technology of LTCC.

The technological process LTCC and its parameters are considered. LTCC technology is considered in the example of the workshop, and key parameters are identified. It is shown that at each stage of production there are a lot of variable parameters depending on used components, time of the technological process and accuracy of the equipment setting.

A universal model of the structural-functional description of the workplace as a minimal “atomic” nested system of an enterprise, which has all the properties of higher-level systems and is characterized by structure, functions, relations and efficiency, has been developed and investigated.

A mathematical model of SPD of resources, processes and results is proposed; there is also a control function and control feedback at each operation of LTCC technology.

Based on the results of the study, a mathematical model for describing information support of WP based on PP data and tuples of control functions was proposed for the first time. The assessment of the completeness and adequacy of the model was carried out according to the sufficiency of information support data for solving monitoring and management problems. The universal structural-functional model and WP mathematical model form the basis for the development of SPD method for complex nested (hierarchical) systems.

The technology is considered as the activity of staff, controlled by documentation, which has a structure and parameters.

Based on SPD method, the relations within LTCC area and enterprise are shown. A method for describing a manufacturing enterprise in the form of information support (virtual structure) is also proposed. This makes it possible to create a software development methodology of information support for the production of microwave components of LTCC technology.

Original schemes and rules for constructing separate subdivisions and the entire enterprise from the workplace have been developed. Schemes are distinguished by the convenience of decomposition, coding and identification of structural elements for subsequent analysis, optimization and system synthesis.

It was shown that the information support of SPD is a database, where we have a collection of data organized in accordance with the conceptual structure of SPD, which describes the characteristics of this data and the relation between them, supports one or more areas of application.

The methodology for creating information support and Microsoft Access DBMS SPD is proposed.

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