Quality

Manufacturing quality

Rolling Wireless is a fabless company. Our automotive NADs are produced by our manufacturing partner Flex Ltd. in its IATF 16949-compliant facility in Suzhou, China Mainland.  


Manufacturing partner Flex Ltd. →

No-touch manufacturing

Over almost two decades of lessons learned and continuous improvement, working closely with customers and expert advisors, we have turned our production floor from a factory running continuously with more than 300 operators to a fully automated production line managed by a handful of operators and supervisors.

Quality improvement examples include:


Lessons Learn

Past production

Current production

ORT

  1. HUT at 65°C/95% for 21 days in power-off mode
  2. TSKT at 85°C/-40°C for 300 cycles
  1. HUT at 85°C/85% for 10 days in power-on mode
  2. TSKT at 85°C/-40°C for 1000 cycles
Temperature test

Low yield, ~70%

  1. Poor socket contact
  2. One test system control 44 DUTs, too many RF switches impacting RF performance

High yield, above 99%

  1. Socket design improvements (pogo pin, etc)
  2. One shell controls one DUT, simplified RF connection
DBI Dynamic Burn-In at 70°C Increased to 85°C on 100% of the production
Handling Manual pick-up of modules by vacuum Automation and touchless at SMT and Test process
EMS/Supplier audit ISO audit VDA 6.3

Manufacturing showcase

For a brief demonstration of our world-class manufacturing setup, view our showcase video.

Reliability

Rolling Wireless places a strong emphasis on delivering products that meet the highest standards for reliability. We achieve this by incorporating quality and reliability checks at every level in our product design and manufacturing processes, and throughout the product life cycle. 

Product qualification process

High reliability and low defect rates are established during product design. Our standardised approach to automotive designs, building on prior lessons learned, includes:

  • Engineering Validation Test (EVT) to capture design issues and adjust
  • Design Validation Test (DVT): Zero failures = go to market
  • Technology test (TT) enables long-range quality level projection.

Ongoing Reliability Testing (ORT)

We consider that product reliability assessment does not stop at the end of the design phase, but has to be continuously monitored throughout the mass production life of our modules. This is why we apply an Ongoing Reliability Test (ORT) in our factory by sampling, every month, each of our product families.

The ORT helps us ensure process stability and parts quality. We can capture any drift that would be related to product ageing in an automotive environment, and stop any risky lots of modules. Our ORT combines our own experience accumulated over the years with recommendations from world-class reliability experts specialising in the automotive domain.

To be as close as possible to the customer environment and real field stress conditions, our modules are first soldered on PCBAs that simulate the customer application board by size, thickness, and type of PCB materials used, before they undergo the ageing test. In this way, our ORT includes the customer reflow effect as well as possible CTE mismatch effects between the application board and the module.

Based on our experience and confirmed with experts in the domain, the 2nd reflow and CTE mismatches are very high-stress factors that trigger most of the latent hardware defects that would have become visible in the first years of the product's life.

To learn more about our ORT process, please contact us.

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