MATERIAL & PROCESS CONTROL - MSD CONTROL - AEROSPACE AND DEFENSE

The Critical Role of MSD Control in Aerospace and Defense Electronics Manufacturing

January 23rd, 2025
By Cogiscan's Experts

Introduction

Unfailing reliability is the top requirement for products used in the aerospace and defense industries – electronics used in these sectors are vital to mission success, and even a single component failure is not an option. To that end, having a robust Moisture Sensitive Device (MSD) control system is essential, not simply a nice to have. Since these products are expected to have extensive operational lifetimes, A&D manufacturers must make the long-term integrity of MSDs a basic prerequisite to help meet these requirements.

Mandated by a complex set of stringent standards that manufacturers must follow (ex. AS 9100), A&D manufacturers can leverage MSD control tools to ensure compliance. These manufacturers are also under continuous pressure to reduce costs, and in products this expensive, cost becomes a significant consideration as the financial repercussions of component failure can be catastrophically high. Proactive moisture control not only protects the life of components but also helps to avoid unnecessary and pricey rework and even scrapping– just further highlighting the important role of automatic MSD management systems in the A&D sector.

Why must Aerospace & Defense Manufacturers use an automated solution?

The risk of MSDs in electronics manufacturing is that these devices can degrade when exposed to moisture for a certain period, controlled by the Moisture Sensitive Level (MSL) the component is rated for, as defined in IPC/JEDEC J-STD-033 Standard (Revision D). During the reflow process, trapped moisture can expand rapidly, causing internal damage to the component known as "popcorning." Moisture absorption and the subsequent exposure to reflow temperatures can also induce latent defects that might not cause immediate failure (caught during the production process) but can decrease the long-term reliability of the device by causing latent field failures.

Both these examples can lead to very costly (and potentially deadly) device failure, which is unacceptable in all cases and even more critical in aerospace and defense applications where reliability is absolutely mandatory.

The IPC/JEDEC J-STD-033D standard offers a set of uniform practices for handling, packaging, transporting, and using components that are sensitive to moisture and reflow soldering temperatures. These practices are designed to prevent damage due to the absorption of moisture or exposure to the heat of soldering, which can lead to decreased yields, reliability issues, and faulty components. When the procedures outlined in IPC/JEDEC J-STD-033D are correctly applied, they guarantee a minimum shelf life of one year from the date of sealing.

msd control satellite aerospace and defense

Cogiscan’s Platform for Complex Circuit Board Assembly

Cogiscan's MSD Control application is a specialized platform designed to meticulously track, manage and control the exposure and subsequent requirements of different types of MSDs. Here's how it protects the usage of MSDs during the manufacturing process:

Exposure Time Management & Calculations

The application accurately calculates and monitors exposure time, bake/re-dry time, dry storage time, and specific requirements for each part, taking into account characteristics such as moisture sensitivity level (MSL) and part thickness, while also tracking required bake cycles and computing remaining floor life in real-time, therefor ensuring adherence to the IPC/JEDEC J-STD-033 (Rev D) standards.
Double-Sided Reflow Applications

The Cogiscan automatic system accounts for double-sided PCBAs while maintaining an efficient operation by providing real-time status of the materials and advanced warnings of expiration for decision making.
Short Duration Exposure

The system accounts for Short Duration Exposure (SDE) Rules for previously exposed components returned to Dry Storage.
Closed-Loop Process Control

The software interlocks the line to block production when expired moisture-sensitive devices are detected on the assembly line or mounted on a printed circuit board assembly (PCBA).
Real-Time Alerts

Operators are kept informed with automated notifications when MSDs approach their exposure limits or require baking to remove absorbed moisture, thereby preventing potential defects.
Seamless Integration

The system interfaces with dry storage solutions (including Automated Storage Tower), automating the tracking of component storage times.
Complete Traceability

With Cogiscan's MSD Control, every moisture-sensitive component is tracked throughout its lifecycle, from receiving through assembly, providing an often-needed audit trail.
Comprehensive Reporting

The Cogiscan system also includes in-depth reports on the status and history of MSDs to provide to end-customers as needed.

Conclusion

A single failure can have catastrophic results, making the implementation of a rigorous MSD control system not just a precaution but a necessity for mission-critical operations. This is why industry leaders such as Raytheon and BAE Systems implemented and use our automated MSD Control solution, even though their assembly processes each have their own specificities and requirements in terms of software integration.

Our solution is designed for flexibility and can function independently; however, it is also optimized to fit within a broader software ecosystem. Thanks to its modular design, Cogiscan’s MSD Control application can effortlessly merge with comprehensive enterprise platform, such as MES/MOM, ERP and TTC platforms, enhancing its interoperability and utility within the existing digital infrastructure.

Connect with an MSD Expert today to chat about your specific requirements.

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