Advanced Component Testing: X-ray Imaging

In my last post, I wrote about XRF analysis in the first of a three-part series on advanced component testing capabilities. Converge offers each of these capabilities in-house as an added quality assurance measure for our customers. If any discrepancy raises a red flag during our initial 76-point inspection – from suspicious markings to inaccurate measurements – our in-house certified engineers use advanced testing methods to further investigate the authenticity of the components. One of those testing methods is X-ray imaging.

Everyone is familiar with X-ray technology. It is very likely that you have or someone in your family has needed at least one medical X-ray at some point. Even young children can understand how the advanced imaging that X-rays provide is beneficial to physicians.

X-ray imaging for electronic components works in the same way. There are smaller high-resolution X-ray machines that are uniquely designed to look inside components (e.g., ICs, capacitors, diodes, resistors and hybrids) to help detect flaws that aren’t obvious through exterior examination. In addition, X-ray imaging is able to provide this internal view without destroying the parts.

By comparing a component’s X-ray image with the manufacturer’s data sheet, or the internal structure of a known-good sample with the same date and lot code, Converge engineers can detect substandard or counterfeit components that might otherwise go unnoticed. X-ray imaging can reveal differences in die size, die frame, wire bond patterns, and internal lead characteristics. It can identify shorts or bridges, detect cracks in the epoxy, and recognize tampering attempts. This makes X-ray imaging an important part of any quality-driven distributor’s counterfeit-prevention program.

This X-ray image shows integrated circuits in good condition. Multiple parts are viewed to check for consistency of lead frame, die size, orientation, and wire bond placement.

These side-by-side X-ray images show integrated circuits in discrepant condition. While the lead frame and die pad is the same for both parts, the size of the die is different. This is suspect for parts within the same date or lot code. It would not be suspect for different date codes if there was documentation of a die redesign.

However, X-ray equipment is also very expensive and requires expertise to operate. Therefore, many smaller independent distributors do not offer this testing capability. It requires a significant capital investment that many are not able – or perhaps willing – to make. In some instances, other distributors outsource their X-ray testing at significant added cost to their customers.

Converge is proud to offer, at no additional cost, in-house X-ray inspection whenever extra verification is needed, as an added level of protection for our customers. It helps us ensure the authenticity of every order that passes through our warehouse and maintain the integrity of our supply chain. More important, it helps us provide peace of mind to every company we serve.

If you missed Part I of our Advanced Component Testing blog series, you can read it now.

Advanced Component Testing: XRF Analysis

Over the past few months, my colleagues and I have written a number of blog posts to help educate our OEM and CEM customers about our in-depth quality assurance process. We even produced a video that takes viewers inside one of our inspection facilities. Now I’d like to take a deeper dive into some of the advanced component testing capabilities that Converge is able to perform in-house – specifically, what are these techniques and why are they needed? This three-part series will cover XRF analysis, X-ray testing, and decapsulation.

What Is XRF Analysis?

X-ray fluorescence (XRF) analysis is primarily used to verify Restrictions on Hazardous Substances (RoHS) compliance. This European Union 2003 directive, designed to reduce toxic e-waste, restricts the use of six hazardous substances in electrical and electronic components equipment: Lead (Pb); Mercury (Hg); Cadmium (Cd); Hexavelent Chromium (Cr6+); Polybrominated Biphenyls (PBB); and Polybrominated Diphenyl Ether (PBDE). The maximum permitted concentrations are measured in parts-per-million (ppm) by weight of homogeneous material.

A handheld XRF “gun,” or analyzer, uses X-ray fluorescence to determine the elemental breakdown of a scanned component’s lead material. The analyzer offers material concentration results within seconds, along with a pass/fail result that indicates whether or not the component is RoHS compliant. Everything that can be identified as a homogeneous material must be below the concentration limit of 0.1% (except for Cadmium which is limited to 0.01%). In other words, if one material part of a product exceeds the maximum permitted concentrations, the entire product would fail the requirements of the directive.

This information is essential to global electronics manufacturers who need to ensure that their products meet RoHS requirements. Outside the European Union, other countries and states are developing similar hazardous substance regulations, so proving compliance that meets the strictest global regulations is becoming more critical than ever. No manufacturer wants to be held accountable if a component used in a marketed product later turns out to be noncompliant.

Alternatively, some manufacturers need leaded parts for military or aerospace builds. XRF analysis can likewise verify that the parts are indeed leaded and meet the customer’s requirements.

In either case, Converge engineers can compare our XRF analysis results to the manufacturer’s specifications (when available) or to a known good device. When the elemental breakdown doesn’t match, that’s a red flag. When combined with other advanced testing methods, XRF analysis provides an extra layer of protection in our mission to keep substandard components out of the supply chain.

As an independent distributor, Converge specializes in procuring hard-to-find and obsolete components for customers who desperately need them. While we carefully screen all our vendors, this is one more reason that Converge believes XRF analysis is an essential tool for every reputable independent distributor. Has your distributor made the XRF investment?

Read Part II of our Advanced Component Series on X-ray Imaging

Why a 76-Point Quality Inspection?

One question that we continually receive from customers is “Why does Converge have a 76-point quality inspection?” Not that they’re complaining about our obsession with quality – rather, they’re just curious about the number we proudly tout on our website and brochures.

Why 76?

When Converge originally created its robust multi-point quality assurance checklist (which is based on the industry-leading IDEA 1010 standard), we wanted to ensure that no portion of a shipment was overlooked in the inspection and verification process. Our quality team compiled the inspection criteria from the IDEA 1010 standard and then also incorporated the best-in-class requirements from our customers and their site inspection audits. Seventy-six actions were required to ensure that our criteria met or exceeded the highest quality requirements of ALL our global customers. We made all 76 steps mandatory, and the rest is history. Now every order processed by Converge must pass through one of our three global hubs and pass this inspection before it can be sent on to the customer.

Our multi-point quality assurance process has three phases: first, there is a visual inspection to verify that everything is exactly the way the original order says it should be, from the packaging, weight, and order numbers to the physical condition and markings of the materials. Orders that pass the first phase go on to a more in-depth inspection by a certified engineer. Here our engineers perform microscopic inspections on a large sampling of components from each order, as well as marking permanency tests, moisture level checks, and x-ray fluorescence (XRF) analysis.

Escalation points have been developed that require the use of additional advanced in-house testing methods, such as x-ray and decapsulation, when additional verification is required for questionable parts. Every step of the process is carefully documented and recorded, including numerous photographs, in order to protect both Converge and our customers.

Only after successfully completing the first two phases are parts released for shipping. This is the third and final phase: the order is inspected one last time before being packaged, photographed, weighed, and proper shipping labels are verified. Any failure within this process will result in the order being rejected, after which a discrepancy alert process is initiated and followed.

We’re not saying that 76 is a “magic number” when it comes to electronic component inspections. We’re continually working to improve our processes, and one day Converge may be talking about our 100-point quality inspection. But to date, this scrutiny and attention to detail is keeping our customers’ supply chains clear of suspect parts and their operations running smoothly.

So perhaps the question shouldn’t be why does Converge have a 76-point quality inspection, but rather…why doesn’t everyone else?

Converge 2011 Survey Respondents Seek Quality Assurance

Several months ago, Converge conducted its biennial customer satisfaction survey, which many blog readers probably received. If you were one of the hundreds of people who took the time to give us your valuable feedback, we cannot thank you enough. We view this survey as an opportunity not only to gauge (and improve) our performance level, but also to gain valuable insights about the electronic components industry from our global customers.

Converge customers are the innovators of today’s latest technology. They build electronics to fulfill every vertical need from telecommunications to consumer electronics to the industrial market – and beyond. And, of course, almost all our customers work with larger franchises and authorized distributors on a primary basis. But there are times when those normal supply channels become disrupted and a trusted independent distributor becomes the best option for sourcing the parts needed in time to keep production lines moving.

Alternatively, when the market slows and companies find themselves saddled with surplus inventory, they need a remarketing partner that can help them recover value while allowing them to remain focused on their core competencies. So we were not surprised to learn that the No. 1 reason that 2 out of 3 of our 2011 survey respondents say they come to Converge is for shortage solutions, followed by surplus remarketing and then market intelligence.

Keeping these results in mind, we did find it particularly telling that when asked to rank the most important service Converge offers, more than 30 percent chose “quality inspections” and nearly the same percentage chose “onsite anti-counterfeit equipment.”

When more than 60 percent of survey respondents say they come to Converge primarily for sourcing shortage materials, it is little wonder that the same percentage places the highest importance on our robust quality inspection program and our advanced on-site component testing services. Yes, our customers need parts that can be found only on the independent market, but in this day and age, they also know the risks involved in working with “any broker” to procure them. And many of them have decided that working with a distributor that doesn’t have in-depth inspection capabilities is not a chance they are willing to take.

Our survey respondents also told us that order accuracy and on-time delivery are highly important to them. We thought so. And we’re proud that more than 95 percent of them believe that Converge is meeting or surpassing their expectations when it comes to getting quality parts to them in time to meet their deadlines.

At Converge, we really love what we do – thanks, in no small part, to all of our innovative customers. Converge is proud to be your quality-driven partner for sourcing and remarketing quality electronic products in the independent market. We look forward to serving you even better in 2012.

Consignment Visibility Tool Simplifies Surplus Remarketing

Trying to remarket surplus electronic components can be a tremendous amount of work for manufacturers and EMS providers. Unless your company is equipped with market intelligence, it’s not easy to find out how much your excess inventory is really worth or who might be interested in buying it. There is also the danger of finding the wrong buyer – e.g., a broker instead of an end user – whose markups and fees can minimize your financial return. In addition, dealing with product staging and global shipping logistics can be a real hassle when those activities are not part of your company’s core mission.

Converge specializes in helping technology manufacturers solve their complicated surplus problems, while minimizing effort for the manufacturer and maximizing return potential. One way that we make the remarketing process as easy as possible for our clients is through our consignment program. Converge consignment is a turnkey solution in which the customer ships the surplus inventory to Converge, where it is inspected, sanitized, and marketed to our global network of contacts. However, the customer retains ownership of the inventory until it sells.

Converge’s proprietary online Consignment Visibility Tool (CVT) simplifies the process even further by allowing customers to view and manage all consigned inventory via one centralized hub. Some of our CVT features include:

• 24-7 transparency. Customers can log in to see their surplus inventory status at any time.

• Improved chain of communication. Our customers’ third-party partners – such as contract manufacturers – can also participate and access the CVT system, so customers can keep their entire supply chain streamlined and connected.

• Inventory balancing ability. If customers’ forecasts change and they need some of their consigned products back, they can simply look in the CVT to view what is available. Converge will ship the products back at no cost.

• Real-time financial forecasts. Consigners can see how much of their inventory sold, at what price it sold, and how much revenue to expect at the end of the month.

• Flexible reporting. Converge sends regular consignment inventory reports and payments on a monthly basis. Clients can also download information to create their own reports at any time through the CVT.

Many companies struggle to find an effective way to get excess inventory back into the supply chain. Converge can help you return that value back to your bottom line … without all the work that goes with selling your own inventory one line item at a time.

Q&A with Scot Hennessey on Supply Chain Disruptions

Shortages. For OEMs and EMS companies, few words can impart more angst and uncertainty. Electronic component shortages can virtually stop production lines, resulting in substantial loss of productivity and revenue. So what can manufacturers do to keep production (and profits) on track when the supply chain is unexpectedly disrupted? To learn more about supply chain disruptions, we discussed this topic in a Q&A with Scot Hennessey, Director of Sales for the Americas at Converge.

Q: What is the main cause of supply chain disruptions?

A: Supply chain disruptions can be caused by two different dynamics, one being demand-based and the other being supply-based. On the demand-based side, it could be due to new technology that instantly becomes popular, inaccurate forecasts, or seasonal demands. A supply-based shortage is typically due to raw material shortages or capacity restraints. Another prime cause is natural disasters, such as the flooding experienced in Thailand and the earthquake and tsunami in Japan, for example. Supply-based shortages can also be caused by geopolitical issues interfering with the normal business operations of a particular region or by parts going end-of-life. The reality is that no manufacturer can ever know with 100 percent certainty what will happen in the supply chain. It can be very unpredictable.

Q: What can manufacturers do to find the parts they need when the supply chain is disrupted?

A: The first thing most manufacturers will do when they encounter a shortage is go to an authorized distributor to try to find a solution. If that doesn’t work, companies can turn to a trusted independent distributor with market intelligence and a global reach. An exception-based partner that can offer market knowledge, such as Converge, will utilize its comprehensive database, sourcing strategy, and vast network of global partners to find material to fill the gap in a company’s supply chain.

Q: Should customers be concerned about where those parts are coming from?

A: We are. In this day and age, you can’t take anything for granted. That’s why Converge has invested in creating a comprehensive quality control program consisting of a 76-point inspection process and in-house advanced testing capabilities. Before any material is shipped to a customer, it must go through one of three Converge global hubs for screening. We also have an in-depth vendor screening and management process that tracks and continually scores our vendors.

Q: Do all independent distributors operate the same way?

A: In the past, I would have been inclined to say that practices were more similar among independents than I would today. But nowadays, the barriers to entry and the ability to meet industry-standard requirements separate most independent distributors from those that are best-in-class. Electronics manufacturers are looking for a certain level of supply chain confidence that can only be provided by distributors who are capable of making significant capital investments in engineering, equipment, infrastructure, and industry certifications such as IDEA. There are only a handful of independents in each region that can really scale to the quality requirements needed.

Q: So how would a manufacturer seek out a “best-in-class” partner in the independent space?

A: If possible, companies should be proactive and evaluate multiple exception-based partners before supply chain disruptions even occur. When doing so, I would audit facilities in person to verify there is a rigorous quality inspection process. Ideally, manufacturers should work with a firm that has certified component engineers in house so they are participating in the authenticity process. If an independent is not willing or able to make the investment in engineering resources and proper testing equipment, that should be a red flag.

Q: Do independent distributors have any insight on when a shortage is going to end?

A: No one can predict the future. The aftereffects of some supply chain disruptions linger longer than others. Sometimes parts are in shortage for months, and other times shortages resolve abruptly, leaving many manufacturers with surplus inventory after compensating for their shortage concerns by placing multiple product orders. The good news is that if manufacturers have already established a relationship with a trusted exception-based partner, that distributor will be ready to help with excess inventory challenges as soon as the market changes.

Why Working with an IDEA Member is a Great Idea

Have you ever seen an independent electronic components distributor touting its affiliation with a group called IDEA and wondered what that meant? What’s the big idea behind IDEA – and why should you care?

IDEA is the Independent Distributors of Electronics Association. This is a non-profit trade association whose mission is to enhance the quality of electronic products and services in the independent market, and to standardize the techniques and methods used to test and screen parts. Before IDEA was formed in 2006, each distributor had to rely on its own collected information and experiences while inspecting products for non conformance. Since its inception, IDEA has worked with quality leaders from many distributors to create the first reference manual of industry best practices and recommendations for inspecting and testing electronic components in the independent market.

This “standard,” Acceptability of Electronic Components Distributed in the Open Market, was updated earlier this year with the latest industry information (IDEA-STD-1010-B). STD-1010-B offers hundreds of new photos that help explain testing techniques, in addition to more than 400 example photos of acceptable versus nonconformance parts. This detailed inspection criteria, differentiated by product and package type, gives inspectors an enhanced ability to detect suspect parts from any region of the globe. In addition, the standard gives detailed provisions for managing test service providers and advanced inspection techniques. Any electronic component distributor can purchase copies online, and would be wise to do so, and follow its recommended guidelines.

Converge goes a step beyond simply following the recommended IDEA guidelines; we are also an IDEA member. Companies are accepted into membership only after meeting a long list of requirements and receiving a confirmation by the IDEA board of directors, which is comprised of a peer group. It is important to note that not every company that applies will be accepted. The standards are high.

This means that when you work with an IDEA member, you are guaranteed that the company, among other requirements:

• Maintains a demonstrated, sophisticated, and continually improving Quality Management System (QMS).

• Has incorporated IDEA-STD-1010: Acceptability of Electronic Components Distributed in the Open Market into its QMS.

• Holds at a minimum both ISO 9001 and ANSI/ESD S20.20 certifications.

• Maintains product liability insurance at a minimum of $1 million per incident and $2 million aggregate annually.

• Has at least one (1) IDEA-ICE-3000 Certified Professional Inspector at each inspection location around the world. (Converge has more than 30.)

I would hope that those are the kinds of guarantees in a distribution partner that help supply chain managers sleep better at night. I know I would – especially knowing how many independent distributors there are who are NOT IDEA members. In today’s technology industry, you constantly have to ask yourself: who can you really trust? Working only with IDEA members just might be a great idea.

You can read the full list of IDEA membership requirements on the IDEA website.

Download Free Shortage Market White Paper

Sooner or later, every technology-driven company will face an electronic components shortage. After all, the only predictable thing about the electronics supply chain is that it’s unpredictable. So how can manufacturers keep production lines moving when needed parts are not flowing through the typical distribution channels? That is one of the topics explored in the Converge white paper “Finding Components in a Shortage Market.”

This brief white paper also answers the most common questions about navigating the potential pitfalls of widespread supply chain disruption and allocation, including:

• What are the risks associated with shortages?

• What capabilities should you look for in a shortage inventory partner?

• Is there a way to plan ahead for shortage situations?

If you prefer podcasts to white papers, then listen to our informative conversation with industry expert Scot Hennessey, Converge Director of Sales for the Americas, as he offers insight on “What You Need to Know About a Shortage Market.”

Supply chain disruptions in the electronic components industry may be a reality, but that doesn’t mean they have to derail your business. Partnering with a trusted independent distributor can give your company a significant edge when it comes to procuring shortage parts and protecting your supply chain from unwelcome interruptions.

Seeing Is Believing in the Electronic Components Industry

At Converge, we like to say that seeing is believing in the electronic components industry. For more than 30 years, we have been among the leaders in quality assurance processes for independent distributors – starting with our original 76-point inspection. With each passing year, we further enhance our inspection and testing capabilities to continue to protect the supply chain from substandard components.

One of the many things that sets Converge apart is that we welcome customers who want to see our quality assurance processes in action. For customers who haven’t had the chance to visit, we have produced a short video that takes you inside one of our inspection facilities to highlight our in-depth quality inspection process. We hope you will take a few minutes to see what makes Converge such a reliable distribution resource:

When it comes to electronic components, it is imperative to verify your supplier’s inspection process and capabilities. Converge carefully screens all of its suppliers, and we urge our customers to do the same. It is the only way to guarantee the quality and peace of mind that your customers deserve.

What to Do When Parts Go End-of-Life

Every electronic product and component has a finite life cycle. In a world of rapidly changing technology, companies need to react quickly in order to stay competitive in the marketplace. For example, when a component manufacturer introduces a new chip to the market, it already has engineers working on the next generation of that technology. Once the manufacturer has perfected the new and improved technology, customers are alerted that the old chip will be going end-of-life (EOL). Typically, customers using the old chip to manufacture their products will then have a short window to decide what to do next.

When a needed component goes EOL, manufacturers using that part have a few options:

• They can switch to other previously qualified alternatives from their Approved Vendor List options.


• They can “spec” in the next generation of the chip from the manufacturer. This would require engineering support and likely carry significant financial costs and time-to-market considerations.


• Based on the product life cycle, they can estimate how many of the EOL parts will be required to continue manufacturing and servicing the product through a specified period of time. They can then order that quantity from the chip manufacturer as a last-time buy. This option places a large economic burden on the buyer, who must pay all the material costs up front and take possession of the product, which requires ongoing logistic and storage expense.


• They can come to an independent distributor, like Converge, for market intelligence. Converge has a team of expert commodity managers who can give companies visibility into the liquidity of a particular part in the independent market. What manufacturers really want to know is: “Do we need to make this last-time buy right now? Can we lessen our financial burden of carrying costs long term? Will this part be readily available in two years if we need more?” These are questions that independent distributors can help companies answer – at no cost and no obligation.

The next time your company is faced with an EOL situation, why not put an independent distributor’s market intelligence to work for you? You might be surprised to find that you and your EOL parts can be happily reunited in the “afterlife” in the independent market.