Al Wright - Field Applications Engineer
How many years have you worked at Epec and has your role changed?
I started in 2001 so it has been 15 years, plus a couple of months. That was the "old" company, before Ed McMahon (CEO) came in and we went to our current model. I got the job because one of the cam operators here got a really rare disease. The company I had been working with went out of business so I ended up applying at Epec.
The role was incredibly limited when I got here. It was really just a CAM operator position, so I could stay in the industry, but it wasn't what I had thought of as a CAM operator job. Where I had been before, you basically got handed a sales order and you did all the engineering, the process sequence, the photo data prep, NC programming, and test fixtures. If you needed to make direct contact with the customer, you did that, too -- the whole shebang. Here it took seven people to do what I had been accustomed by doing myself at my other company.
They were still doing first piece inspection drilling, which I hadn't seen in quite a while. It was very expensive because you had to drill a panel and stop a production machine to do it. That can be done on screen with software at almost no cost, so I couldn't really see the point of putting so many resources into such a basic step. It was very different from what I was accustomed to. As far as computers go, the methods engineers had one computer between them. Everything was reams of paper, colored pencils, and rubber stamps. It was like it was still World War II. The entire Internet was running off AOL. The CAM program was running on DOS. Then of course everybody smoked inside the building, so it was just crazy. It reminded me of when I first started in the business. I have a 40-mile commute, so I'd tell people I was going back in time 6 months for every mile I drove to work.
The CAM position was kind of weird, totally underutilized. We'd just turn the Gerber files into films, with minimal editing, not even adding an etch allowance like the rest of the world, not scaling internal layers on multilayer boards. I'd find little design problems where if you did a little edit, the job would run better, but you had to clear things like that with internal people who didn't want to modify anything, so nobody wanted to hear about it. It was like they wanted everything to be as difficult as it could be, instead of suggesting improvements to the customer.
The CAM operators didn't even edit their own drill files. Drill programming was separate, like it was in the 1980s, when it actually required time and effort. It was just plain odd, how each tiny task was all done by separate people. I'd say it was like firefighting in the days when people passed buckets of water to each other and the last person threw the water on the fire. It was totally inefficient, and the buildings always burned down anyway.
That was how the old Epec was; the old owner liked it that way. All the positions were narrowly defined, nobody seemed to know or care how their job affected the next person's job. When Ed McMahon bought the company we started acquiring companies and everything changed. Tell me about a project or accomplishment that you consider to be the most significant in your career.
Tell me about a project or accomplishment that you consider to be the most significant in your career.
I don't usually think that way, but there was a series of Northrop Grumman extreme copper jobs that took about four years in development that has just started to go into production. It was gratifying to see large orders coming in for that because of the long term development. Some of the long development projects can end up not going forward after you've put a lot of effort into it -- you can never be sure what will stick around long term. It was good to see that one pay off after all the work I'd done. A lot of other people had contributed too, so that was a big win. It's also an important product in terms of its end use. So yeah, that one.
What kind of technology was available at the time when you started?
When I started in 1981, things were pretty primitive. Some of the big companies had what were called captive shops, meaning they had their own PCB shops set up with fairly modern equipment for that time and they'd build their own boards. But even their great equipment for that era couldn't do much by modern standards. Like photo plotting the films. You were talking about plotting four or eight sheets of film per shift, where modern photo plotters could do that many in 5-10 minutes. That's why standard lead times were on the order of 8-10 weeks and 3 weeks was a quick turn, if you can get your arms around that.
When I first started, mom and pop job shops like where I worked didn't have anything like photo plotters. We were actually doing contact films, then developing in pans or in trays. You'd have three different trays, developer, fixer, and rinse. The only way to make duplicate images was to take one image, reduce it to 1:1 in a room-sized reduction camera, make copies, and then develop the copies. After that, everything had to be touched up because the environment was grungy, so there'd always be specks and pin holes in the film emulsion.
The whole front end process was really, really, slow. Even making drill programs was a nightmare because you had to use the actual films to locate the holes. If you were lucky you had one of those Excellon Opic III machines which was a big scope with a hood and mirrors that were just coming into play, so you could bomb-sight the holes very accurately. There were also a lot of jobs where you had to type in the X and Y coordinates to show the machine where the drill would drill the holes. Sometimes you'd get a customer-supplied paper tape with the drill information. That was a luxury.
Plating and other wet processes tended to be all tank stuff. There wasn't a whole lot of automated plating, there wasn't a whole lot of automated anything. When I first started, I used to do stuff for overtime like hand sanding boards after drilling, or stripping resist by hand agitation. You'd lower the boards into a square plastic tub full of stripper on a little rack and swish them around until the resist was dissolved. That's why they still call low-end circuit board shops "bucket shops". There was a lot of crazy stuff like that.
Even imaging was so primitive. At first we didn't use a lot of film imaging or dry film imaging. Instead we used silk screening technology, meaning the circuity would be screened onto the board, which isn't all that accurate. It's a similar process to what they do now for letter screening, except letter screening is less critical. For the circuit image couldn't really resolve any kind of fine circuitry. You would spend a year and a day touching things up after you print the image. There would be armies of touch-up employees with brushes that would touch up pin holes on boards and so forth – talk about a WPA project.
What was pretty cool then, living in the Rte. 128 tech belt, there was a big support industry that grew up around where the actual fabricators were located. If you went to town you would see places that did CNC drilling, metals finishing, or things like artwork reduction – processes that were expensive for small shops to own, but it was necessary to have them available. It was a pretty vibrant subculture or ecosystem. There are still services like that, but mostly it is really contracted like the whole industry.
If a genie granted you 3 wishes right now, what would you wish for?
A fabrication drawing with every incoming data package. More time. What else? Maybe a better set of eyes to look at it all with. If the genie made me prioritize my wishes, I'd ask for the extra time first.
If you could have dinner with anyone from history, who would it be?
Wow! I think if I wanted to be entertained and kind of be just a fly on the wall and not necessarily participate but just to watch someone else around a dinner table, I would pick someone like Mark Twain or Christopher Hitchens. Those two could talk on so many different subjects, and make it entertaining.
As far as living people go, I'd say Sam Harris. He's most famous as an atheist debater, but he's a neuroscientist by training. I respect him because his thought process is very logical and he's intellectually honest. He questions himself even as he's saying things, whereas most people just dig in and defend their own position. I think we are living in a very non-fact based world right now, where there is a lot of belief without supporting facts, and Harris is very rigorous about making arguments that are strictly evidence-based. I really enjoy that about him.
He also doesn't raise his voice. He just lets you hear the actual words, and to process them, so you can draw your own conclusion. That's kind of a lost art in public life. And while he's not a comedian, I also like his way with a joke. He keeps things very, very, dry, then he springs something unexpected at the end. It's kind of a Stephen Wright deadpan delivery with a Mark Twain joke structure.
If you were guaranteed to be successful in a different profession, what would you want to do?
I probably would have taking a harder whack at music. In the eighties I did a lot of songwriting and recording, even a couple of really low-end videos. I was pretty good at hockey. If I'd had the skills to make a living at that, I'd have jumped at the opportunity. Those jobs are like when a little kid says he wants to be a fireman and a cowboy when he grows up. As far as real life, my high school prophecy said I would show up at the 20th reunion as a famous cartoonist. I liked journalism and studied it some, back when that was a respectable profession, and I wrote for the local paper for a while. I would have liked running a used vinyl record store in the old days, but dealing with the public is not my thing. A record store is also not a place to get rich. Or maybe digging dinosaur bones in the desert would be OK, as long as I could come home at night. I'm not much for roughing it, or living out of suitcases. I like to end the day surrounded by my stuff.
If you could eat only 3 foods for the rest of your life, what would they be?
I don't know. I'm no foodie. Food is fuel to me, kind of a necessary evil. I have a love hate relationship with food in general on account of some health issues. I can't think of anything that's less appealing to me than traveling to a restaurant to eat, because it ends up taking four hours to do what you could do in fifteen minutes. But to answer the question, I'd probably go for anything with cold water fish in it. I like my starches, so rice works. Maybe a pepper, mushroom, egg grinder every 2 weeks – those are always good. That's a pretty boring list. Oh, and potato chips as a side dish with everything.