This ISO 9001 Quality Certificate smells fishy!
SAE International recently responded to the problem of counterfeiting by completing this
past fall a new standard designed to mitigate the risks of receiving and
installing counterfeit electronic parts. The SAE standard, AS5553:
Counterfeit Electronic Parts; Avoidance, Detection, Mitigation, and
Disposition, which was created by the Counterfeit Electronic
Parts Committee (G-19), standardizes the requirements, practices,
and methods related to parts management, supplier management,
procurement, inspection, test/evaluation, and response strategies when
suspected or confirmed counterfeit parts are discovered.Electronic Supply Chain Solutions‘ President Matthew Heaphy is among the small group of individuals that make up the G-19 committee.
The standard was recently adopted by the U.S. Department of Defense.
How do counterfeit parts get into the supply chain of the aviation
industry, which has a reputation for thoroughness and security? It
begins with simple economics – supply and demand. The volume of
electronics used by the military and the airline industry is miniscule
compared to the public’s use, which includes cell phones, computers
and entertainment systems. Chip manufacturers focus on meeting
these large volume needs and subsequently stop producing the less profitable
aerospace components.
When original equipment manufacturers can no longer buy from an
original component manufacturer, they must go to the open market and
find a broker who can supply the equipment. Counterfeiters are aware
of the shortages and begin approaching brokers with the bogus goods.
Brokers must rely on the word of the suppliers and have no way of
determining if the electronic parts are bogus.
The control plan includes processes to specifically address
counterfeit part risk mitigation methods in electronic design and parts
management, supplier management, procurement, part verification,
material control and response strategies when suspect or confirmed
counterfeit parts are discovered.
The standard calls for maximized availability of authentic parts;
procurement of parts from reliable sources; assuring authenticity
and conformance of procured parts; control of parts identified as
counterfeit; and reporting counterfeit parts to other potential users and
government investigative authorities.
The Counterfeit Electronic Parts Committee has recently begun work
on a new related document, AS6081, Counterfeit Electronic Parts;
Avoidance Protocol, Distributors. Watch for more info as it becomes available.
SAE AS5553: Counterfeit Electronic Parts;
Avoidance, Detection, Mitigation, & Disposition
What is AS5553?
*This AS5553.info website is for information only. We do not market or sell anyone’s product.
Any links to products for items that may be purchased are provided strictly as a guide to information or content.
SAE AS5553 standardizes the requirements, practices and methods to reduce counterfeit parts entering the supply chain. It provides Requirements and Guidance by outlining actions an organization can take to address the growing problem of counterfeit parts across the entire electronics industry.
You can Buy a Copy of AS5553 from Tech Street.
Component Management
Supplier Management
Procurement
Inspection
Test/Evaluation Methods
Response strategies when counterfeit components are suspected or detected
Who needs AS5553?
All electronic industries:
Defense, Aerospace, Civil & Commercial
Industry Associations
Aerospace Industries Association (AIA)
Best Manufacturing Practices Center of Excellence (BMPCOE)
ERAI, Inc.
Government Electronics & Information Technology (GEIA)
Independent Distributors of Electronics Association (IDEA)
How bad is the problem?
It is an industry-wide global problem, particularly ind AS&D industries. ERAI, Inc. receives ~200 suspect counterfeit part complaints/month and confirmed more than 2800 brokers selling counterfeit components.
- View NASA PowerPoint on impact of counterfeits
- View SAE PowerPoint on the Counterfeit Parts
- View Business Week Article and video on their investigation
What are the Benefits of AS5553?
More information available:
To fight the growing threat of counterfeiting and piracy to the economy, jobs, and consumer health and safety, the business community, led by the U.S. Chamber of Commerce’s Global Intellectual Property Center, organized itself through a broad-based business coalition, the Coalition Against Counterfeiting and Piracy (CACP).
The CACP 2009 Goals:
- Pass, fund and implement all components of the Campaign to Protect America. (Learn more)
- Strengthen state and local anti-counterfeiting and piracy enforcement efforts. (Learn more)
- Conclude a strong and enforceable ACTA and improve existing trade policy tools. (Learn more)
- Promote industry-led, market based, technological solutions to intellectual property protection by all industries involved in the manufacture, distribution and marketing of IP-based products and services.
- Find out what recent goals the CACP has achived below or contact ESCS@727-723-8255 to learn how you can make a difference. http://www.combatcounterfeits.com
August 2009 the DOD adopted SAE’s AS5553 standard on courterfeit electronic parts
Electronic Supply Chain Solutions sponsors http://www.as5553.info/ to educate those who are looking to implement a risk mitigation stratagy for counterfeits.
What is AS5553? |
The Aerospace AS5553 Standard – Counterfeit Electronic Parts; Avoidance, Detection, Mitigation, and Disposition was developed by the G-19 committee of SAE International, and has just been issued in April, 2009.The standard is designed for adoption by aerospace and military manufacturers and contractors, providing uniform requirements, practices and methods to mitigate the risk of receiving and installing counterfeit electronic parts. The AS5553 standard documents requirements, practices and methods related to:
The AS5553 certified contractor or manufacturer must flow down the relevant requirements of the standard to all their sub-contractors and parts suppliers. |
Benefits of AS5553 |
There is no process or standard of operation that can absolutely prevent a company from receiving or installing a counterfeit part. The AS5553 standard, however, provides a framework for risk assessment that pinpoints potential problem areas and ensures management has an understanding of what specific risks exist of receiving counterfeit components. This allows informed decisions to be made on the level of risk for any given component procurement requirement, and to weigh that risk against other alternatives. If the risk is deemed excessive, the project team may accept a longer lead-time delivery or seek a re-design to utilize only franchise or original component manufacturer supplied parts.In addition, the AS5553 standard provides clearly defined expectations that can be communicated to suppliers for their performance.
AS5553 certified companies provide their customers with the objective assurance that a disciplined quality management approach is being applied to all phases of their operation impacting the ability to mitigate counterfeit parts risk. |
THE BIG NEWS is……….
The U.S. Department of Defense recently has adopted AS5553–Counterfeit Electronic Parts; Avoidance, Detection, Mitigation, and Disposition. SAE International had issued the standard earlier this year. In response to an increasing volume of counterfeit electronic parts entering the aerospace supply chain, SAE in 2007 created the G-19 Committee to develop a document standardizing requirements, practices, and methods related to counterfeit parts risk mitigation. The resulting product presents solutions in addressing counterfeit electronic parts issues across a large cross section of the electronics industry by requiring those who adopt it to develop and implement a counterfeit electronic parts control plan. The control plan includes processes to specifically address counterfeit part risk mitigation methods in electronic design and parts management, supplier management, procurement, part verification, material control, and response strategies when suspect or confirmed counterfeit parts are discovered. Electronic Supply Chain Solutions President Matthew Heaphy III is one of the 20 members that currently make up the G-19 committe and discussions with Matthew Heaphy III an expert on counterfeit components can provide your company with the tools needed to Combat Counterfeits
Supplier Verification |
The AS5553 standard imposes an obligation on manufacturers to verify that all supplier operations are in conformance with the flow down requirements of the standard. This burden is greatly reduced where suppliers are certified to the aerospace AS9120 standard.An AS9120 quality certification provides objective evidence of a distributors conformance to supplier management, split lot traceability and inventory control documentation. Manufacturers can then focus their verification efforts on the additional requirements of the AS5553 standard, such as ensuring appropriate inspection and testing processes are being consistently applied.
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NASA Mandates Compliance |
NASA has already mandated compliance with the Aerospace AS5553 standard. NASA Policy Directive NPD8730.2C – “NASA Parts Policy”, was issued November 3rd, 2008, and applies for all NASA operations.View the Policy Directive here. |
NAVAIR Requires Contractor Compliance |
The Naval Air Systems Command included compliance with the AS5553 standard for all bidding contractors in the recently issued Statement of Objectives for the Small Tactical Unmanned Aircraft System.Section 3.8 requires submission of a plan for “component compliance certification” that must be in accordance with the AS5553 standard.
It’s a reasoable bet that future government projects will also hold contractors to the AS5553 standard as well. |
ESCS President Matthew Heaphy III an expert in counterfeit electronic components and consults those in need.
ESCS Online Workshops -Provide Counterfeit Risk Mitigation
How far along is your company in developing a robust counterfeit risk mitigation strategy?
ESCS hosts a range of workshops, each targeted to addressing one specific aspect of how your company can implement policies and procedures tailored to your specific operational environment. “Bite-sized” 30 minute workshops. Each is structured to present key information that is always thought-provoking, and that allows for questions and interactive discussion. Up to 15 locations may participate in a single workshop. From individuals at their own desks to conference room groups, ESCS uses GoToMeetingTM conference technology to give you the flexibilty your organization requires. Best of all, there is no cost or obligation. At ESCS, we know that when you have an appreciation for our quality expertise, you will also understand the value of utilizing our quality services for your most challenging procurement needs. |
Currently Available Workshops
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WORKSHOP: “Counterfeit Industry Overview” |
This workshop presents a review of the global development of electronic component counterfeiting, and allows opportunity to delve into specific areas that directly affect your company’s operations. What types of components are you buying? How active are counterfeiters with these parts, and how can you be sure you’re catching the types of fakes they produce to meet your type of component demand?The workshop also reviews available objective and subjective data on what’s actually happening in the industry today. What are companies really experiencing, and how are they reacting? What are the strategies they are putting in place, and how relevant might these be for your company? |
WORKSHOP: “Risk Assessment – Your Current Situation” |
You can’t make a plan without a clear understanding of the problem! This workshop take you through a process to review what your company’s actual counterfeit experience has been as well as a look at the current level of protections (or lack thereof) embedded in your procurement, receiving inspection and vendor management policies. |
WORKSHOP: “Distributor Selection & Management” |
“Vendor Reduction” might be the buzz-phrase everyone’s using; but is that really an adequate response? This workshop looks at the benefits of vendor reduction, and helps you outline criteria you will use to evaluate current and prospective suppliers from the perspective of what will best help to mitigate counterfeit risk while still giving your procurement operations the flexibility they need.You’ll take a look at quality certifications such as ISO 9001 and the Aerospace AS9120, and understand the difference between “compliant” and “certified”. The subjects of inspection and traceability, as well as vendor performance reporting are also covered. |
WORKSHOP: “Performance Management – Plan, Do, Check, Act!” |
Every plan for organizational change is only as good as the process used to get it done combined with the follow-up included to ensure success. This workshop walks you through how best to apply the tried and true methodology of “Plan, Do, Check, Act” in relation to development and implementation of your counterfeit risk mitigation strategy. |
ESCS MITIGATES YOU RISKS
What People Are Saying |
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“Thanks, ESCS, for getting our whole quality group energized and focused on the changes we need to make.” Bill W., Florida“We had six managers in four locations, and it couldn’t have been easier to get us all together with ESCS’s use of GoToMeeting functionality. And we actually got it done on our lunch break, within the 30 minutes!” Janice L., Arizona |
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“LUNCH n LEARN” is Preferred | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
To date, most of the ESCS Counterfeit Mitigation Workshops have been held as a “Lunch ‘n Learn” event. It’s an easy way to accomplish the goal without the need to schedule yet another meeting in everyone’s busy day.Professor Quality says, “Join me at the next ESCS Lunch n Learn workshop!” |
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Schedule your workshop today |
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The Tricks They Play – A Gallery of Counterfeit Examples
A Growing Business |
Counterfeiting of electronic components has become big business in many parts of the world, but nowhere more so today than in China. U.S. electronics “recyclers” divert containers full of scrapped circuit boards into Hong Kong, where they are smuggled across the border into mainland China. There the chips are stripped from the boards and become the raw material for the counterfeit industry. Violation of intellectual property rights is rampant and for the most part is simply ignored by local Chinese authorities, allowing trade in counterfeit goods to flourish.These counterfeiters prey on U.S. businesses looking for “bargain” pricing, or brokers who are either unscrupulous enough or simply too inexperienced to properly manage their own supply sources.
Manufacturers facilitate the trade as well by not properly screening their independent distributors, or requiring quality certifications, etc. Please see our section on “Distributor Qualifications” for more information. |
Please contact us to contribute an image depicting an aspect of electronic component counterfeiting not represented in the photos below. Your contribution could help someone else combat counterfeits.
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Counterfeit Examples |
Some problems are more immediately apparent than others. A simple observation of the quality of the markings, or even misspelling within the logo can expose the deception, as on the integrated circuit depicted here. This batch of parts caused burning on the circuit card, resulting in a total loss because the damage was too extensive to rework.Note the misspelling in the logo ‘PHILIS’ instead of ‘PHILIPS’. The markings were offset printed instead of laser etched.
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Another case shows markings that do not meet marking permanency requirements and demonstrateS an attempt to rework recycled parts pulled from boards as be passed off as more expensive, high reliability parts.The marking permanency tests require exposing the parts to three different groups of common solvents used in electronic manufacturing. Authentic parts should not be damaged by this test. |
Compare both the top and the bottom markings of the part against a known, good sample. Check to ensure the finish is even and matches on both faces.In this instance, the marking on the bottom of the part was erased and the finish shows signs of center abrasion. Additionally, a partial number is still visible to confirm this part had been altered.
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A simple plating adhesion test shows that the fake markings were branded onto a new nickel plating over a new gold plating. |
This example demonstrates the critical importance of using a quality photographic microscope.The new gold plating disguised the fact that broken leads were reworked by welding new legs to the part and the solder on the unbroken leads was stripped off. The nickel plating on the lid hid the gold flash that did not belong there. However, gold does not adhere well to the base metal and is removed by simply peeling with adhesive tape.
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These two parts were both laser etched but differ in the font styles and in the marking content. The date code 0028 parts were breaking apart during the constant acceleration test at the 30,000g level and had a high failure rate during the hermetic seal test.They also differed electrically with the date code 0028 part failing every test. |
When parts are sanded, it will usually leave some microscopic evidence of a directional abrasion pattern.Here you can see not only the sanding marks, but a bottom indented marking (most likely country of origin) that has been not quite entirely sanded off.
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Sanding of parts is generally done by hand, so may show imperfections from poor handling.The upper left edge of this part got a beveled angle sanded into it. |
This photo shows the internal markings of the above part, by doing a de-lid.The 0028 date code was a valid QPL period for the Analog Devices part; but the mask number shows the wrong part number, ‘AD7581’ and not the correct ‘AD7582’.This type of counterfeiting occurs when a hard to locate part can be replaced with a part more readily available from scrap.
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This part had a slight discrepancy in printing, where the lower case ‘r’ in ‘StrongARM’ was lower than all the other letters. |
With a known good part, you can compare the indents on the molded plastic casings.These two parts have idential part number markings, but one has 3 versus 2 indents, and the position and shape of the indents are different.
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Often the original markings are sanded off before re-marking with the counterfeit information. If there are very shallow indents, they can actually be sanded off in the process.Notice the lower part is missing the very shallow indent present on the right-hand side of the top, authentic part. |
Original molding indents are always clean with sharply defined edging. When “black-topping” is done to paint over the original markings, the indents will often show signs of excess black-topping material.Here you can see the indent has been nearly filled, with material almost totally obscuring some of the edging.
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If a remarked part lacks the proper indents, some counterfeiters attempt to create them through various etching techniques. This can be detected if the indent surface shows lines or other signs of the etching process.Inspection of this part under a microscope revealed the evidence of etching. |
X-ray photography provides another inspection and diagnostic technique to reveal issues.This x-ray shows that all the wires are swept and broken in this part.
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This x-ray of another part shows that all the wires are missing inside. |
Do your suppliers have the inspection experience needed to mitigate your risk of receiving counterfeits? Have you purchased your copy of the A2Z Inspection & Test Protocol and Inspection Check List?
Component Inspection – Your Front Line Defense in Counterfeit Avoidance
You can’t catch what you’re not looking for.Inspection can’t be your only line of defense; but your ability to avoid counterfeits is only as good as the inspection processes used to detect them. When sourcing components through the independent market, how do you ensure a competent and consistently applied inspection process is being used?
To answer these questions, you need an understanding of current industry best practices, and a realistic assessment of your company’s unique operational requirements. Below we outline current industry practices, initiatives and resources available to you in developing a policy that will most effectively protect your company’s supply chain. |
What needs to be inspected? |
Components ordered directly from the manufacturer or an authorized franchise present the least risk, yet it’s still prudent to perform in-bound visual inspection. It’s not unheard of for an authorized distributor to accept returns which are then co-mingled with stock received directly from the manufacturer. Your receiving group needs a clear standard of visual tests to be performed.Components ordered through an independent distributor should be subject to a more in-depth inspection process, and be further tested for authenticity and functionality. This should be completed before the parts are shipped to you, and your purchase order conditions should explicity state your testing and documentation requirements.Read this brief ESCS “Infomin” on purchase order conditions. |
What inspection and testing can be done? |
Various standards and checklists have been defined to determine component authenticity and confirm functionality. In general, these fall into four classes:
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Available inspection standards & check-lists |
To date, there is no auditied inspection standard for testing of electronic components to confirm authenticity or functionality. There are, however, some resources available that attempt to define the specific visual and invasive test methods that can form the basis for a sound standard of inspection.Electronic Supply Chain Solutions has taken “the best of the best” in available component inspection testing methods, and has combined that with their own experience-based knowledge of electronic component inspection. The result is a very comprehensive testing protocol that is available for all manufacturers and distributor’s use. |
An Industry Resource Center Explore this site. Share it freely, use it to educate, or as an information source and research tool in developing risk mitigation strategies. Here you will find information and counterfeiting tricks and examples, resources on quality systems, inspection protocols, industry standards and certifications, counterfeit reporting and much, much more.
The battle to combat electronic component counterfeiting requires on-going attention and diligence. ESCS believes education and training, along with the development of strong industry standard best practices is the most effective approach to mitigating counterfeit risks.
CombatCounterfeits.com should be just one of your tools in the battle. Please check the “Other Resources” section of this site for information on government and industry associations who are active in the fight to combat counterfeits.
This site is updated frequently. Please check back regularly for current news and information.
Many representatives from prime contractors
returned home from the QLF, and Counterfeit Workshop in California in
October with new found knowledge and a large quantity of business
cards. As a reminder. Electronic Supply Chain Solutions is both a
franchised and stocking independent distributor with quality and
counterfeit avoidance as its cornerstone. Inaddition to being a member of the QLF Quality Leadership Forum, ESCS sponsors quality web sites www.Combatcounterfeits.info www.AS5553.info www.AS9120.info www.escsinfo.com and our main website of www.escs9120.com links you to the many productivity products designed to provide you the information you need to make sound business decisions. ESCS has had 6 AS9120 aerospace audits, is a member of GIDEP, ERAI, CACP Coalition Against Counterfeiting & Piracy and our President, Matthew Heaphy III is one of 20 voting members of the SAE G-19 committee that addresses aspects of preventing, detecting, responding, to and counteracting the threat of counterfeit electronic components.
If you missed NASA’s last QLF, ESCS’ President Matthew Heaphy III was a speaker on the topic of Aerospace Sourcing Assurance where he introduced our Safe Source Seal Program that is the only audited inspection program that addresses the origin of in coming electronic components. Visit www.SafeSourceSeal.com to learn more.
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