Process Audit / Process Optimization
Investigations into root cause conditions sometimes require Foresite to
visit the customer's manufacturing facility to witness the actual production
sequences. We review the materials used, equipment setup, operator actions,
in process and final product status.
Foresite also offers educational seminars to manufacturing, quality, and
management personnel regarding various topics related to residue identification,
product reliability impact, specification compliance, handling precautions,
sources of contamination, measurement techniques, and general process control
and optimization.
Foresite engages in consultation with each customer prior to any activity to identify
project goals, design an applicable test matrix, and provide technical information
derived from our experience and knowledge of contamination effects on product
reliability.
Foresite On Site Report Deliverables
- Summary of Foresite observations at facility
- Specific goal of visit — defined at time of quote
- Description of customer specifications — cleanliness levels
- Process Sequence Flowchart — as defined by customer and observed by Foresite
- Material matrix indicating fluxes and chemistries used in process
- Foresite recommendations for any process optimizations or additional testing
- On Site report electronically sent to customer project contact (fax or e-mail)
- Original hard copy report mailed upon completion of project
- Telephone support included for discussion of report
Foresite On Site Educational Deliverables
- Training presentation and discussion with attendees
- Presentation formats available — PowerPoint or overhead transparencies
- Presentation Master file supplied to reproduce for each attendee
- Reference material pertinent to subjects discussed
- Applicable Foresite case study discussions
- Discussion of specification compliance issues
- General educational consultation regarding processing contaminants
Dates for On Site Services established upon receipt of approved Purchase Order via fax or mail
Foresite Inc. On Site Services
To provide the customer with an efficient on site evaluation or training
exercise, process related information is required in advance of Foresite arriving
at the facility. The accuracy and completeness of the requested information
is imperative to the success of the evaluation or training.
The following information will be requested prior to on site services:
- Is a detailed history of the process and the current situation available?
- Has your company qualified the current manufacturing process? How? By whom?
- Has the existing process performance been baseline validated to establish a reference?
- What are the product requirements and goals for field reliability? (IPC Class 2 or 3)
- What is the Product Classification? (automotive, medical, military, general commercial)
- What is the service environment of the products produced? (geographical locations)
- Is the product manufacturing a captive operation or contract service?
- Where is the assembly plant located?
To evaluate the operation, the materials and
process options must be identified: (portions
of this list will be recorded at the time site observation)
- Material specifications — base laminate material, surface finishes, solder resist, fluxes
- Solder resist vendor and formulation nomenclature
- Flux types used — OA (water soluble), NC (no-clean/low-residue), other
- Flux vendor and formulation nomenclature
- Flux application method (spray or foam)
- Cleaning technology used — tap water, DI water, solvent
- Cleaner type — vendor, batch or in-line
- Stage(s) at which assembly will cleaned (post reflow, post wave, hand, rework)
- Assembly equipment to be used (automated and hand)
- Types of components to be assembled (thru-hole, surface mount, COB, BGA, HDI)
- Thermal profiles for all heat excursions product will see (reflow, wave, hand, rework)
- Atmosphere to be used during reflow and wave process - (oxygen or nitrogen)
- Solder pot temperature
- Other assembly materials (adhesives, temporary masks, coatings)
- All hand operations and materials (post-wave, irons used, cleaning methods)
- Assembly drawings and process sequence flow charts
The requirements for on site training are:
- Classroom or conference room adequate for size of audience
- Digital projector for PowerPoint presentation or overhead projector for transparencies
- Customer specific material identified by Foresite prior to training session
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