ESD Audits - Dangelmayer

ESD AuditsDangelmayer Associates’ audits are conducted by Engineers with first handmanufacturing experience, advanced degrees and unparalleled expertise! Our auditsprovide findings reports, photographs of findings, detailed recommendations, and theassignment of corrective action priorities. Gaps will be identified between current bestpractices today’s technological challenges such as Class 000, CDM, CBE, EOS andS20.20.“Wow – this is really an excellent assessment and report! I was justthinking how our other consultants haven’t really dealt with the qualitysystem, so I appreciate you giving us a whole “turn-key solution”.- Bob Herrick, PhD – Finisar, Senior Reliability Engineer1) EPM Performance & Benchmarking /Audit2) Advanced Technical Assessment/Audit3) S20.20 Pre-Assessment Audit4) Root Cause Analysis1) EPM Performance & Benchmarking /Audit:Note: Applications include manufacturing & supply chain“You do not need to do this: survival is not mandatory.”- Dr. W. Edwards Deming

EPM Performance Benchmarking 100EPM nacceptable017 12 6 4 21 11 8 5 2 26 25 19 15 24 37 20 10 29 14 28 18 32 31 33 42 16 3 36 27 7 13 38 41 1 34 30 9 40 37 35 12 44Case Study SiteTier 1 – CM’sTier 2 – CM’sOne Year LaterCase StudyCustomer SiteCopyright 2009 Dangelmayer AssociatesManufacturing SitesNote:1) May be used alone for benchmarking of individual or multiple sites or the supplychainThe EPM Performance & Benchmarking Assessments will be done over thephone. This may also be done independently without a technical assessment forbenchmarking purposes of company locations and/or the customer’s supplychain. It is an accurate tool for quantifying the quality of an ESD Program and forqualifying suppliers. For instance, a site may end up with a score of 37% and bein the high risk zone or 97% and be in the preferred zone.The questions are designed to analyze the ESD quality system. This is becausethe quality system ultimately governs the outcome of a manufacturing process.Questions are asked such as “Has management formally appointed an ESDProgram Manager?” and “Are current best practices such as CDM, CBE andClass 0 adequately addressed in the governing ESD requirements document?”.Extensive data confirms that the Performance Benchmarking Score correlatesto manufacturing yield improvements (see example below).Upon completion, this highly effective tool becomes a road map for improvementor development of a sound ESD Program. The metrics generated by thisprocess provide management with capability to measure and track the ESD

program performance of individual sites as well as the corporation’s relativeposition within the industry. The survey results are discussed in the ExecutiveSummary of Annual Technical Assessment and are summarized in a PowerPointpresentation.Benchmarking Case StudyCorresponding Yield DM Training 80% EPMPerformanceS20.20 ProgramBenchmarking In Place90% EPM(HBM Focused)PerformanceBenchmarking 4549WeekCopyright 2009 Dangelmayer AssociatesExample: Correlation between Yield and Performance Benchmarking Score Top of Page

2) Advanced Technical Assessment/Audit:Note: Conducted by Engineers with first hand manufacturing experience,advanced degrees and unparalleled expertise!“Wow – this is really an excellent assessment and report! I was justthinking how our other consultants haven’t really dealt with the qualitysystem, so I appreciate you giving us a whole “turn-key solution”.- Bob Herrick, PhD – Finisar, Senior Reliability EngineerThis advanced technical assessment/audit, in concert with our EPM PerformanceBenchmarking , Assessment provides the most comprehensive roadmap forimprovement available today. Our assessments/audits provide findings reports,photographs of findings, detailed customized recommendations, and the assignment ofcorrective action priorities. Gaps will be identified to current best practices as well as tothe Customer's choice of standard, such as Internal Requirements, S20.20 or EIA-625.Technical Assessment Benefits: Provides detailed information that can be used for either improvingprograms or resolving ESD problems. Identifies problems and provides solutions to the root cause of existingfailure mechanisms. Qualifies manufacturing facilities for present and future productrequirements. Contributes to increased yields, process control, profitability, andcustomer satisfaction.Technical Assessment/audit Highlights: This is our most comprehensive assessment/audit and is intended for the qualityconscious company that is serious about not only solving ESD problems but alsoabout preventing recurrence. A two day thorough sampling evaluation of the ESD process characteristics, ESDhandling procedures/protocols, and state-of-the-art electrical and ESD event detectionmeasurements of the ESD facilities automation, and test equipment.

Emphasis will be placed on the analysis of automation/test equipment and chargeddevice model mitigation techniques. Internal auditors will be invited to observe during the assessment and will be shownhow to perform the assessments. Gaps will be identified to current best practices as well as to the standard of customerchoice, such as Customer Requirements, S20.20 or EIA-625. Comprehensive documentation (approximately 50 pages) of specific findings andrecommendations will be included along with photographs of findings and prioritiesfor corrective actions. Technical explanations of findings will be shared during the assessment to facilitatecustomer understanding of the issues and any corrective actions that may benecessary.State-of-the-art Test Equipment: Three varieties of ESD Event Detection Equipment Comprehensive set of ESDA ANSI Compliant test equipmentTop of Page3) S20.20 Pre-Assessment Audit:Note: Conducted by Engineers who have managed ESD manufacturingprograms that were S20.20 Certified under their leadership."I’ve audited literally hundreds of ESD programs and, without adoubt; this program is the best I have ever seen. It's a world classbenchmark ”- Bill Gifford, DNV ISO 9000 Registrar, S20-20 Lead Auditor.This S20.20 Pre-Assessment Audit may be done solely for the identification of gaps toS20.20 and expert recommendations for achieving S20.20 certification on the first try. Itmay also be combined with our Advanced Technical Assessment as described above for acomplete assessment of gaps to both S20.20 and current best practices.A complete analysis will be conducted of the Administrative and Technical Elements ofS20.20 such as the ESD Control Program Plan. Gaps to S20.20 will be succinctlyidentified along with customized expert recommendations for corrective actions.S20.20 - 2007 Administrative Requirements:

ESD Control Program PlanTraining PlanCompliance Verification PlanS20.20 - 2007 Technical Requirements:S20.20 TABLE 1. Grounding / Equipotential Bonding RequirementsTechnicalRequirementGrounding /Bonding SystemImplementingProcessTest MethodEquipmentGroundingConductorANSI/ESD S6.1 1.0 ohm impedanceAuxiliaryGround 25 ohms to theEquipmentANSI/ESD S6.1GroundingConductorEquipotentialBondingANSI/ESD S6.1 1.0 x 109 ohmsRequired Limit(s)S20.20 -2007 TABLE 2. Personnel Grounding roduct Qualification1Compliance VerificationTest MethodRequiredLimit(s)Test MethodRequired Limit(s)Wrist StrapSystem2ANSI/ESDS1.1 (Section5.11) 3.5 x 107ohmsESD TR53Wrist StrapSection 3.5 x 107 ohmsFlooring /FootwearSystem –ANSI/ESDSTM97.1 3.5 x 107ohmsESD TR53FlooringSection 3.5 x 107 ohms

Method 1Flooring /FootwearSystem –Method 2(bothrequired)ANSI/ESDSTM97.1ANSI/ESDSTM97.2ESD TR53FootwearSection 3.5 x 107 ohms 109 ohmsESD TR53FlooringSection 1.0 x 109 ohms 100 voltsESD TR53FootwearSection 1.0 x 109 ohmsS20.20 -2007 TABLE 3. EPA ESD Control ItemsProduct Qualification1 Compliance VerificationTechnicalESD ControlRequiredRequirement ItemTest MethodTest Method Required Limit(s)Limit(s)2ANSI/ESD S4.1Worksurface and/orANSI/ESDSTM 4.2EPAWrist StrapCordANSI/ESDS1.1Wrist StrapCuffANSI/ESDS1.1Wrist StrapANSI/ESDCordS1.1Bending LifeFootwearANSI/ESDSTM9.1FootGroundersESD SP9.2FlooringANSI/ESDS7.1 1 x 109ohmsand/or 200volts0.8 x 106to1.2 x 106ohmsInterior 1 x 105ohmsExterior 1 x 107ohmsESD TR53 1 x 109 ohmsWorksurfac resistance toe SectiongroundFor compliance verification of awrist strap system, see Table 2. 16,000cycles 1 x 109See Table 2ohms 1 x 109See Table 2ohms 1 x 109See Table 2ohmsSee Table 2See Table 2See Table 2

SeatingIonizationother TM 12.1ANSI/ESDSTM 3.1- Dischargetime- OffsetvoltageANSI/ESDSTM3.1- Dischargetime- nts 1 x 109 ESD TR53ohmsSeating Section 1 x 109ohmsresistance togroundUserESD TR533defined - Discharge time 50 - Offset voltagevoltsUser defined 50 voltsUserdefined 150voltsESD TR533- Discharge time User defined- Offset voltage 150 voltsESD TR53 1 x 109WorksurfaceohmsSectionESD TR53 1 x 109 MobileohmsEquipmentSectionESD TR53UserContinuousUser defineddefined MonitorsSectionStaticControl 1xESD TR53Garment1011Garments(ANSI/ESD ohmsSectionSTM2.1)GroundableStaticESD TR53Control 1 x 109GarmentsGarmentohmsSection(ANSI/ESDSTM2.1) 1 x 109ohmsresistance toground 1 x 109ohmsresistance togroundManufacturer defined 1 x 1011ohms 1 x 109ohms

GroundableStaticControlESD TR53 3.5 xGarmentGarments107 ohmsSystemSection(ANSI/ESDSTM2.1) 3.5 x 107ohmsTop of Page4) Root Cause Analysis:Note: Conducted by our most experienced Engineers and Scientists with advanceddegrees and/or specialized expertise including product ESD designed-in protection.We are uniquely equipped to efficiently locate the root cause of ESD damage in complexmanufacturing operations due to our team of advanced engineering experts and over 200years experience. We pioneered many aspects of ESD event detection techniques andhave unequalled experience with these an other advanced auditing techniques, Thus, it ispossible to readily analyze sophisticated automated or manual production lines andpinpoint the root cause of ESD failure.Once the root cause has been identified we can draw on our depth of experience andtechnical understanding of the physics of ESD to efficiently resolve manufacturing issuesor to redesign products to enhance designed-in protection.Top of Page

ANSI/ESD STM97.2 100 volts ESD TR53 Footwear Section 1.0 x 109 ohms S20.20 -2007 TABLE 3. EPA ESD Control Items Technical Requirement ESD Control Item Product Qualification1 Compliance Verification Test Method Required Limit(s)2 Test Method Required Limit(s) EPA Worksurface ANSI/ESD S 4.1 and/or ANSI/ESD STM 4.2 1 x 109 ohms and/or 200