Project Analysis

A component Testing Department was identified as a potential source for the creation of latent failures.  Department consisted of ~80 employees, 2 shifts 80% first shift, 20% second shift.  Area was under ESD and class 100,000 cleanroom SOP guidelines.

The Strategy

To identify potential sources of latent failure contributors discreet physical observation was conducted incorporating both shifts.  Particulate testing, ESD floor surface testing, and physical examination of area cleanliness were conducted during shift operation as well as off hours.  To complete the assessment associate interviews were conducted.  Interviews were designed to gauge associate understanding and commitment to the SOP.  Additionally,  the process is used to develop a baseline that identifies  conditions that influence commitment.

• Inservice designed to increase associates knowledge and purpose of SOP.
• Promote a system of identifying protocol lapses and corrections through a team support structure.
• Revise ESD floor surface protocol to ensure ESD compliance.
• Couple ESD footwear with disposal ESD shoe covers.
• Consider implementing disposable ESD lab coats that remain in work area.
• Locate wrist-straps at the work stations.
• Repair and inspect workstations to ensure ESD efficacy.
• Standardize procedures identifying noncompliant workstation.
• Revise cleaning procedures to ensure particulate counts stayed within designated parameters. 
• Post the improvements
• Create a culture of awareness 

Proven Results

Client anticipated a 5 million dollars annual benefit.