AFFINITY STATIC CONTROL CONSULTING llc

While most people do not realize it, static electricity has an impact on every conceivable business and process. Fortunately, most of the impact is not noticeable but there are a significant number of occurrences where static electricity does cause a problem. Static electricity causes six (6 ) problems in industry; one or more could be draining your resources:Electrostatic damage to productsMaterial handling difficultiesElectronic product malfunction/lock-upDust and lint attractionPersonnel shockFire and explosion

Affinity personnel can assist you in the investigation, reduction or mitigation of any problem caused by static electricity in any of your processes. From reducing your insurance premiums to saving products from damage, Affinity personnel have the industry experience to help you save your process and production money.

Measurements of electrostatic voltage on isolated conductors and electrostatic fields from insulators allow a prediction of isolated conductor and Charged Device Model (CDM) types of risk to sensitive items within any process. Measurement of resistance to ground from all the conductors in a process, including personnel, helps to determine Human Body Model (HBM) risks. Process monitoring requires advanced knowledge of electrostatic principles to understand what needs to be measured and which tools to use in any given circumstance.

Affinity Static Control Consulting, LLC (Affinity) has process monitoring experience that is well beyond that of most consulting companies. Process monitoring experiences include all phases of electronics manufacturing as well as investigations in nearly any other imaginable industry. Understanding electrostatic phenomenon within process equipment helps establish process capability. Equating process capability to the measured component sensitivity as determined by HBM, isolated conductor and CDM test methods is a current goal. Electrostatic risk assessment is based on a comparison of the collected data from the process capability evaluation to the measured sensitivity of components. The acceptable risk level is set for all points within the process using statistical analysis techniques. Process monitoring and electrostatic risk can be established within most activities including, but not limited to, the following:

·  Human Handling

·  Mobile Carts and Shelves

·  Pick and Place Machines

·  Inspection Stations

·  Manual Placement

·  Rework Stations

·  Packaging Stations

·  Chemical Cleaning

·  Conformal Coating

·  Shipping Evaluations

·  Chemical/Material Handling

·  Industrial Processes

·  Munitions and Explosives

·  Petrochemical Processes

·  Printing

·  Polymer Processing

·  Extrusion and Molding

·  Pharmaceutical Processing

Affinity has a laboratory facility that provides testing of ESD Control Materials at the required humidity levels to satisfy the requirements of material qualification for ANSI/ESD S20.20. Since 2010, it has been necessary to show proof that the materials used in an ESD control program meet the specification requirements of S20.20 when tested according to ESD Association test methods. Affinity can provide 3rd party testing of most of the materials used in an ESD Control Program, including the following:

·  Surface and Volume Resistance/Resistivity of materials and items according to ANSI/ESD STM11.11 and ANSI/ESD STM 11.12

·  Worksurface resistance tests according to ANSI/ESD STM4.1

·  Floor material resistance tests according to ANSI/ESD STM7.1

·  Footwear/Foot Grounder resistance tests according to ANSI/ESD STM 9.1

·  Flooring and Footwear in combination with a Person – Resistance, according to ANSI/ESD STM 97.1 (In cooperation with ESD Association Services, Inc.)

·  Flooring and Footwear in combination with a Person – Voltage Generation according to ANSI/ESD STM 97.2 (in cooperation with ESD Association Services, Inc.)

·  Wrist strap electrical properties according to ANSI/ESD S1.1

·  Garments according to ANSI/ESD STM2.1

·  Ionization testing according to ANSI/ESD STM3.1

·  Seating resistance tests according to ANSI/ESD STM 12.1 (in cooperation with ESD Association Services, Inc.)

·  Glove resistance test according to ANSI/ESD SP 15.1

Quotes for material testing are available on request and testing generally can be completed within 10 days of material receipt. Conditioning at specific humidity settings needs at least 48 hours each at both moderate and low levels.  Material testing takes place in the conditioned environment in accordance with the individual Standards, Standard Test Methods and appropriate Standard Practices.

In addition, Affinity can provide application related testing of materials, items and products in those instances where test methods are not specifically established. Affinity also provides significant capability in evaluation of triboelectric charge generation to help establish process risk. Evaluation of triboelectric charge generation is the first step in developing reliable electrostatic mitigation techniques suitable for any given application. Affinity has a good understanding of electrical fields and associated risk related to charged process essential insulators.

While nearly every company that produces or handles electronic parts or products recognizes the need to consider control of static electricity in their operating procedures, many do not have a clearly defined ESD Control Program Plan. Seeking Certification to ANSI/ESD S20.20 forces each company to prepare and implement an ESD Control Program Plan that will provide protection for susceptible parts whenever and wherever they are handled or stored. S20.20 also forces a company to understand the sensitivity level of parts during the program plan development.

Affinity will conduct a thorough and expert review of your Program Plan and make recommendations to ensure compliance to the most current version of ANSI/ESD S20.20, including international implications. Affinity will also assist in the revision of your existing Program Plan as needed.

Preparation of a Program Plan may be the most time consuming aspect of S20.20 Certification, particularly if your own personnel require additional training and experience before taking on the task. Affinity will work with your staff to create a custom ESD Control Program Plan designed specifically for your applications and requirements, saving you considerable time and internal resource allocation. It is well known within the industry that an effective and well run ESD Control Program saves any size company “lots” of money in the long run.

An example of the process to obtain certification or conformity to ANSI/ESD S20.20 or IEC61340-5-1 the technically equivalent standard from Technical Committee 101 – Electrostatics is shown below.

• ANSI/ESD S 20.20 Certification Process Flow
• General Guidelines
• 1.Prepare an ESD Control Program following the intent of S20.20 or IEC51340-5-1
• ï  Documented ESD Control Program Plan
• ï  Training Program Plan
• ï  Technical Elements for affected areas
• ï  Quality System Document/Data Control
• ï  Compliance Verification Plan
• Control of Measuring and monitoring devices (calibration)
• Control of nonconforming product
• Corrective and Preventative Action
• Process Audit type and frequency
• Technical element verification schedule
• Test methods and limits
• 2.Make sure all process areas follow the pre-set requirements of the Plan
• 
  
• 3.Contact an Official ISO Certification Body that has trained S20.20/5-1 Auditors on staff. For a list of trained Certification Bodies inquire at ESD Association Headquarters in Rome, NY – www. esda.org
• 
  
• 4.Arrange for a Pre-Assessment Audit either through the ISO Certification Body or a Consultant.
• ï  Document Review (all pertinent documents related to ESD Control Program Plan) – 1 day
• ï  Facility Audit – 1 day + travel (large facilities may add 1 day)
• ï  Management Review – ½ day
• ï  Findings Review
• ï  Implementation of corrective action
• ï  Follow-up Pre-Assessment Audit – 1 day + travel
• 
  
• 5.Schedule Formal ANSI/ESD S 20.20 Audit
• 
  
• 6.Annual Follow-up/Re-Certification

Audit & Certification Follow Up

A poor audit report need not ruin your reputation. It can help to make your operations better if you are open to improvement. Affinity can help you make productive improvements to your ESD Control Program.

An internal audit, second party audit or a customer audit may find flaws or faults in your ESD Control Program. As the recipient of the audit, you may not agree to some of the “flaws and faults” found by the auditor. Obtaining Certification to ANSI/ESD S20.20/IEC61340-5-1 should reduce the number and severity of disagreement between parties. However, prior to receiving Certification, facilities may experience difficult audit situations.

Affinity can help you develop a corrective action plan to fix all ESD Control Program Plan deficiencies after an unsuccessful customer or second party audit. In addition, Affinity can provide expert third-party consultation and arbitration in the event of disagreement over implementation of ESD control technical elements or interpretation of administrative requirements.

New facilities and new companies that handle ESD susceptible parts must have an ESD Control Program Plan, even if they have no aspiration to seek ANSI/ESD S20.20 Certification. Often, ISO 9000 Auditors will discover situations that demand closer scrutiny relative to static control and create a “finding” in their report. Since static control is normally considered a Quality Assurance issue, having a plan in place that details how parts are protected is very important and relevant to the overall operations within the facility.

Affinity provides a complete ESD Control Program Plan preparation service. The result is a state-of-the-art ESD Control Program Plan, designed to meet ANSI/ESD S20.20 and IEC61340-5-1, based on your facility applications, processes and requirements. Affinity personnel are deeply involved in the development of industry standards, so you are assured of the most current information possible.

Preparation of a complete Program Plan from a “blank piece of paper” requires a thorough understanding of your operations, therefore, Affinity personnel must be on-site for a period of time to observe operations and create an operational map of product flow and processes. The time required for this activity is dependent on the physical size of the facility, number of personnel, type of manufacturing operation and number of individual processes.

The publication of an ESD Control Program Plan that meets ANSI/ESD S20.20 requirements represents (arguably) 60% of the Certification effort. While the Plan must be detailed, it need not be cumbersome. Keeping the Plan simple yet effective should be the goal.

Affinity can prepare individual as well as group training programs; custom designed to fit company, facility and process needs. Training for production workers, engineering staff and management can be tailored to meet any application or technical requirement.

Course content customized to meet YOUR specific training needs from the following list of subjects:

• Electrostatic Fields and Induction

•  Basics of Static Electricity and Static Control

•  Ionization

•  Grounding Considerations

•  Packaging of electronic products for storage and shipment

•  Workstation design

•  Flooring

•  Understanding and Implementing ANSI/ESD S 20.20

•  ESD Control Standards

•  Auditing and Measurements

•  Electrostatic Control in the Cleanroom

•  Electrostatic Attraction and Small Particles

Test method development for new materials requires an understanding of the intent of the manufacturer. What is the material suppose to do? How will it be used? What will happen if it is not used correctly? Is there a hazard involved? Is this material replacing something else in the same application? What are the benefits to the end-user? These questions and others will help in creating a test protocol that will help define the material performance attributes. Once that is done, test methods can be created to evaluate the material to the anticipated and defined performance attributes.

Known or standard materials are often used to create a new product, a new configuration for an existing product or fit a product into a new application. The new configuration or application may require a different understanding of performance. Evaluation of the performance attributes of a new product or configuration could require modification of existing test methods. Affinity will evaluate the new application or configuration and recommend test method modifications that will accurately determine the new performance attributes.

Test methods are necessary to determine material performance to specifications. New materials or applications will require setting new specifications. Affinity is well suited to assist in determining specifications and limits based on evaluations with new test methods.

Affinity can assist in developing special tests for evaluating the following properties:

·  Electrical Resistance

·  Electrostatic Charge Decay

·  Electrostatic Charge Generation/Triboelectrification

·  Electrostatic Discharge Energy

·  Electrostatic Shielding/Discharge Shielding

·  Ionization Decay Rate/Ion Balance