ESD Program Management

1 Twelve Critical Factors in ESD Program Management.- The Twelve Critical Factors.- Factor One - An Effective Implementation Plan.- Factor Two - Management Commitment.- Factor Three - A Full-Time Coordinator.- Factor Four - An Active Committee.- Factor Five - Realistic Requirements.- Factor Six - Training for Measurable Goals.- Factor Seven - Auditing Using Scientific Measures.- Factor Eight - ESD Test Facilities.- Factor Nine - A Communication Program.- Factor Ten - Systemic Planning.- Factor Eleven - Human Factors Engineering.- Factor Twelve - Continuous Improvement.- Points To Remember.- 2 Implementing an ESD Control Program: The Basic Steps.- The Basic Steps.- Step 1: Study and Understand the Technology of ESD Control.- Step 2: Gather Scientific Evidence of the Economic Value of ESD Control.- Step 3: Establish an Active ESD Committee.- Step 4: Develop a General Implementation Plan.- Step 5: Write or Adopt a Set of Realistic Handling Requirements.- Step 6: Prepare a Detailed Statement of Policy Including Individual Responsibilities.- Step 7: Prepare a Presentation for Management.- Step 8: Establish a Top Management Commitment.- Step 9: Develop the Details of ESD Program Management.- Step 10: Present the Program to Middle and Lower Management.- Step 11: Begin Implementation of the Control Facilities.- Step 12: Begin Training of the Entire Work Force, Including Management.- Step 13: Begin Using Facilities Immediately After Training.- Step 14: Begin Formal Auditing of All Manufacturing Departments.- Step 15: Report Auditing Results, Graphically and With Regularity, to All Levels of Management.- Step 16: Continuously Improve the Process.- Points To Remember.- 3 Fundamentals of Electrostatics.- Basic Elements.- Electric Charges.- Electric Field.- Electrostatic Potential.- Capacitance.- Charge Generation.- ESD Failure Models.- Charge Removal.- Charge Dissipation and Protective Materials.- Points To Remember.- 4 An Economic Analysis.- Case Study 1: Resistor Failure Due to Automation in Production.- Experiment 1.- Experiment 2.- Case Study 2: Bipolar Discrete Device Failure.- Experimental Evidence.- Case Study 3: Device and PWB Assembly Failures.- Experiment 1.- Experiment 2.- PWB Assembly Shop - Failure Analysis.- Manufacturing Evidence.- HIC Shop Manufacturing Data.- PWB Assembly Shop Manufacturing Data.- Case Study 4: Latent Failure Due to Prior ESD Damage.- Experimental Evidence.- Case Study 5: Ultrasensitive Devices.- Device Testing.- PWB Assembly.- Conclusion.- Points To Remember.- 5 Designed-In Protection and Product Testing.- Device Protection.- Protection at the PWB Assembly Level.- System Level Protection.- Device Testing.- PWB Assembly Testing.- System Level Testing.- ESD Design-Dealing with the Trends.- Points To Remember.- 6 ESD Test Facilities.- Field Audit Kit.- General Laboratory.- Analytical/FMA Laboratory.- Instrument Descriptions.- Instrument #1: Charge Plate Monitor (CPM).- Instrument #2: Electrostatic Field Meter.- Instrument #3: Residual Voltmeter (RVM).- Instrument #4: Surface Resistivity Meter (SRM).- Instrument #5: Resistance to Ground (RTG) Meter.- Instrument #6: Combination SRM/RTG Meter.- Instrument #7: Static Decay Time Tester With a Controlled Humidity Chamber.- Instrument #8: Megger Meter (High Resistance Ohmmeter) with NFPA Probes.- Instrument #9: Charge Analyzer (Faraday Cup).- Instrument #10: Personnel Voltage Tester (PVT).- Instrument #11: Air Ionizers.- Instrument #12: ESD Simulators.- Points To Remember.- 7 Realistic Requirements.- Sensitivity Classification.- Control Techniques.- Three Basic Rules for ESD Control.- Definitions.- Static-Safe.- Static Conductors and Nonconductors.- Surface Resistivity.- Conductive Materials.- Antistatic Property.- Static-Dissipative Materials.- Static-Generating Materials.- ESD-Insensitive Devices.- Minimum Requirements.- ESD Awareness Training.- ESD Training Program.- Auditing Compliance to ESD Procedures.- Checks and Maintenance.- Personnel Certification.- Facility Certification.- ESD Acceptance Criteria for Equipment Associated with Manufacturing, Handling, and Testing.- Personnel Grounding.- Wrist Straps.- Footwear.- Heelstraps/Toestraps.- Bootstraps.- Conductive Boots.- Conductive Shoes.- Conductive and Dissipative Floor Mats.- Stationary Work Positions (Benches, Test Sets, Etc.).- Mobile Work Positions (Packing, Mass Soldering, Etc.).- Transporting Products.- Carts.- Static-Safe Packaging.- Static-Safe Bags, Shipping Tubes, and Tote Boxes.- Dissipative Table Mats.- Dissipative Tabletops.- Dissipative Floors/Floor Finishes.- Conductive Edge Connector Shunts.- Extraordinary Measures.- Other Controls.- Factory Standards.- Points To Remember.- 8 Implementing an Auditing Program.- Why Auditing Puts the Coordinator in Charge.- What Must Be Audited.- Process Checkers.- How to Obtain Meaningful Data.- A Full-Time Inspector.- Auditing Reports Supersede Yield and FMA Data.- The Auditing Inspector: Qualifications and Duties.- Qualifications.- Duties.- The Inspector's Guide and Checklist.- ESD Data Base Management Software.- Summary.- Points To Remember.- 9 Using Auditing Results To Manage The ESD Program.- Trend and Pareto Analysis Charts.- When and How to Report the Results.- Preliminary Auditing Reports.- Final Auditing Reports.- Staff Summary Reports.- View-Graph Presentations.- Engineering Analysis.- Case Study 1: Four Years Of Continual Improvement.- Case Study 2: Solving a Wrist Strap Problem.- Case Study 3: Solving a Bench Top Problem.- Illustrations on the Use of Graphics.- Illustration 1: Departmental Comparisons.- Illustration 2: A One-Page Summary of Two Years Results.- Illustration 3: Rewarding Success With a Zero Deviations Award.- Illustration 4: Auditing Subcontractors or Suppliers.- Summary.- Points To Remember.- 10 Purchasing Guidelines: Finding the Hidden Costs and Problems.- Purchasing Principles.- Vendor Partnership Agreements.- Quality Oriented.- Credible.- Dependable.- Responsive to Your Needs/Receptive to Change.- Cost Competitive.- Equipment Selection Guidelines.- Standards.- Quality, Reliability, and Cost.- Testing Compatibility.- Suitability for Intended Application.- Human Compatibility and Training Implications.- Wrist Straps.- Heelstraps.- Shoes.- Floor Mats.- Workbenches.- Work Surface Mats.- Conductive Floor Finishes.- Bench and Room Ionizers.- Packaging and Handling Materials.- Points To Remember.- 11 Training for Measurable Goals.- One: Setting Measurable Goals.- Study The Three Principles of The Psychology of Training and Learning.- Derive Measurable Goals Based on the ESD Handbook.- Use Auditing Reports and Personal Observations to Uncover Training Problems.- Use Engineering Solutions to Provide Permanent Solutions to Training Problems.- Two: Planning Classes and Recommended Courses.- Find Resources to Train Everybody.- Determine Class Size-Mass Training Versus Small Group Training.- Ask Questions and Move About.- Demonstrate the Nature of Electrostatics and the Effect of ESD on Devices.- Basic Equipment.- Basic Demonstrations.- Videos.- Recommended Courses.- Conclusion.- Points To Remember.- 12 Packaging Considerations.- Antistatic Materials.- Material Characterization.- Static Dissipative Materials.- Material Characterization.- Conductive Materials.- Material Characterization.- Capacitive Coupling and Air Gaps.- Integrated Circuit Shipping Tubes.- Tote Boxes.- Bubble Packs Versus Bags.- Fighting ESD Failure Scenarios.- Points To Remember.- 13 Automation.- The Nature Of Automation-Caused ESD Damage: Different, Serious, and Difficult.- One: Prevention Considerations and Techniques.- Qualification Criteria and Test Equipment.- Qualification Procedures.- Two: Automation Case Studies.- Conclusion.- Points To Remember.- 14 Payback and Benefits.- Implementation Cost Control.- Quality Improvements.- Reliability Improvements.- Intangible Benefits.- Points To Remember.- Appendix 1 AT&T ESD Policy.- Appendix 2 Industry, Military, and AT&T Standards Used to Evaluate ESD Control Materials, Equipment, and Devices.- Appendix 3 How to Test the Integrity of the Ground Connection on a Work Surface.- References.