Expert Day Discussion Topics

Day 1 – October 18, 2021

Technical Cleanliness Standard Analysis – ISO 16232

1. Standard Extraction and Filtration Methods

Markus Rossler – Glaeser Inc.

2. Automated Light-Optical Analysis

Peter Feamster – JOMESA North America

Automated Light-Optical analysis according to ISO 16232 is a standardized method for detecting, measuring, and categorizing particle contamination present on 47mm filter membranes. This presentation will focus on the key features of particle analysis software that are standardized in order to make measurements from different manufacturers comparable across the automotive industry.

Day 2 – October 19, 2021

Common Challenges with Technical Cleanliness Inspections

1. Manufacturing Cleaning Association

Matt Gilmore – Manufacturing Cleaning Association

Matt will introduce the Manufacturing Cleaning Association. The MCA is an industrial trade association formed for the benefit of manufacturers who use cleaning processes in their operation. The goal of the MCA is to create a support network centered around the questions and challenges associated with industrial cleaning. Participants in Expert Day are encouraged to sign up as MCA members for future support and updates.

2. Common Challenges with Particle Extraction for Cleanliness Analysis

Markus Rossler – Glaeser Inc.

3. Common Challenges with Light-Optical Analysis

Peter Feamster – JOMESA North America

The ISO 16232 standard for particle analysis is not always sufficient to measure the contamination from any given manufacturing process. In this presentation, Peter will discuss different methods for “extended analysis”, or analysis that uses special microscope setups outside of the normal ISO standard. Different examples will be shown and discussed.

4. Dealing with abrasive particles in practice – detection, origin, measures

Thomas Rosemann – Brose Wuerzburg

The cleanliness analysis has been standardized by VDA 19.1 and ISO 16232. But the part’s specific extraction procedure needs to be defined as well to guarantee comparability of test results. Therefore, Brose is creating test specification for its parts and connect these to the particle’s specification on the drawing. Thereby it becomes an obligation for the worldwide suppliers and for the different Brose plants. There are meanwhile five cleanliness laboratories within the Brose group.

In parallel Brose audits the cleanliness laboratories of its suppliers either by on-site visits or by providing a specific questionnaire.

Day 3 – October 20, 2021

Environmental Cleanliness Analysis

1. Environmental Cleanliness Monitoring

Markus Rossler – Glaeser Inc.

2. Technical Cleanliness in Assembly and Production Processes

Michael Klepzig – Continental Ingolstadt

Day 4 – October 21, 2021

Inspection of Electronic and Autonomous Driving Components

1. Proliferation of Electronics into Harsh Environments and the Effect on Reliability

Mike Konrad – Aqueous Technologies

Since the evolution of no-clean soldering processes, many assemblers have enjoyed the cost and time savings a no-clean process affords. The proliferation of electronics into harsh environments has however, highlighted the well-established link between process residues and electro-chemical migration (ECM) caused failures. Higher operational voltages, increased component densities, assembly miniaturization, and increased reliability expectations increase the relationship between clean assemblies and long-term reliability.

This webinar will detail the relationship between clean assemblies and reliability and the reasons an historically successful no-clean process is measurably less successful on modern assemblies, especially when products are installed in harsh environments. Factors that affect circuit assembly residue tolerance will be presented as well as residue mitigation processes.

Real-world examples of residue-related failures from the automotive and communications space will be presented along with the solutions adopted by the manufacturers. Multiple residue-induced failure mechanisms will be reviewed including ECM, conformal coating adhesion, frequency distortion, corrosion, and cosmetic. Additionally, the relationship with reflow profiles and residues will be presented.

Newly updated IPC cleanliness quantification standards will also be presented in order to answer the age-old question, “how clean is clean (enough)”.

2. Cleaning Bath Monitoring and Parts Inspection – An overview to common methods

Andre Lohse – Sita Messtechnik

To achieve stable parts cleanliness, cleaning processes must be monitored regularly.
André will present methods for aqueous and solvent cleaning with regard to concentration and pollution, as well as inspection methods for parts cleanliness with focus to chemical-filmic contamination.

3. Filmic Contamination Analysis

Darren Williams – SHSU / Cleaning Research Group

Day 5 – October 22, 2021

Escalation Strategies, Root Cause Analysis

1. Complete Manufacturing Cleanliness

Christian Tichopad – Glaeser GmbH

For products with challenging cleanliness requirements it is important to maintain Technical Cleanliness along the whole manufacturing chain. Christian Tichopad from Gläser HQ in Germany provides an overview over the most important factors for reaching your quality goals, covering process flow, inspection steps, responsibilities and competencies leading to an ongoing and successful improvement process.

2. The Structural Change in Industrial Component Cleaning

Gerhard Koblenzer – LPW Reinigungssysteme GmbH

The world is changing. New challenges in industry require a look at technical cleanliness in the entire
process chain and high-quality tests in advance. This decades of experience of LPW now meets a
changing industrialized world. New requirements in the automotive industry (fuel cell, electric drives,
and autonomous driving), higher requirements e.g., in vacuum technology, laser technology, in analysis
devices or in medical device technology require new approaches and a consideration of the entire
process chain under the aspect of technical cleanliness. Planning a new process must include a clear
analytical approach and realistic tests. There is also the benchmark with comparable processes.
We are talking at least about a Feasibility check regarding the required cleanliness specification:
• Definition of the process and the requested parameters.
• Determination of the suitable detergents and rinsing media.
• Determination of process and time critical sub-processes.
• Balancing between cycle time and process time.
• Determination of the suitable filtration and media treatment.
For this we need several Pre-Conditions
• Cleanliness of the environment should be near to the real conditions.
• The entire spectrum of cleaning, rinsing and drying processes should be available.
• The media (e.g., water, air) does have to supply the required quality.
• The sample parts must correspond to the real conditions in terms of Type, material, condition,
geometry, contamination and packing density.

3. Using Optical and SEM/EDX to help determine contamination sources

Peter Feamster – JOMESA North America

Cleanliness requirements have evolved greatly along with the complex systems the components are intended for. When contamination particles are detected that exceed these strict requirements, timely steps must be taken to find the source of the particles in order to remove or keep them away from the surfaces of the final product. Using optical microscopes and SEM/EDX analysis together may help to identify the material and/or process origin of the contamination.

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