A major aerospace corporation's implementation of MC2 Contamination Control Program, improved product and manufacturing processes resulting in increased product yield.
THE CLIENT
The client was the defense contract division of parent company based in Connecticut and employing more than 37,000 people worldwide. The defense contract division employed over 450 people.
THE CHALLENGE
MC2 was tasked to eliminate contamination related product failures which were near 20% of the real throughput yield.
MC2 ACTIVITY
An extensive Contamination Control Assessment covering every aspect of the program from receipt of sub-components, assembly to final test, packaging and ship of completed product to customer. It included facility assessment and evaluation of all processes was performed. It involved every point of the parts processing as well as the facility.
FINDINGS
Cleanroom airborne particle counts exceeded requiements. Significant airborne particle fallout at product process and assembly areas. Ultrasonic parts cleaning process incorrectly designed. Tools, fixtures, and work aids not designed for cleanroom use. Solutions used for cleaning and test not monitored for cleanliness. Cleanroom laminar flow benches incorrectly located in relation to HEPA filters. Incorrect gowning room procedures and layout.
CORRECTIVE ACTION
Contamination Control Program established and governed by a new Contamination Control Committee. Cleanroom training and certification instituted for all personnel. Cleanroom product assembly laminar flow clean benches properly located in relation to HEPA filters. Deficiencies in ultrasonic cleaning processes corrected. Tools, fixtures, and work aids redesigned for clean room use. Witness plate testing for periodic monitoring of airborne particle fallout was instituted, as was in-line fluid contamination monitoring. Contamination characterization begun. Cleanroom consumable testing instituted. Solvent filtering started. These and other measures enabled the company to improve product and employee efficiency.
RESULTS
The implementation of corrective actions over the course of a year enabled the company to improve its real through-put product yield by 16%, from 82 to 98%.
