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Tables of Contents for Esd Program Management
Chapter/Section Title
Page #
Page Count
Foreword and Dedication
xix
2
Preface
xxi
2
Acknowledgments
xxiii
4
Introduction
xxvii
Chapter 1 Twelve Critical Factors in ESD Program Management
1
16
The Twelve Critical Factors
2
12
Factor One--An Effective Implementation Plan
2
1
Factor Two--Management Commitment
3
1
Factor Three--A Long-Term Process Owner
4
1
Factor Four--An Active Leadership Team
5
2
Factor Five--Realistic Requirements
7
1
Factor Six--Training for Measurable Goals
8
1
Factor Seven--Auditing Using Scientific Measures
9
1
Factor Eight--ESD Test Facilities
10
1
Factor Nine--A Communication Program
11
1
Factor Ten--Systemic Planning
11
1
Factor Eleven--Human Factors Engineering
12
1
Factor Twelve--Continuous Improvement
13
1
Points to Remember
14
3
Chapter 2 Common Myths
17
8
Myth 1: "Small" Companies Cannot Afford Large Company ESD Programs
17
1
Myth 2: PWB Assemblies Are Not ESD Sensitive
18
1
Myth 3: One ESD Sensitivity Classification Is Sufficient for All Areas
18
1
Myth 4: Human Body Model (HBM) Data Are Sufficient for Detecting Device Sensitivity Levels
19
1
Myth 5: Air Flow Causes Charging
20
1
Myth 6: Metalized or Highly Conductive Shielding Layers Are Essential
20
1
Myth 7: Highly Conductive Materials Provide Increased Protection
20
1
Myth 8: Grounded Metal Is a Safe Surface for ESD Sensitive Components or Assemblies
20
1
Myth 9: Designed-In ESD Protection Precludes the Need for ESD Handling Controls
21
1
Myth 10: Smocks Are an Essential Element of an ESD Program
21
1
Myth 11: The "Three-Foot Rule" Is an Important ESD Safeguard
21
1
Myth 12: Touch Ground Procedures Are Effective
22
1
Myth 13: One Heel Grounder Is Sufficient Protection
22
1
Myth 14: Individuals Wearing Wrist Straps at ESD Work Stations Cannot Damage Sensitive Devices or Assemblies
22
1
Myth 15: Supplier Data Sheets on ESD Materials Can Be Accepted Without Question
23
1
Points to Remember
23
2
Chapter 3 Implementing an ESD Control Program: The Basic Steps
25
14
The Basic Steps
26
12
Step 1: Study and Understand the Technology of ESD Control
26
1
Step 2: Gather Scientific Evidence of the Economic Value of ESD Control
27
1
Step 3: Establish an Active ESD Leadership Team
28
1
Step 4: Develop a General Implementation Plan
28
1
Step 5: Write or Adopt a Set of Realistic Handling Requirements
29
1
Step 6: Prepare a Detailed Statement of Policy, Including Individual Responsibilities
30
1
Step 7: Prepare a Presentation for Management
30
1
Step 8: Establish a Top-Management Commitment
31
1
Step 9: Develop the Details of ESD Program Management
31
2
Step 10: Present the Program to Middle and Lower Management
33
1
Step 11: Begin Implementation of the Control Facilities
33
1
Step 12: Begin Training of the Entire Work Force, Including Management
34
1
Step 13: Begin Using Facilities Immediately After Training
35
1
Step 14: Begin ESD Statistical Process Controls (SPC)
36
1
Step 15: Begin Internal Auditing of All Manufacturing Departments
36
1
Step 16: Report Auditing Results, Graphically and With Regularity, to All Levels of Management
37
1
Step 17: Continuously Improve the Process
37
1
Points to Remember
38
1
Chapter 4 Fundamentals of Electrostatics
39
18
Basic Elements
39
17
Electric Charges
39
1
Electric Field
40
1
Electrostatic Potential
40
1
Capacitance
41
3
Charge Generation
44
1
ESD Failure Models
45
8
Charge Removal
53
1
Charge Dissipation and Protective Materials
54
2
Points to Remember
56
1
Chapter 5 Economic Benefits: Seven Convincing Case Studies
57
28
Case Study 1: ESD (Field-Induced CDM) Caused by Charged Plastic Faceplate
59
2
Case Study 2: Ultrasensitive Devices
61
5
Device Testing
62
1
PWB Assembly
63
3
Case Study 3: Resistor Failure Due to Automation in Production
66
3
Experiment 1
67
1
Experiment 2
68
1
Case Study 4: Bipolar Discrete Device Failure
69
1
Experimental Evidence
69
1
Case Study 5: Device and PWB Assembly Failures
70
7
Experiment 1
70
1
Experiment 2
71
1
PWB Assembly Shop -- Failure Analysis
72
1
Manufacturing Evidence
73
1
HIC Shop Manufacturing Data
73
2
PWB Assembly Shop Manufacturing Data
75
2
Case Study 6: Latent Failure Due to Prior ESD Damage
77
2
Experimental Evidence
77
2
Case Study 7: System Upsets-Long Distance Central Office
79
1
Conclusion
80
2
Points to Remember
82
3
Chapter 6 Designed-In Protection and Product Testing
85
20
Device Protection
85
2
Protection at the PWB Assembly Level
87
4
System Level Protection
91
1
Device Testing
92
5
PWB Assembly Testing
97
1
System Level Testing
98
1
ESD Design -- Dealing with the Trends
99
2
ESD Case Studies in Cordless Telephone Design
101
1
Points to Remember
102
3
Chapter 7 ESD Test Facilities
105
30
Field Audit Kit
107
2
General Laboratory
109
1
Analytical/FMA Laboratory
110
2
Instrument Descriptions
112
21
Instrument #1: Charge Plate Monitor (CPM)
112
2
Instrument #2: Electrostatic Field Meter
114
1
Instrument #3: Residual Voltmeter (RVM)
115
2
Instrument #4: Surface Resistivity Meter (SRM)
117
3
Instrument #5: Resistance to Ground (RTG) Meter
120
2
Instrument #6: Combination SRM/RTG Meter
122
1
Instrument #7: Static Decay Time Tester with a Controlled Humidity Chamber
122
1
Instrument #8: Megger Meter (High-Resistance Ohmmeter) with NFPA Probes
122
2
Instrument #9: Charge Analyzer (Faraday Cup)
124
3
Instrument #10: Personnel Voltage Tester (PVT)
127
1
Instrument #11: Air Ionizers
127
1
Instrument #12: ESD Simulators
127
2
Instrument #13: ESD Event Detectors
129
4
Points to Remember
133
2
Chapter 8 Realistic Requirements
135
24
Sensitivity Classification
136
6
Four Basic Rules for ESD Control
138
1
Static-Safe
138
2
Definitions
140
1
Antistatic Property
140
1
Static Conductors and Nonconductors
140
1
Surface Resistivity
140
1
System-Level Testing
141
1
Device Testing
142
1
ESD Control Requirements Specified by Class
142
15
Minimum Requirements
142
1
Work Area Classification
142
1
Documentation of Work Area Classification
143
1
Warning Signs
143
1
Personnel Training Program
143
1
Personnel Certification
143
1
Auditing
143
1
Statistical Process Control
144
1
Process Control Documentation
144
1
Process Control Methods
144
1
Production Equipment Certification
144
1
The ESD Acceptance Criteria for Equipment Associated with Manufacturing, Handling, and Testing Equipment
145
1
Personnel Grounding
145
1
Overall Requirements
145
1
Wrist Straps
146
1
Footwear
146
1
Seated Work Positions (Benches, Test Sets, Etc.)
147
1
Standing Work Positions (Packing, Mass Soldering, Etc.)
148
1
Flooring, Finishes, and Mats
148
1
Dissipative Floors/Floor Finishes
148
1
Floor Finishes/Carpeting
148
1
Conductive and Dissipative Floor Mats
148
1
Transporting Products
149
1
Carts
149
1
Static-Safe Packaging
150
1
Static-Safe Bags, Tubes, and Tote Boxes
151
2
Static-Generating Material Control
153
1
Dissipative Work Surfaces
154
1
Dissipative Table Mats
154
1
Dissipative Table Tops
155
1
Dissipative Gold Finger Shunts
155
1
Extraordinary Measures (Class 0 Devices)
155
1
Other Controls
156
1
Installation Standards
157
1
Points to Remember
157
2
Chapter 9 Common Problems in Smaller Companies
159
14
Lack of Common Point Grounds
159
2
Ungrounded Personnel
161
1
Static Generating Materials
162
1
Unsafe Surfaces for Devices and Assemblies
162
1
Improper Documentation/Procedures
163
1
Work Areas Not Classified by Device Sensitivity
164
2
Unsafe Parts Bins
166
2
Inadequate Training
168
1
Lack of or Improper Use of Ionizers
169
1
Unqualified Manufacturing Equipment
170
1
Points to Remember
170
3
Chapter 10 Guidelines for Smaller Companies: An Innovative System Audit
173
18
Large Company Benefits
175
1
Small Company Dilemma
175
1
The ESD System Audit
175
1
The ESD Program Analysis Survey
176
1
Quality System Audit (QSA)
177
1
Case Studies
178
3
Case Study #1: Electronics PWB Assembly Supplier
178
1
Case Study #2: A System Assembly Subcontractor
179
1
A Guide to Understanding the ESD Program Analysis Survey
180
1
Sample ESD Program Analysis Survey
181
8
Survey Section I: Policy and Procedures
181
4
Survey Section II: Work Area Classifications
185
1
Survey Section III: Auditing
185
2
Survey Section IV: Product Design Transfer
187
2
Points to Remember
189
2
Chapter 11 Internal Auditing
191
18
Why Auditing Puts the Process Owner in Charge
192
2
What Must Be Audited
194
1
How to Obtain Meaningful Data
194
1
One Designated Inspector
195
1
Auditing Reports Supersede Yield and FMA Data
196
1
The Auditing Inspector: Qualifications and Duties
197
3
Qualifications
197
1
Duties
198
2
The Inspector's Guide and Checklist
200
4
ESD Data Base Management Software
204
1
Summary
205
1
Points to Remember
206
3
Chapter 12 Using Auditing Results to Manage the ESD Program
209
18
Trend and Pareto Analysis Charts
210
1
When and How to Report the Results
210
8
Preliminary Auditing Reports
211
1
Final Auditing Reports
211
1
Staff Summary Reports
211
1
View-Graph Presentations
212
1
Engineering Analysis
212
1
Case Study 1: Thirteen Years of Continual Improvement
212
2
Case Study 2: Solving a Wrist Strap Problem
214
2
Case Study 3: Solving a Bench Top Problem
216
2
Illustrations on the Use of Graphics
218
5
Illustration 1: Departmental Comparisons
219
3
Illustration 2: A One-Page Summary of Five Years' Results
222
1
Illustration 3: Rewarding Success with a Zero Deviations Award
222
1
Summary
223
1
Points to Remember
224
3
Chapter 13 Statistical Process Control and ISO-9000
227
12
Statistical Process Control (SPC)
227
3
ESD Process Checkers
230
1
Process Control Layout (PCL) Document
231
1
ESD Process Quality Enhancements
232
1
Training Considerations
233
1
ISO-9000 Compliance
233
3
Points to Remember
236
3
Chapter 14 Material Characterization and Auditing Measurements
239
32
Part One: Materials Characterization
240
16
Basic Tests for ESD Materials
241
1
Company and Industry Standards
242
2
Examples
244
1
Example #1--Tape and Reel
245
5
Example #2--ESD Safe Bags
250
4
Example #3--Wrist Straps
254
2
Part Two: Auditing Measurements
256
12
Wrist Straps
256
1
Test #1: Total System Resistance
256
2
Test #2: Cord Resistance
258
2
Floor Finishes
260
1
Test #1: Surface Resistivity
260
1
Test #2: Evaluation of Unknown Floor Finishes
261
1
Footwear
261
1
Test: Total System Resistance
261
1
Table Mats
262
1
Test #1: Resistance to Ground
262
1
Test #2: Evaluation of Unknown Table Mats
263
1
Air Ionizer
264
1
Test: Electrostatic Potential Decay
264
1
Packaging Materials
264
1
Test: Static Decay
264
1
ESD Chairs
265
1
Test #1: Resistance from Seat to Casters
265
1
Test #2: Seat Back and Point-to-Point
266
1
Garments
266
1
Test: Resistance Panel to Panel and to Ground
266
2
Points to Remember
268
3
Chapter 15 Purchasing Guidelines: Finding the Hidden Costs and Problems
271
32
Purchasing Principles
271
2
Vendor Partnership Agreements
273
2
Quality Oriented
274
1
Credible
275
1
Dependable
275
1
Responsive to Your Needs/Receptive to Change
275
1
Cost Competitive
275
1
Equipment Selection Guidelines
275
4
Standards/Laboratory Analysis
276
1
Quality, Reliability, and Cost
276
1
Testing Compatibility
277
1
Suitability for Intended Application
277
2
Human Compatibility and Training Implications
279
1
Wrist Straps
279
4
Heel Straps
283
2
Shoes
285
1
Floor Mats
286
1
Workbenches
287
3
Work Surface Mats
290
2
Conductive Floor Finishes
292
2
Conductive Carpeting
294
4
ESD Bags
295
3
Bench and Room Ionizers
298
1
Packaging and Handling Materials
299
2
Points to Remember
301
2
Chapter 16 Training for Measurable Goals
303
22
Part One: Setting Measurable Goals
305
5
Study the Three Principles of the Psychology of Training and Learning
305
2
Derive Measurable Goals Based on the ESD Handbook
307
1
Use Auditing Reports and Personal Observations to Uncover Training Problems
308
1
Use Engineering Solutions to Provide Permanent Solutions to Training Problems
309
1
Part Two: Planning Classes and Recommended Courses
310
12
Find Resources to Train Everybody
310
2
Delivery Techniques
312
1
Preparation
312
1
Delivery
313
2
Visual Aids
315
1
Be Concise
315
1
Use Proper Format Consistently
316
1
Videos
316
1
Recommended Courses
317
5
Conclusion
322
1
Points to Remember
323
2
Chapter 17 Training Demonstrations
325
36
Basic Equipment
325
2
Part One: ESD Event Detection Demonstrations: A Training Breakthrough!
327
16
Part Two: Basic Demonstrations
343
16
Basic Demonstrations
343
3
Basic Classroom Demonstrations
346
13
Points to Remember
359
2
Chapter 18 Packaging Considerations
361
20
Antistatic Materials
363
1
Static Dissipative Materials
364
1
Conductive Materials
365
1
Packaging Application Examples
366
4
Tape and Reel Packaging
366
2
ESD Bags
368
2
Capacitive Coupling and Air Gaps
370
6
Integrated Circuit Shipping Tubes
371
3
Tote Boxes
374
1
Bubble Packs Versus Bags
375
1
Fighting ESD Failure Scenarios
376
3
Points to Remember
379
2
Chapter 19 Automation
381
22
The Nature of Automation-Caused ESD Damage: Different, Serious, and Difficult
382
1
Part One: Prevention Considerations and Techniques
383
6
Qualification Criteria and Test Equipment
383
5
Qualification Procedures
388
1
Part Two: Automation Case Studies
389
9
Conclusion
398
2
Points to Remember
400
3
Chapter 20 Strategic and Economic Benefits
403
8
Implementation Cost Avoidance
404
1
Quality Improvements
405
1
Reliability Improvements
406
1
Strategic Benefits
407
1
Points to Remember
408
3
Appendix 1 Lucent Technologies ESD Policy
411
2
Policy
411
1
Intent
411
1
Responsibilities
412
1
Appendix 2 Industry, Military, and Lucent Technologies Standards Used to Evaluate ESD Control Materials, Equipment, and Devices
413
10
Appendix 3 How to Test the Integrity of the Ground Connection on a Work Surface
423
2
Appendix 4 Installation and Maintenance Costs of Carpet
425
2
Glossary
427
10
References
437
8
Index
445