ESD Controls In Manufacturing (RQ316)

SynopsisAs technology keeps driving things smaller and faster, the trend towards miniaturization has brought new challenges for ESD control. The ESD damage threshold of semiconductor devices has been ever decreasing and the number of devices falling into the Class 0 category has been steadily increasing. The most damaging consequence is the latent defects i.e. failures that are "walking wounded" and cannot be screened out by the normal manufacturing process.

This ESD course aims to provide a good understanding and a solid foundation for those who need to deliver ESD controls in their work environment. The course begins with an overview of ESD which is then followed by the fundamentals of ESD. Once a strong understanding of ESD is established the course will continue to discuss and explore the various methods of ESD prevention and protection. The participants will then study how to implement an effective ESD control program in a plant in detail.

The lecturer will draw on his wealth of experience in ESD controls to provide a lot of industrial case studies, applications of ESD concepts and live demonstration of critical ESD test and measurement tools for tackling ESD issues.

What previous participants say about this course
Answers to the question 'what did you like most about the course'

• "ESD knowledge" - 27 Jan 11
• "Demonstration" - 27 Jan 11
• "Related to work, practical" - 27 Jan 11
• "Practical approach & hand-on testing" - 27 Jan 11

What You Will Learn

• ESD Fundamental
• Common causes of ESD
• ESD Prevention/Protection
• How to establish an effective ESD control program
• How to conduct ESD tests

Who Should AttendManufacturing, product, test and QA technicians and engineers

PrerequisiteParticipants should have at least a basic science and/or engineering background.

Course MethodologyThis course is conducted in a seminar room. Each participant will receive a set of course materials.

Course Duration2 days, 9am - 5pm

Course StructureDay 1

Introduction to ESD

• What is ESD?
• Definition of ESD
• Why is ESD event often ignored?
• Concept of "cradle to grave" requirement
• What is the confusion of EOS over ESD?
• Differences between EOS and ESD
• Importance of ESD
• Difference between catastrophic versus latent failure
• What worsens ESD as technology advances?

Fundamentals of ESD

• Basics of static electricity
• Effects of grounding on insulators versus conductors
• Concepts of Faraday cage
• Law of induction
• Basic grounding requirements
• Relationship of charge,capacitance and voltage
• Methods of electrostatic voltage generation (contact and contactless methods)
• Triboelectric series
• Effects of humidity on ESD charges
• Helmoltz method of generating ESD charges
• How ESD damages sensitive components?
• Component/board direct and indirect charging
• Concept of virtual grounding
• ESD device susceptibility
• Level of sensitivity of device, board and system versus voltages
• How does dielectric breakdown and meltdown occurs?
• How to distinguish between EOS and ESD failures?
• Common causes of ESD
• Human negligence and poor ESD controls
• Proliferation of automated systems without proper ESD control considerations
• First case study of ESD damage caused by trim and form machine
• Second case study of ESD damage caused by plastic pick and place suction cups

Day 2

ESD Prevention and Protection

• Understand your product sensitivities
• Classification of product sensitivities
• Human Body Model
• Charge Device Model
• Machine Model
• IEC 801-2 system model
• ESD protection schemes employed by integrated circuits
• Eliminate any potential electrostatic voltage sources
• Role of materials in ESD protection
• Classification of material ie conductive,dissipative and insulative materials
• How is surface resistivity measured?
• Surface resistance and resisitvity classifications
• Surface resistivity versus discharge times
• Resistivity scale
• How to control unavoidable electrostatic voltage sources?
• Theory of ionization
• Concept of Faraday Shielding
• Use of antistaticity chemical agents

ESD Control Program

• Primary ESD controls which are absolutely necessary in order to ensure minimum ESD control
• Secondary ESD controls which are additional controls which will assist in further minimizing potential ESD damage
• How to accurately measure charges using Faraday Cup?
• Advantages and disadvantages of ESD shoes, booties and heelstraps
• Use of wrist straps and safety requirements
• Conductive smocks
• Conductive flooring
• How to install an ESD protective workstation
• Use of air ionizers
• Requirements of ESD protective chairs
• Grounding of carts and trolleys
• Static safe packaging and handling material requirements
• Review of verification devices:
• How to implement a 7 steps ESD control in your facility?
• Audit for potential sources of ESD
• Ascertain level of problem and amount of controls required
• Establish a person/group to manage this activity
• Develop a specification to ensure compliance
• Built in the levels of controls required
• Conduct regular audits
• Ensure continuous training and improvements

Practical Sessions

1. How to use Surface Resistance Meters to measure?

• Dissipative mats
• ESD Conductive flooring
• Moving carts/trolleys
• Foot wear
• Smocks
• Garments
• Gloves/finger cots
• Storage racks
• Seating
• Containers/Boxes
• Floor mats

2. How to check for resistance of

• Wrist straps
• Electrical grounding
• Ground cords
• Earth bonding point
• Auxilliary/Machines
• Tools

3. How to check machines if they are ESD safe?

• Equipment grounding
• Potential sources of ESD
• CDM events

4. How to check for functionality of ionizers?

• Decay times
• Positioning of ionzers

5. How to conduct Human Body Walking voltage test?

6. How to check functionality of incoming footwear/wrist strap checker?