ESD Program Management: A Realistic Approach to Continuous Measurable Improvement in Static Control

In today's electronics business, managing an ESD progranris an integral part of a complete quality program. In fact, any electronics firm without an active ESD program puts itself and its customers at risk. This book illustrates one good example of the detail and dedication to quality that AT&T expects within its own operations and from its suppliers. Writing of the book began at a time when Ted Dangelmayer was burdened with many demands. These demands were from AT&T's own operations, internal suppliers, external suppliers, customers and others looking for a better understanding of the phenomenon of ESD, its impact and, most of all, ways to control and manage it. In a way, this book is a response to these demands by making available a reader friendly document that distills the hard-won experiences of Ted and AT&T. The information and methods in this book have been gained at no small cost and produce results that far exceed eXRenses. There is, however, a caveat: Success will not be obtained unless there is real management commitment. This means management must allocate the necessary resources and provide active support to ensure that training, auditing, reporting, tracking and an aggressive corrective action program all take place successfully. Ted is an internationally recognized authority, and you will benefit greatly by listening to his advice and following his recommendations.

Table of Contents:
1 Twelve Critical Factors in ESD Program Management.- The Twelve Critical Factors.- Points To Remember.- 2 Implementing an ESD Control Program: The Basic Steps.- The Basic Steps.- Points To Remember.- 3 Fundamentals of Electrostatics.- Basic Elements.- Points To Remember.- 4 An Economic Analysis.- Case Study 1: Resistor Failure Due to Automation in Production.- Case Study 2: Bipolar Discrete Device Failure.- Case Study 3: Device and PWB Assembly Failures.- Case Study 4: Latent Failure Due to Prior ESD Damage.- Case Study 5: Ultrasensitive Devices.- 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.- Points To Remember.- 7 Realistic Requirements.- Sensitivity Classification.- Control Techniques.- Definitions.- Minimum Requirements.- ESD Awareness Training.- Personnel Grounding.- 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.- Illustrations on the Use of Graphics.- Summary.- Points To Remember.- 10Purchasing Guidelines: Finding the Hidden Costs and Problems.- Purchasing Principles.- Vendor Partnership Agreements.- Equipment Selection Guidelines.- 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.- Two: Planning Classes and Recommended Courses.- Conclusion.- Points To Remember.- 12 Packaging Considerations.- Antistatic Materials.- Static Dissipative Materials.- Conductive Materials.- Capacitive Coupling and Air Gaps.- 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.- 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.