esd work instruction wi-ops-005

OOOptiumOOOptiumOptiumESD Procedures Work Instruction for Chalfont Manufacturing

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WI-OPS-005 Rev.: A Issue Date: 4/30/03 of 17

1. INTRODUCTION

1.1 Purpose

This document describes the methods and materials to be followed for protecting parts and assemblies against damage resulting from an Electrostatic Discharge (ESD). This specification is applicable to all product types and operations involving ESD sensitive components and assemblies.

1.2 Scope

This document covers the ESD tools and consumables, how to use ESD equipment, and the overall ESD procedures for the Optium Chalfont.

2. APPLICABLE DOUMENTS

2.1 WI-OPS-002 ESD Audit Work Instruction2.2 ANSI/ESD S20.20-1999ESD Association Standard for the Development of an Electrostatic

Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

3. EQUIPMENT / TOOLS / CONSUMABLES

3.1 Approved Equipment / Tools3.1.1 Testers / Monitoring Equipment

3.1.1.1 3M 724 Continuous Work Station Monitor3.1.1.2 3M 740 Wrist Strap / Heel Strap Tester Certified

3.1.2 Workstations & Benches3.1.1.1 Production Basics Workstation 2000 w/ESD laminate

3.1.1.2 EZE Workmaster Work Station w/ESD laminate

3.1.2 Personnel Grounding Equipment 3.1.2.1 3M 2381 Dual Conductor Metal Wrist Strap Assembly – 5’ Cord & Small Band3.1.2.2 3M 2382 Dual Conductor Metal Wrist Strap Assembly – 5’ Cord & Medium Band3.1.2.3 3M 2383 Dual Conductor Metal Wrist Strap Assembly – 5’ Cord & Large Band3.1.2.4 3M 2056 Non Marking Heel Strap w/ 1Mega Ohm resistor3.1.2.5 3M 2051 Heel Strap w/1 Mega Ohm resistor3.1.2.6 3M 2059 Economy Heel Strap w/ 1 Mega Ohm resistor3.1.2.7 3M 2053 Toe Grounder w/ 1 Mega Ohm resistor

PRINTED COPY MAY NOT BE THE LATEST REVISION PLEASE REFER TO AGILE FOR CURRENT REVISION.


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3.1.2.8 Technistat 758ST086 Red Hi Visibility heel strap w/ 1 Mega Ohm resistor (Techni-Tool)3.1.2.9 Technistat 758ST757 Non marking heel strap w/ 1 Mega Ohm resistor (Techni-Tool)3.1.2.10 Technistat 758ST559 D-ring heel strap - red w/ 1 Mega Ohm resistor (Techni-Tool)

3.1.3 Chairs 3.1.3.1 Biofit ESD Chair 4V57-1000-K-STR (Techni-Tool # 127BE057

3.1.4 Carts 3.1.4.1 Metro carts with metal split sleeves and drag chains

3.1.5 Handling/Packaging/Packing Supplies 3.1.5.1 Centurian black conductive corrugated bin boxes (includes BN1824 and others)3.1.5.2 Protective Pak black conductive corrugated board box (includes 401-BX and others)3.1.5.3 Quantum Storage Systems black conductive plastic bin boxes (QUS210, QUS230,

QUS25)3.1.5.4 Charleswater Static Dissipative Binders

3.1.5.4.1 12705 – 1.2”3.1.5.4.2 12710 – 1.7”3.1.5.4.3 12712 – 2.3”3.1.5.4.4 12715 – 2.9”3.1.5.4.5 12720 – 4.2”

3.1.5.5 Static shielding bags3.1.5.6 U-Line PN S-1324 antistatic bags3.1.5.7 Charleswater EMI/ESD Moisture Barrier Bag (Starboard PN 13129)

3.1.6 Chemical Containers 3.1.6.1 ESD spray bottle3.1.6.2 Static Safe pump dispenser

3.1.7 Cleaning Products, Antistat Chemicals & Hand Lotion 3.1.7.1 ESD Workstation Cleaner3.1.7.2 Static Dissipative Hand Lotion

4 ESD PROTECTION EQUIPMENT INSTRUCTIONS & SAFETY

4.1 General Instructions4.1.1 All personnel and visitors are required to follow ESD procedures.



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4.2 Safety4.2.1 Use extreme caution around live circuits while wearing ESD protection.

4.3 ESD Protected Area4.3.1 Any entry to an ESD sensitive area will require personnel to wear an ESD smock and

heel/toe grounding device. 4.3.2 ESD sensitive areas are designated with ESD signs. 4.3.3 ESD sensitive devices shall not be stored or handled without proper ESD protection.

4.4 ESD Work Station4.4.1 General Instructions

4.4.1.1 ESD work stations shall consist of an ESD approved surface (ESD laminate or table mat) and a method of grounding the employee.

4.4.1.2 ESD work stations shall be monitored continually for ground integrity using the 3M 724 work station monitor.

4.4.1.3 The work surface should be cleaned as required using ESD Workstation Cleaner.4.4.1.4 ESD table mats may be used in place of ESD approved laminate but the mat must be

grounded. 4.4.1.4.1 ESD table mats are considered grounded if sitting on top of a grounded ESD hard

laminate surface (mat ground wires are not needed).

4.4.2 How to Use the 3M 724 Work Station Monitor

4.4.2.1 Wrist Strap Connection Monitoring 4.4.2.1.1 Put on the wrist strap assembly. See the wrist strap section below for further help.4.4.2.1.2 Attach a 3M dual conductor ground cord to the 732 remote jacks under the table.

Plugging into a jack activates the monitor for that input.



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4.4.2.1.3 The high resistance wrist strap red lamp (H) should illuminate briefly and then the corresponding OK wrist strap green lamp will illuminate.

4.4.2.1.4 If the wrist strap is loose or the cord is damaged or broken that results in a high resistance of >10 Mega Ohms, the high resistance wrist strap red lamp (H) will illuminate and the corresponding audible alarm for the input will sound. For operator 1 this will be a continuous tone. For operator 2 the alarm will be a fast chirping beep.

4.4.2.1.5 If the low resistance (less than 1.5 Mega Ohms) exists, the yellow lamp (L) will illuminate. It has no audible alarm. A low resistance condition can be caused by touching a grounded object or by standing on a conductive surface.

4.4.2.2 Work Surface Monitoring 4.4.2.2.1 The work surface monitoring function is active at all times as long as the power

supply for the monitor is plugged in.4.4.2.2.2 If the resistance across the conductive layer of the work surface and/or ground

connections is greater than 3.7 Mega Ohms, the high resistance red work surface lamp (M) will light and the audible alarm (slow chirping beep) will sound.

4.5 Wrist Strap Assemblies4.5.1 Wear a wrist strap assembly before and during handling of ESDS items. The wrist strap

band must come in skin contact and shall not be worn over clothing.4.5.2 The wrist strap band shall fit snug (make good contact 360 degrees) on the wrist.4.5.3 Grasp the plug when removing the cord from the work station. Do not pull out by the cord.

Pulling by the cord can damage the cord.



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4.5.4 Wrist straps are continually tested using the 3M 724 Work Station Monitor device. Wrist straps shall only be plugged into these stations.

4.5.5 Antistatic hand lotion may be needed on the wrist where the wrist strap band contacts the skin to ensure good electrical contact of the band.

4.5.6 Wrist strap assemblies shall have a 1 Mega Ohm resistor built into the assembly to provide operator safety.

4.6 ESD Footwear - Heel / Toe Straps and Shoes4.6.1 General Instructions

4.6.1.1 ESD footwear shall be worn before and during handling of ESDS items. ESD footwear can be an alternate to the wrist strap assembly when mobility is required provided they are used in conjunction with ESD protective flooring

4.6.1.2 ESD footwear (Heel/toe straps) shall be worn on BOTH feet.4.6.1.3 Heel/toe straps should have a 1 Mega Ohm resistor built into the strap to provide operator

safety.4.6.1.4 ESD footwear is only effective when in contact with the ESD protective flooring and

therefore can only be used when standing or walking. A wrist strap shall be worn when sitting at a workstation even if you are wearing heel/toe straps because of the possibly of picking up your feet.

4.6.1.5 ESD footwear (each foot tested separately) shall be tested using the 3M 740 heel strap tester every time they are put on. See operating instructions for the 3M 740 heel strap tester in this document.

4.6.1.6 Complete the Heel Strap Log (FORM-ESD-001) after testing.

4.6.2 How to Put on Heel/Toe Straps 4.6.2.1 Re Usable Heel Straps

4.6.2.1.1 The strap is placed over the heel of the shoe and held in place by the Velcro. Next tuck the ribbon in-between the sock and the foot or between sock and the shoe.



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4.6.2.2 Re Usable Toe Straps4.6.2.2.1 Hook the toe grounder over the front of the shoe and the elastic strap around the

back of the shoe. The black portion should be to the bottom of the shoe. Tuck the ribbon between the foot and inside of the shoe.

4.7 ESD Footwear TesterThe 3M 740 Wrist /Heel Strap tester can test both wrist straps and ESD footwear but the dual conductor wrist strap cord end does not fit into the tester. The 3M 724 Work Station Monitor checks the dual conductor wrist strap continually therefore the tester will only be used for ESD footwear.

4.7.1 How to Use the 3M 740 ESD Footwear Tester 4.7.1.1.1 Put on the approved ESD footwear.4.7.1.1.2 Switch on the tester by pressing the “ON/OFF” switch located near the bottom

right of the unit. See picture below. All the LED’s will flash for approximately 1 second as the unit checks their function.



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4.7.1.1.3 Stand with one foot only flat on the foot plate.4.7.1.1.4 Depress the metal contact plate for the shoe test until one of the indicator LED’s

near the top of the unit is lit.4.7.1.1.5 The green LED “OK” indicates the resistance of the ESD footwear is between

750K Ohms and 10 Mega Ohms. 4.7.1.1.6 The red LED “<” indicates the resistance of the ESD footwear is below 750K

Ohms. If the resistance is below this value, replace the ESD footwear and re test.4.7.1.1.7 The red LED or “>” indicates the resistance of the heel strap is above 10 Mega

Ohms. If the resistance is above this value, clean the bottom of the ESD footwear, check if the ESD footwear was properly installed and re test. If the red LED “>” is still lit, replace the ESD footwear.

4.7.1.1.8 Repeat the test for the other foot.4.7.1.1.9 Complete the ESD footwear log FORM-ESD-001 when you are complete.

4.8 ESD Smocks4.8.1 Smocks must be worn before entering an ESD sensitive area. ESD sensitive areas are

designated with ESD signs.



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4.8.2 Smocks are to be buttoned up and have no clothing protruding from the sleeves or front.4.8.3 Sleeves cannot be shortened above the cuff.4.8.4 A cleaning service for smocks is provided and dirty smocks can be dropped off in the

designated area.4.8.5 For visitors or employees who infrequently enter an ESD sensitive area, there are visitors'

smocks located in the main lobby closet that can be borrowed and returned after use.

4.9 Conductive Internal Handling Boxes4.9.1 Only conductive handling boxes shall be used.4.9.2 Items shall be completely contained within the box and the lid installed during transport

outside ESD areas.

4.10 Static Shielding Bags4.10.1 ESD approved bags will be allowed to carry ESD sensitive items.4.10.2 Discard any bags that are cracked, ripped or have holes. 4.10.3 Bags can be recycled/re used if the bag is less than 4 years old and meets the other

requirements within this section. The bag should have a date code marked near the manufacturer's logo. e.g. 02-05 would mean the bag was manufactured in May 2002. If no date code is marked on the bag, discard the bag.

4.10.4 Bags must be closed to provide proper ESD protection. The use of an ESD label (PN09900009) for closing the bag is required.

4.11 ESD Protective Flooring4.11.1 ESD protective flooring is used in conjunction with ESD foot protection to provide a means

for grounding personnel.4.11.2 ESD protective flooring shall be cleaned on a regular basis at a minimum of once per week.4.11.3 ESD protective floor wax shall be applied to the flooring on a monthly basis.

4.12 Air Ionizers4.12.1 Air ionizers are to be used at all times when work is being done at a work station. 4.12.2 Air flow shall flow at an item but shall not be blocked by other items.4.12.3 Air ionizer pistols or guns should be used when compressed air must be blown over ESD

sensitive items.

4.13 Shelves4.13.1 All shelf units within an ESD protected area shall be grounded. This includes each

individual shelf. On wire shelves, ensure metal split sleeves are installed on enough posts that each shelf gets grounded.

4.13.2 Metal shelves sitting on an ESD floor do not need to have a ground wire attached unless insulated from making contact with the ESD floor. This is considered an adequate ground.



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4.13.3 Shelves not sitting on an ESD floor should have a ground wire connected to ground. An acceptable ground point is the third wire on an electrical plug or a chassis connected to electrical ground.

4.14 Carts4.14.1 All carts shall have a metal drag chain attached. The chain should be long enough to make

contact with the floor.4.14.2 On wire shelf carts, ensure metal split sleeves are installed on enough posts that each shelf

gets grounded.

4.15 Chairs4.15.1 Only ESD approved chairs are allowed in an ESD protected area. ESD chairs (as described

in the approved materials section) have a lightning bolt on the casters.4.15.2 All chairs shall have at least one ESD caster, metal leg or drag chain. Metal drag chains shall

be long enough to make contact with the floor.

4.16 Binders4.16.1 Only ESD approved binders are allowed in an ESD protected area.4.16.2 ESD binders contain an ESD symbol somewhere on the cover.

4.17 Chemical Dispensers4.17.1 Only ESD approved chemical dispensers are allowed in an ESD protected area.4.17.2 ESD chemical dispensers contain an ESD symbol somewhere on the outside of the container.

5 SPECIFIC INSTRUCTIONS / PROCEDURE

ESD handling procedures and precautions form the base of an ESD program therefore, handling procedures and precautions will be followed by all personnel. For instructions and procedures for ESD equipment, see the section above.

5.1 The ESD classification for Optium Corporation in accordance with the ANSI/ESD S20.20 standard and associated documents is class 0. A classification chart of voltage sensitivities is listed in Table 1.



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Class Voltage Range

0 < 250

1A 250 to < 500

1B 500 to < 1000

1C 1000 to < 2000

2 2000 to < 4000

3A 4000 to < 8000

3B 8000

Table 1

5.2 General Handling and Precautions5.2.1 Ensure all personnel have been trained in ESD procedures.5.2.2 All electronic or electrical components are to be considered ESD sensitive.5.2.3 Once an ESDS part is placed on an assembly, that assembly becomes static sensitive. Also

when one assembly is placed into a higher assembly, the higher assembly becomes static sensitive.

5.2.4 No person shall enter a designated ESD protected area unless wearing an ESD smock and heel/toe strap or ESD footwear. Anyone can tell that person to leave an ESD protective area if no not meet the above criteria, no matter who it is.

5.2.5 Only ESD approved materials are allowed at an ESD work station.5.2.6 All work involving ESDS items must be done at ESD approved work stations.5.2.7 A person shall be properly grounded before handling an ESD item or removing an item from

an ESD safe bag or container.5.2.8 ESDS items routed between ESD protected areas must be protected by the use of appropriate

ESD handling devices. Hand carried ESDS items must be protected in static shielding bags or conductive containers with the lid on.

5.2.9 When ESDS items are not in their protective containers, do not set them on any surface other than an ESD approved surface.



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5.2.10 Carts used to transport ESDS items must have a drag chain and/or conductive casters. If transport of product on a cart is required outside an ESD area, the item must be static shielding packaging.

5.2.11 Try to handle ESDS items by the edges. For example do not grab IC's by the leads, handle by the case.

5.2.12 Do not slide containers across floors or any other surface.5.2.13 ESDS items will be covered with an approved ESD material or put back in the ESD bag or

container when left unattended at an ESD work station.5.2.14 IC tubes/trays should be fully enclosed by static shielding bags when being stored or routed.

The bag should be folded over and if possible held shut by an ESD label.5.2.15 Guidelines for humidity levels in ESD areas are 30% to 60%. Manufacturing areas are not

controlled to these levels. Levels below 30% humidity can result in larger static charges being generated. Levels above 60% can result in metal corrosion of product and/or equipment.

5.3 Manufacturing Areas5.3.1 Ensure the use of protective devices at all necessary points where ESD items are handled

outside their protective packaging.5.3.2 The manufacturing groups are responsible to ensure that the integrity of ESD protected areas is

maintained. This is performed by regular verification and maintenance of all ESD equipment.

5.3.3 Upon completion of work, repackage ESDS items in ESD protective packaging material and assure proper marking. Place the ESDS items in protective totes or trays for transporting to next work station.

5.3.4 When using test equipment, make sure all equipment is properly grounded. If test equipment cannot be grounded, touch any test probes to ground before touching any components or assemblies.

5.4 Shipping/Receiving/Storage Areas5.4.1 Be aware of all ESDS items delivered by Vendors.5.4.2 Do not open, unless necessary, packages containing ESDS items. If packages need to be

opened, do so only at ESD approved work stations following handling precautions.5.4.3 Ensure all packages and kits issued from the stockroom containing ESD items are marked with

ESD sensitive symbols and cautions.5.4.4 Ensure all ESDS items submitted for shipments have been received in ESD protective

packaging material. If an ESDS item is not received in approved ESD packaging, notify the manufacturing floor.

5.4.5 Package the ESDS items in ESD protective material for shipment as required by contract.



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5.4.6 IC tubes should be fully enclosed by static shielding bags when being stored or routed. The bag should be folded over and if possible held shut by an ESD label.

5.5 Training and Certification5.5.1 All personnel shall received training on ESD including static fundamentals and practical

procedures as in this document yearly.5.5.2 The static fundamentals portion is a computer program that automatically logs that the person

has received the course.5.5.3 The practical procedures will be a review of this procedure and the person will sign an

attendance sheet that he/she has taken the course. The Quality Coordinator will enter the attendance sheet into the computerized training log.

5.6 Other Guidelines for Program Quality5.6.1 Audit to ensure that regular verification and maintenance is being performed on ESD approved

materials to maintain ESD integrity (e.g. ESD workstations, shelves, wrist/heel strap logs, etc.).

5.7 Design Guidelines5.7.1 Whenever possible choose items which are less sensitive to ESD.5.7.2 Ensure all new drawings and documentation for ESD sensitive items contains ESD warnings.

6 DEFINITIONS

6.1 Charge6.1.1 A charge exists when there is an imbalance of electrons on an object. Charge is measured by

the number of electrons on an object (negative charge) or the number of electrons not on an object (positive charge).

6.2 Static Electricity6.2.1 An electric charge at rest.

6.3 Electrostatic Discharge (ESD)6.3.1 A transfer of electrons from one body to another at a different potential. This can be done by

direct contact or simply by being very close to a conducting material.

6.4 ESDS6.4.1 ESD Sensitive



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6.5 ESDS Component6.5.1 Any component that can be damaged by an electrostatic discharge.

6.6 ESDS Assembly6.6.1 Any assembly with one or more ESDS Components. Once an ESDS Component is placed on

an assembly that assembly then becomes ESDS unless otherwise specified on the production process.

6.7 ESDS Item6.7.1 A component or assembly sensitive to static discharge.

6.8 Catastrophic Failure6.8.1 The ESDS item fails immediately after an electrostatic discharge occurs.

6.9 Latent Failure6.9.1 The ESDS item fails in the field (later) after an electrostatic discharge occurs.

6.10 Triboelectric Effect6.10.1 The generation of static electricity caused by the rubbing of two substances. The

electrostatic charge can be created by a joining or a separating process.

6.11 Induction6.11.1 The process by which electrical properties are transferred to a neighboring body without

direct contact.

6.12 Capacitive Charging6.12.1 The process in which a voltage is increased on a body by its changing capacitance relative to

another body or ground. When the capacitance is reduced the voltage increases. V = Q/C.

6.13 Static Dissipation6.13.1 The ability of a material to allow a static charge to be transferred at a specific rate of flow

(high, low or whatever).

6.14 ESD Protective Material6.14.1 Material capable of one or more of the following:

6.14.1.1 limiting the generation of static electricity6.14.1.2 rapidly dissipating electrostatic charges6.14.1.3 providing shielding from ESD spark discharge or electrostatic fields



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6.14.2 ESD protective materials are classified in accordance with their surface resistivity (or alternate conductivity) as conductive, static dissipative or antistatic.

6.15 Conductive Material6.15.1 A material that has a low resistance to the flow of electrons allowing a static charge to be

transferred easily, therefore, the material is extremely dissipative.

6.16 Static Dissipative Material6.16.1 A material that has a medium resistance to the flow of electrons, thereby being somewhat

dissipative.

6.17 Anti-static Material6.17.1 A material that has a high resistance to the flow of electrons, thereby being non-static

generative with slow dissipation.

6.18 Electrostatic Field6.18.1 A voltage difference between an electro statically charged surface and another surface of a

different electrostatic potential.

6.19 Static Shielding6.19.1 Material that prevents penetration of an electrostatic field.

6.20 Grounding6.20.1 The neutralizing of static charges by constant dissipation (draining) through to an electrical

ground.

6.21 ESD Protected Area6.21.1 An area which is constructed and equipped with the necessary ESD protective materials and

equipment to limit ESD voltage below the sensitivity level of ESD item handled therein.

6.22 ESD Protected Workstation6.22.1 Any workstation with an approved work surface that is grounded and equipped with a

method of grounding the employee.

6.23 ESD Protective Packaging6.23.1 Packaging with ESD protective materials to prevent ESD damage to ESDS items.

6.24 ESD Symbols



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6.24.1 Symbols used to alert people of ESD Sensitive Items. It may appear on the item, packaging on signs in ESD areas.

6.25 Antistat6.25.1 An antistat is a chemical that is applied to a non-ESD approved material to make that item

antistatic.

6.26 Ionizer6.26.1 A device that dissipates electrostatic charges by forming both positive and negative ions.

6.27 Ions6.27.1 At atom or group of atoms that carries a positive or negative charge.

6.28 Static Meter6.28.1 A device capable of sensing and measuring static charges.

7 ACRONYMS

Acronyms Definition ESD Electrostatic DischargeESDS ESD SensitivePN Part Number



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6 Appendix A: ESD Control Equipment Performance Recommendations

ESD CONTROLLED ITEM RECOMMENDED RANGE REF. STD.Wrist Strap Cord 0.8 106 to 1.2 106 ohms ESD S1.1Wrist Strap System < 35 106 ohms ESD S1.1ESD Flooring - Foot Wear System

< 35 x 106 ohms or < 100 volts

ESD STM 97.1 or ESD STM 97.2

ESD Flooring 105 to 109 ohms ESD STM7.1ESD Seating 105 to 109 ohms ESD STM12.1

ESD Garments1 105 to 1 1011

ohms ESD STM2.1

ESD Totes Boxes and Containers < 109 ohms N/A

Shelving (Fixed and Mobile) < 1 x 109 ohms ESD ADV53.1Mobile Equipment (Carts) < 1 x 109 ohms N/AAC Power Tools < 1 ohm ANSI/ESD S20.20Soldering Irons < 2 ohms ESD STM13.1Battery Powered Hand Tools < 1 x 1012 ohms ANSI/ESD S20.20Pneumatic Hand Tools < 1 x 1012 ohms ANSI/ESD S20.20Static Dissipative Work Surface 105 to 109 ohms ESD S4.1Static Dissipative Work Floor Mats 105 to 109 ohms ESD S4.1

Portable Ionizers < ± 50 Volts Voltage Offset ESD STM3.1Room Ionizers < ± 150 Volts Voltage Offset ESD STM3.1Humidity 30% to 70% RH ANSI/ESD S20.20Ground Continuity From Groundable Point < 1 Ohm ESD S6.1



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8 REVISION HISTORY

RECORD OF ISSUE

ApprovalsRev. Description of Change Originator Date Reviewed By: Date

A Initial Release. S.Antonacci 04/28/03 I.Saleh In Agile


esd work instruction wi-ops-005

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