Clean Manufacturing Conception & Realisation
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- Elmer Gallagher
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1 Clean Manufacturing Conception & Realisation Using the example of the LuminaLED research and production facility and the PERiMETER quality competence center for Eastern Europe Dipl.-Ing. (FH) Frank Buerger Key Account Manager Certification Ultraclean Technology and Micromanufacturing, Fraunhofer IPA, Stuttgart, Germany
2 Key Figures: Project Project tasks: Ramp-up of a turnkey LED research and production facility (LuminaLED) AND Realisation of a quality competence center for Eastern Europe (PERiMETER) Financing: EU structural funding of the Romanian Ministry of Education (ANCS) Overall project budget: approx. 17 Million EUR EU funding: approx. 10 Million EUR Target markets: Romanian and Eastern European automotive manufacturers (Renault, Dacia, etc.) Other quality and cleanliness relevant industries (semiconductor, life science, etc.) Project duration: 2 years Cleanroom realisation: 6 months
3 Key Figures: LED Technology LEDs are semiconductor light sources Main advantages: Low energy consumption Robustness Small size Fast switching properties High life expectancies and reliability LEDs are products with high expected growth rates consumer LED s Comissioned LED production facilities source:
4 Key Figures: LED Technology Contamination sensitive production: Particles Electrostatic discharge (ESD) Outgassing Installed capacity Detection of harming contamination types and sources Realisation quality competence center to suporting the LED production facility
5 Quality Competence Center The idea behind the Quality Competence Center: Set up appropriate cleanliness standards for the local LED research and production facility Future - to support other cleanliness markets in Central and Eastern Europe Cleanrooms Main tasks: Installation of a quality validation platform to assess the cleanliness state/quality of products for various contamination-sensitive branches Skilled Personnel A platform to assess, optimize and certify the cleanliness suitability of equipment and materials Establishment of a pan-european strategic alliance to transfer knowledge in the field of cleanliness technology Equipment
6 Lock-In Quality Competence Center Quality Competence Center: Quality Validation Platform Laboratory Management System: Cross-linking of Infrastructure Core Cleanliness Area (ISO Class 1 CR) 3D sample preparation Cleanliness Sensitive LEDs unknown cleanliness state potential contamination hazard (prodcut functionality, infection, etc.) Validation of Cleaning/ Cleanability Analysis direct analysis quantitative results integral analysis identification of contamination sources Production Related Methods exact identification of contaminants avoidance strategies removal strategies
7 Quality Residues Particulate Contamination Quality Competence Center: Quality Validation Platform Analysis Equipment Light Microscopes (LM) Number Morphology Wafer Scanner Atomic Force Microscope (AFM) Scanning Electron Microscope (SEM) Material Analysis Raman Spectroscopy Correlative Analysis Species Organics Anorganics Gas Chromatography-Mass Spectrometry (GC/MS) Ion Chromatography (IC) High Performance Liquid Chromatography (HPLC) Accuracy surface roughness measuring tool hardness measuring tools coordinate measuring machine computed tomography
8 Construction Site Both parts of the project combined in one location. LED research and production facility AND the quality compentence center The construction site was a former stately-owned production facility
9 Construction Site Solid structures were available Clean manufacturing environments had to be built from scratch
10 Planning and Concepts Completely new room concept Using the available spaces Cleanroom as built
11 Planning and Concepts Concept: Process Modules Planning air handling
12 Realised Cleanroom Labs: 800 m 2 ISO-class 8 and 130 m 2 ISO-class 1 New labs: include 800 m² of ISO-class 8 for the LED research and production facility Quality competence center is located in 130 m² ISO-class 1 cleanroom environment.
13 Realised LED Research and Production Facility in ISO-class 8 Cleanrooms
14 Realised Quality Competence Center in ISO-class 1 Cleanroom
15 Contact Fraunhofer Institute for Manufacturing Engineering and Automation IPA Ultraclean Technology and Micromanufacturing Key Account Manager Certification Dipl.-Ing. (FH) Frank Bürger Phone ADDRESS: Nobelstr. 12, Stuttgart Germany INTERNET:
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