Blog Archives

11 Steps to Establishing an ESD Control Plan

1. Define what you are trying to protect.

What is the Human-Body Model (HBM) withstand voltage of the most sensitive item? A prerequisite of ESD control is the accurate and consistent identification of ESD susceptible items. Some companies assume that all electronic components are ESD susceptible. However, others write their ESD control plan based on the device and item susceptibility or withstand voltage of the most sensitive components used in the facility.  A general rule is treat any device or component that is received in ESD packaging as an ESD susceptible item.

2. Become familiar with the industry standards for ESD control.

A complimentary .pdf of ANSI/ESD S20.20-2014 can be downloaded from the ESD Association web site at www.ESDA.org. Also consider purchasing the ESDA’s ESD Handbook ESD TR20.20-2008.

3. Select a grounding / equipotential bonding system.

The 3rd-wire AC electrical equipment ground is the preferred, recommended ground reference.

4. Determine the method of ground for operators (Personnel Grounding).

The two options for grounding an operator are a wrist strap or foot grounders.  Wrist straps must be worn if the operator is seated. If foot grounders are used, an ESD flooring system must be used.  In some cases both wrist strap and foot grounders will be used. The 3rd-wire AC electrical equipment ground is the preferred, recommended ground reference.

5. Establish & Identify EPA(s) – ESD Protected Area(s).

ESD Control Plans must evolve to keep pace with costs, device sensitivities, and the way devices are manufactured. Define the departments and areas to be considered part of the ESD Protected Area.  Consider if customers and/or subcontractors should be included. Implement access control devices, signs, and aisle marking tape to identify and control access to the ESD Protected Area(s).

6. Select ESD control items to be used in the EPA based on your manufacturing process.

Elements that should be considered include: worksurfaces, flooring, seating, ionization, shelving, mobile equipment (carts), and garments.

7. Develop Packaging (Materials Handling & Storage) Plan.

When moving ESD susceptible devices outside an ESD protected area, it is necessary for the product to be packaged in an enclosed ESD Shielding Packaging.

8.  Use proper markings for ESD susceptible items, system or packaging.

From ANSI/ESD S20.20-2014 section 8.5: “the Organization, in developing the ESD Control Program Plan, shall consider the need for marking.”

9. Implement a Compliance Verification Plan.

From ANSI/ESD S20.20-2014 section 7.4: “A Compliance Verification Plan shall be established to ensure the Organization’s fulfillment of the technical requ.rements of the ESD Control Program Plan”.

10. Develop Training Plan.

From ANSI/ESD S20.20-2014 section 7.2: “Initial and recurrent ESD awareness and prevention training shall be provided to all personnel who handle or otherwise come into contact with any ESDS items.”

11.  Make the ESD Control Plan part of your internal quality system requirements.

A written ESD Control Plan provides the “rules and regulations”, the technical requirements for your ESD Control Program. This should be a controlled document, approved by upper management initially and over time when revisions are made. The written plan should include following:

  • Qualified Products List (QPL)A list of EPA ESD control items is used in the ESD control Plan
  • Compliance Verification Plan- Includes periodic checking of EPA ESD control items, and calibration of test equipment per manufacturer and industry recommendations.
  • Training Plan- An ESD Program is only as good as the use of the products by personnel. When personnel understand the concepts of ESD, the importance to the company of the ESD control program, and the proper use of ESD products, they will implement a better ESD control program improving quality, productivity, and reliability.
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How to Properly Use An ESD Shielding Bag

A basic principle of ESD control in a manufacturing environment is that ESD susceptible items should only be removed from ESD protective packaging when they are in an ESD protected area (EPA). Most EPAs are made up of “Islands” of control; the packaging / materials handling system must provide proper protection for ESD susceptible items during transport and storage outside those “islands” of control. When moving ESD susceptible items outside an EPA, it is necessary for the product to be packaged in closed ESD Shielding Packaging.

BagUseLabel

Tip# 1 – Not a Worksurface

Do not use a shielding bag as an ESD worksurface. Although a shielding bag is safe to use around ESD susceptible products, it is not intended to be a worksurface for product. It should be set aside or discarded after removing the product from the bag.

BagUseProbe

Tip# 2 – No Potholders or Tacos

BagUseTaco

Do not use a shielding bag as an “ESD potholder” or “ESD taco.” This type of use offers no ESD protection to the product.

Tip# 3 – Enclose Product

BagUseCircuitBoard

Shielding bags should be large enough to enclose the entire product and closed with a label or zipper style bag. 

Tip# 4 – Remove Charges

BaguseMat

Place closed bag on an ESD worksurface before removing product to remove any charge that might have accumulated on the surface of the bag.

Tip# 5 – Don’t Over-Use

BagUseOveruse

Re‐using shielding bags is acceptable so long as there is no damage to the shielding layer. Bags with holes, tears, or excessive wrinkles should be discarded.

So, are you using your ESD bags correctly?

If you have questions regarding shielding bags or ESD control, please click HERE.

Click for more information on Metal-In Shielding Bags.

 

ESD Control – Other Considerations

Application Photo of Surface Resistance Test Kit

OTHER CONSIDERATIONS
Discipline
A significant increase in the discipline of implementing the fundamentals of ESD control noted in ANSI/ESD S20.20 Foreword, calls for:

  • Ground all conductors in the EPA including people
  • Remove all insulators from the EPA or use ionizers for process necessary insulators
  • Package ESD sensitive items going outside the EPA in packaging that provides electrostatic discharge shielding

Insulators
We encourage developing a hatred for insulators. The alternatives are:

    Remove the insulative item from the EPA

  • Substitute the item with an ESD protective version (such as tape, document holders, material handling containers, plastic bottles, etc.)
  • Periodically treat insulative surface with a topical antistat
  • Neutralize electrostatic charges using ionization

Other ESD Control Items
Other EPA ESD control items to add to the ESD control program might include shelving, mobile equipment (carts), gloves, and/or seating.

Improve Compliance Verification Plan

  • Consider greater frequency of internal audits per ESD TR53
  • Use of computer data collection system for wrist straps and footwear testing, continuous monitors, and ionizers
  • Use of ground continuous monitors for worksurfaces and other ESD elements
  • Test ionizers more frequently, consider self monitoring ionizers, consider computer based data collection
  • Increased testing using static field meter to verify that automated processes (like auto insertion, tape and reel, etc) are not generating charges above acceptable limits.

Application Photo of Volt Meter and Software in Factory STM97.2 Testing Voltage Charge on Person (Photograph courtesy of TREK, INC.)

Improve Training

  • ESD awareness training for all in the EPA or who may come into the EPA including suppliers
  • Testing to verify comprehension and training adequacy
  • Training on the proper use of test equipment
  • Training on proper compliance verification test procedures

Application Photo CD-ROM ESD Training

Conclusion
Just to maintain a company’s current level of quality and reliability may require a substantial improvement in a company’s ESD control program. Now is the time for improvement as ESD sensitivity withstand voltages continue to get lower and companies may soon be handling class 0A HBM items. To combat HBM failures improved personnel grounding is required. For example, heel grounders should be replaced with full coverage foot grounders. However, most failures are CDM. To combat CDM failures, ionization should be added or improved, and conductive surfaces should be covered with dissipative material. In general, disciple should be enhanced implementing ESD control fundamentals, compliance verification testing should be increased, and training should be improved.

From published article “Now is the Time for ESD Control Programs to be Improved” by Fred Tenzer and Gene Felder. See full article at InCompliance Magazine- September 2012

NEW Plastek™ ESD Trash Receptacles

ESD Safe Trash Receptacle and Liner

Trash Receptacles:

  • ESD protective product to replace high charging plastic trash cans
  • Chemical and moisture resistant
  • Superior strength and durability; made from extruded
    high impact polypropylene material
  • Convenient fold down design for easy storing
  • Conductive Rtt 1 x 10E2 < 1 x 10E5 ohms
  • Reusable
  • ESD protective liners also available
  • Made in the United States of America

Economy Pink Liners:

  • Ideal for use inside ESD protected areas
  • Low cost, economical
  • Surface Resistance: < 10E11 ohms
  • Durable Thickness: 0.002 in (2.0 mil)
  • Packaged 50 bags per pack
  • Made in the United States of America
Item Description 1+ 25+ 50+ 100+*
37816 Trash Receptacle, 12-1/2” x 10” x 14”, 10 Gal. $35.93 $34.85 $33.81 $32.12
37817 Trash Receptacle, 21” x 12-3/4” x 28”, 36 Gal. $54.29 $52.66 $51.08 $48.53
37822 Economy Pink Liner, 26” x 26”, 10 Gal. $25.90 $24.61 $22.70 $22.01
37823 Economy Pink Liner, 36” x 40”, 36 Gal. $62.10 $60.24 $58.43 $56.68

“It should be understood that any object, item, material or person could be a source of static electricity in the work environment.
The removal of unnecessary nonconductors, replacing nonconductive materials with dissipative or conductive materials and
grounding all conductors are the principle methods of controlling static electricity in the workplace, regardless of the activity.”

*The prices in the Protektive Pak Online Catalog supersede all pricing on new product announcements and may change without notice.

Click HERE for Printable Version | Request a sample HERE | See a list of sales reps HERE
All items & programs are available through your participating distributor | Submit your question HERE

Protektive Pak In-Plant Handlers and Kanban Systems

Kaizen or continual improvement programs should often involve the ESD control program. When quality defects occur, many corrective actions will be improvements to the ESD control program to prevent recurrence.

Muda or Waste includes The Seven Wastes: Defects, Overproduction, Transportation, Waiting, Inventory, Motion, and Overprocessing.

We recommend using ProtektivePak In-Plant Handlers as a Kanban system. Just start with the three dimensions of the loaded PCB or other ESD sensitive item and determined the optimal size In-Plant Handler. Go to Tek Search.

We recommend using Protektive Pak impregnated corrugated which has a surface resistance of 1 x 10E6 < 1 x 10E9 ohms and is in the middle of the dissipative range. The ESD Association Packaging standard ANSI/ESD S541 section 7.2.2 includes “Packaging materials that are in intimate contact with devices should be dissipative.”

ProtektivePak In-Plant Handlers reduce ESD and physical defects, and can reduce work-in-process inventory as well as eliminating wasteful non-value added activities. As a Kaban container the In-Plant Handler can replace some or all documents. Instead of planners generating work orders, determine how many In-Plant Handlers to have on the shop floor and when cells are empty they signal the need to manufacture more of a particular item. Knowing the quantity of cells in the In-Plant Handler, one can quickly glance at the number of empty cells and know the count.

Some users do use a Kanban card and attach to the In-Plant Handler using Protektive Pak Dissipative Document Holders.

Protektive Pak impregnated corrugated has a buried shielding layer. For ESD shielding protection, with the lid in place, the In-Plant Handler can be moved or shipped outside the ESD Protected Area eliminating the need for ESD shielding bags. Per Packaging standard ANSI/ESD S541 section 6.2 Outside an EPA “Transportation of sensitive products outside of an EPA shall require packaging that provides:

  1. Low charge generation.
  2. Dissipative or conductive materials for intimate contact.
  3. A structure that provides electrostatic discharge shielding.”


Note: the ESD Association sells most of their documents, however, the Packaging standard ANSI/ESD S541 is available as a free download. Go to www.ESDA.org, click “Standards”, then “Documents” and scroll down to Packaging for the yellow highlighted Complimentary PDF Download.

New Economy Trash Receptacles and Liners

Economy Trash Receptacles


  • Economical ESD protective product to replace high charging plastic trash cans
  • Static dissipative surface of 10E6 – 10E8 ohms
  • Easy assembly without the need for tape, glue, or staples
  • Can be knocked down for storage purposes
  • Impregnated corrugated material; greater durability than coated or printed material
  • Buried shielding layer minimizes sloughing and rub-off contamination
  • Made from 100% recycled material, and is 100% recyclable
  • Static dissipative liners also available – Click here
  • Made in the United States of America
Item Size 1 25+ 50+ 100+
37814 12.5″ x 10″ x 14″ $11.05 $10.72 $10.40 $9.98
37815 21″ x 12.75″ x 28″ $20.20 $19.59 $19.01 $18.25

Economy Pink Poly Liners

  • 10 gallon capacity / 36 gallon capacity
  • Ideal for use inside ESD protected areas
  • Low cost, economical
  • Surface Resistance: < 10E11 ohms
  • Durable Thickness: 0.002 in (2.0 mil)
  • Packaged 50 bags per pack
  • Made in the United States of America
Item Size 1 10+ 25+ 50+
37822 26″ x 26″ $25.90 $24.61 $22.70 $22.01
37823 36″ x 40″ $62.10 $60.24 $58.43 $56.68

“It should be understood that any object, item, material or person could be a source of static electricity in the work environment. The removal of unnecessary nonconductors, replacing nonconductive materials with dissipative or conductive materials and grounding all conductors are the principle methods of controlling static electricity in the workplace, regardless of the activity.” [ESD Handbook ESD TR20.20-2008 section 2.4 Sources of Static Electricity].

The prices in the Protektive Pak Online Catalog supersede all pricing on new product announcements and may change without notice.

Sign Up HERE | Request a Sample HERE | See list of sales reps HERE
All items & programmes are available through your participating distributor | Submit your questions HERE

Do Protektive Pak In-Plant Handlers need to have lids on while ESD sensitive items are in them? How do these Protektive Pak In-Plant Handlers work?

Outside the ESD protected area (EPA), the Protektive Pak lids need to be in place to provide the electrostatic discharge shielding ESD control property which is required by the Packaging standard ANSI/ESD S541. Per section 6.2 Outside an EPA “Transportation of sensitive products outside of an EPA shall require packaging that provides: 1. Low charge generation. 2. Dissipative or conductive materials for intimate contact. 3. A structure that provides electrostatic discharge shielding.”

Inside the EPA, it would still be a good idea to have the lid in place, but it is not a requirement. The Protektive Pak impregnated corrugated has a buried shielding layer. In shielding, we utilize the fact that electrostatic charges and discharges take the path of least resistance. The charge will be either positive or negative; otherwise the charge would balance out and be no charge.

Like charges repel and so the electrostatic charge will reside on the outer conductive surface.

A Faraday Cage effect can protect ESDS contents in a container with a shielding layer (this is what a shielding bag has). This Faraday Cage effect protects people in real life when a lightning bolt strikes an airplane or automobile with the charge residing on the outer metal fuselage or car body.

The Faraday cage effect causes charges to be conducted around the outside the surface of the conductor. Since like charges repel, charges will rest on the exterior.

To complete the enclosure, make sure to place lids on boxes or containers, and close shielding bags. Packaging with holes, tears, or gaps should not be used as the contents may be able to extend outside the enclosure and lose their shielding as well as mechanical protection.

To ask an ESD question Click Here

To view In-Plant Handlers Click Here

10% off all Document and Card Holders

Convenient method for securing paperwork throughout the ESD protective area

  • Part numbers 47515 – 47519 have full adhesive back
  • Transparent clear material allows bar code scanning
  • Imprinted with ESD Protective Symbol
  • Packaged 25 per pack, 50 for 47518 and 47519
  • Made in United States of America

Online orders only. This cannot be combined with any other Protektive Pak promotional offer.
Not Valid on Custom Orders

Sign Up HERE | Request a sample Click HERE | See list of sales reps HERE
All items & programmes are available through your participating distributor | Submit your questions HERE

ESD Control: What Is ANSI/ESD S20.20?

Gene Felder of Desco Industries describes the ANSI/ESD Standard S20.20 and how it applies to an ESD control program.

To see Protektive Pak’s video channel Click Here.