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Plasma cleaning uses ions or charged molecules to physically sputter thin organic contaminant layers from a substrate. Expert has experience with plasma cleaning and has used it successfully to increase wire bonding in aerospace accelerometer manufacturing applications.

Since the early 1980's, Expert has been involved with carbon dioxide (CO2) “snow” cleaning. He was one of the early adopters and promoters of the technology, and holds two patents for cleaning systems utilizing the technology. He has developed, designed, and implemented CO2 cleaning systems for consumer electronics, aerospace, optics, ceramics, and other industries. The systems have ranged from hand-held to fully automated equipment for large-scale operations.

When the assessment identifies an out-of-specification issue, Expert implements a corrective action program, resolution deadline, and preventive plan. For every issue, the root cause is identified and appropriate measures established to prevent recurrence. This ensures that the underlying problem is addressed. A quantitative report on the causes and corrective actions is provided as a tool to track the corrective action plan and evaluate the effectiveness of preventive measures.

Once the contaminant has been identified, its source can be determined. Common sources of contamination are cleanroom personnel, water systems, process chemicals, electrostatics, corrosion, wear, residues, filter material, external or foreign objects, restricted materials, packaging, paint, sealants, among others. Once the source is determined, the problem can be addressed, and its effects mitigated.

Expert also offers a Contamination Control Technologist training program for selected personnel requiring more in-depth training in contamination control methods, practices, theory, and practical applications. This training is not product, company, or facility specific, but is intended to give the technologist a broad contamination control background, enabling him to properly use the technology in virtually any application. The course covers contamination control history and overview, theoretical modeling, contamination types and effects, specifications and procedures, clean areas and processes, laminar airflow. Localized Process Control, clean area administration, clean area cleaning, personnel contributors to contamination, personnel protocols, clean area garments and supplies, contamination characterization, microscopy, high purity water engineering and testing, high purity gases and solvents and safety, product precision cleaning methods, ultrasonic cleaning, CO2 cleaning, clean packaging, electrostatics, approved and restricted materials.

Expert has developed 18 meg ohm ultra pure water systems for small to mid-sized applications, and has experience with influent, blocking and final filtration, Reverse Osmosis, Deionized water, U/V sterilization, and recirculation.

Expert uses the results of a Contamination Control Assessment and conceptual filtration performance models to assist in the decision making process to select the correct particle filtration scenario for the application. He places specific emphasis on High Efficiency Particulate Air (HEPA) filtration, Ultra Low Particulate Air (ULPA) filtration, and laminar airflow management.

The overall CCP developed is based on the sensitivities and performance goals of the product, and specifies design, fabrication, assembly, integration, testing, packaging, and transportation criteria to prevent the probability of contaminating critical surfaces. This includes the physics of contamination, clean area specifications, facility administration and management, components and accessories, processes, contamination monitoring and assessments (airborne particle monitoring, visual inspections, black light, tape lifts, and witness plate testing), air filtration, liquid filtration, personnel garments, cleanroom consumables and supplies, personnel disciplines, equipment and control, materials, facility cleaning, laminar airflow, workbenches, Localized Process Control (barrier isolation) and mini-environments, contamination measurement, analysis, and characterization, high purity water engineering, testing, and safety, clean robotics and automation, engineered precision cleaning systems including ultrasonic, CO2, plasma, UV/Ozone, strip coating, optical radiation cleaning methods, assembly and clean packaging, electrostatics and air ionization, cost effective cleanliness, and product/process specific training programs as applicable to product requirements.

As with most technologies, there has been considerable progress in the design of ionizers over the last twenty years. Specialized ionizers exist for protecting extremely ESD-sensitive components, high-speed industrial web applications, and high quality cleanroom applications among many other applications in electronics assembly, optics, and medical devices. Manufacturers of ionizers have learned to make the best use of the variety of ionization technologies available. Expert uses his expertise with electrostatics and air ionization to determine the best solution for the application.

In addition to typical ultrasonic systems, Expert has developed and designed a new ultrasonic cleaning system utilizing a unique transducer application. This system creates instantaneous cavitation requiring no degassing of the cleaning solution. The solution is continuously replenished while the post cleaning contaminated solution is removed out of the cleaning tank by cascade overflow at a rate that totally eliminates any cross contamination of the fresh cleaning solution. The system also generates cavitation in various size ranges giving the system the capability of removing different contaminant sizes into the submicron range. This system resulted in a significant savings in both time and cost for the company for which it was developed.

Expert has been at the forefront and a leader in developing Localized Process Control (LPC). Expert uses proprietary materials and methods to create a localized clean airfoil or barrier system around product and processes in contamination critical zones, thereby reducing contamination risks at a fraction of the cost of conventional clean rooms or clean room upgrades. LPC have been used in Class Systems that Expert has developed have been employed in Class 7 (10,000) or Class 8 (100,000) cleanrooms and even non-traditional clean areas or uncontrolled areas, to create localized clean process zones to Class 5 (100) or cleaner, depending on the application.

He has been involved in: 1. the design phase of cleanrooms where his expertise in Bi-Level and Localized Process Control (LPC) air flow management has beeen valued to achieve the most cost-effective and cleanliness-effective clean room operations and methods of achieving product/process cleanliness; 2. clean room build stage where he lends his expertise to deliniate corrective actions required before the area can "Go Clean" and commence full scale manufacturing; 3. fully operational established clean rooms to address real thru-put product yields impacted by contamination related defects.

As many personnel at all levels must use the clean room, Expert has successfully developed and implemented the Clean Room Administration system, or CRA which is established in conjunction with Contamination Control Programs (CCP), to meet the cleanliness requirements of the specific product for which the CCP is designed. The CRA is a support system to the overall Contamination Control Program and is a comprehensive program required for the control of contamination for precision products and is supported by the Clean Room Manager, Contamination Control Group and the Reliability Safety and Monitoring Group. Each group has their own multipoint program essential to the proper functioning of the program. Expert develops each multipoint program to meet specific CCP product requirements.

Personnel and the associated disciplines are part of the clean room operations. Cleanliness is dependent upon specially garmented, trained and motivated personnel who understand the importance and concepts of contamination control. Garments and personnel training and the programs that Expert presents are discussed in another paragraph. As personnel carry out the operations in the clean room, special garmenting scenarios are required, depending on the clean room, product, and process applications. Expert has expertise in the design, construction, and laundry of clean room garments and in the assessment of precision laundry facilities and operations to determine their effectiveness in maintaining the cleanliness and effectiveness of the garments.

Expert has much experience in working with ISO, Federal, ASTM, IEST, and SEMI standards as they apply to specific clean room classifications, processes, materials, disciplines, and so forth.

The expert has broad in-depth experience, and provides solutions to product contamination problems. His actions have improved clean processes, cleanroom facilities, and precision cleaning systems. The implementation of his recommendations have resulted in improved product yield, reduced cost, and increased return on investment.

The expert was also Project Manager for a $4.7 million state-of-the-art Large Optical Component assembly for Advanced Technology Products. He managed the project budget, maintained product performance, quality, schedule, and cost and all additional aspects to achieve project contract compliance.

• The direct result of the implementation of the experts corrective actions and recommendations following an extensive Contamination Control Assessment at a major aerospace component manufacturer, was an increase in the products real throughput yield from 82% to 98%, a savings of $1.65 million/100 units produced. The assessment included airborne particle monitoring and airborne particle fallout witness plate testing, evaluation of the facility, product, manufacturing, assembly and precision cleaning processes, equipment, operations, pure water system, and personnel protocols, disciplines, and training. A Contamination Control Program was established and corrective actions taken to: 1) Totally reorganize the cleanroom equipment and processes in accordance with recommended cleanroom practices; 2) Implement bi-level and Localized Process Controls at contamination critical locations; 3). Upgrade pure water system materials and layout; 4) Improve ultrasonic cleaning process; 5) Improve product testing procedure and materials and fluids used; 6) Train all personnel from technicians to management in contamination control technology; and, 7) Establish metrics for reporting product improvements.
• The expert performed a comprehensive Contamination Control Assessment at a major electronics manufacturer. A key component had a high real throughput yield loss in production. All of the failures were traceable to the following contaminants: rust caused by inadequate drying following the aqueous cleaning process, particulate contaminants not removed in the cleaning process, or weld spatter coming loose during product operation.The expert ran extensive tests on CO2 cleaning as a possible replacement for the aqueous cleaning process. His tests concluded that not only were contaminants, including weld spatter removed, but rust was eliminated. Based on the test results he developed a fully automated robotic cleaning system resulting in the following benefits: 1) Elimination of the costly, labor-intensive aqueous cleaning and drying processes; 2) Elimination of rust; 3) Increase in the effectiveness of removal of particle contamination, weld spatter, and burrs by 30% to 70%; 4) Remove oils and greases; 5) Cleaning cost reduction; 6) Improvement in real throughput yield; 7) Reduction in component handling damage; 8) Reduction in lead-time; 9) Decrease in failures in the field; 10) Increase in overall product life; 11) Increased coating adhesion; 12) Reduction of in-house and customer line rejects
• The expert found in the manufacturing of a particular camera for a major manufacturer, that not only were the optical properties of the camera being degraded over time, but the mechanical functioning of the camera was also being affected. In an investigation into this problem, he found that lubricant used on the cameras internal mechanism was outgassing into the internal camera environment and over time created a thin film haze on the optical elements resulting in the reduction in image quality. The thin haze film also provided a retention mechanism for the accumulation of particles. Over time the particles increased to a level that impeded the mechanical functioning of the camera. The expert recommended another lubricant that would provide the necessary lubrication qualities without outgassing. This corrective action eliminated both the poor image quality and the mechanical failure of the camera.
• High-pressure aqueous cleaning used on an automotive engine component had a low efficiency of cleaning, leaving behind particles that would adversely affect engine performance. The expert investigated CO2 cleaning as a replacement for the high-pressure washer and developed and performed tests to determine its effectiveness. The results showed that the CO2 cleaning process was highly effective in removing contaminants left in the part following the high-pressure aqueous cleaning process. Contaminants removed by the CO2 cleaning process were collected by a vacuum fixture and examined by optical microscopy utilizing a Leitz Orthoplan with polarizing and Nomarski differential interference contrast capabilities. Three types of contaminants were found, 1) Native or those which were from the materials comprising the component itself; 2) Environmental and process types form the manufacturing process and environment; and, 3) Foreign being those which are contributed by personnel, clothing, general handing, equipment and machinery. The percentage of contaminants by type was found to be 90% of the native variety with the remaining 10% being of the other two.
• Optical quality glass tubes used for light transmission had surface artifacts causing light scattering to unacceptable limits. The expert conducted an extensive Contamination Control Assessment and found a number of factors contributing to the defect condition. These included: 1) Wrong frequency used in the design of the ultrasonic cleaning system creating a much too aggressive cavitation resulting in etching of the glass tubing; 2) Recontamination of the cleaned tubes in the drying system from unfiltered air being pulled in from a contaminated facility area; 3) Harsh chemicals used in the aqueous cleaning process resulting in etching of the glass surface; 4) Inadequate rinsing after the cleaning process leaving cleaning solution residue on the glass surface. The expert's assessment of the deficiencies and setting forth of detailed corrective actions, along with a Contamination Control and Administration Plan significantly improved the cleaning effectiveness, reduced defects and increased product yields.

• Expert in Removal and generation prevention of particles on a disk drive suspension.
• Clean room expert for review of manufacturer's clean room processes.
• Expert in clean room processing for consulting on precision cleaning system.
• Water quality expert deionized for consulting on DI Water System Survey.

• Expert in FDA litigation for consulting on microbiological contamination of pharmaceuticals.