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Analysis Methods

Process Qualification

Process Validation

Process Monitoring

Failure Analysis

Cleanliness Analysis

Process Assessment

General Cleanliness Package

Support Products

On Site Investigation

Cleaning

Material and Process Consultation and Training

MRTC Program

Cross Sectioning

Services: Process Monitoring
What is Process Monitoring?
Process monitoring is an effective tool used to maintain control of a manufacturing operation, as well as demonstrating ongoing compliance to specifications. Once the qualification and/or validation exercises are completed, a baseline cleanliness reference can be established. By executing scheduled monitoring of the process during normal operation, the control limits can be checked to insure the process remains within the defined boundaries. Process monitoring programs are focused on production product with stable build schedules. Often, when Foresite re-establishes a client's process that has experienced field service failures, monitoring is required by the end customer to insure the fault condition does not re-occur. The Process Monitoring Program is exercised on a specific product, process sequence, and material list defined at the beginning of the monitor period. The goal of the program is to quickly identify deviation from the baseline performance. Thus, no testing of other products, processes, or materials can be inserted into the monitor program.

Ion Chromatography (IC) analysis is applied in process monitoring by comparing IC results to data recorded with the customers existing ROSE testing system, establishing a baseline performance threshold, and providing an ongoing validation of performance via periodic sample checks of product. IC is a very effective tool when used to check the consistency of incoming PCB cleanliness.

Foresite engages in consultation with each customer prior to any activity to identify project goals, design an applicable test matrix, and provide technical information derived from our experience and knowledge of contamination effects on product reliability.

Initial Report — contains deliverables identified in Qualification and/or Validation service

Monitor Report — monitoring interval and report generation established at time of quote

Foresite Monitor Report Deliverables
Qualification and/or validation of process must be established prior to monitor program.

  • Account of samples sent, production lot record, date of analysis
  • Performance chart showing baseline reference versus current results
  • Trend charts showing monitoring history at specified intervals
  • Identification of residues present - ionic data indicating type and amount
  • Foresite cleanliness limit recommendation for each ionic species identified
  • Foresite interpretation of data and conclusions from our technical team
  • Foresite recommendations for any process optimizations
  • Formal monitor report electronically sent to customer project contact
  • Original hard copy report mailed upon completion of each monitor exercise
  • Telephone support included for discussion of each monitor report
Monitor Program requires an open Purchase Order to Foresite for billing at monitor intervals.

The Foresite Approach to Process Monitoring
To provide the customer with the deliverables mentioned, monitor samples are produced as part of normal production operations. These samples will be sent to Foresite for evaluation and reporting. Proper handling of the samples is critical to insure test samples are exposed only to those contaminants resident in the process.

The following protocol is required for process monitoring programs:
Upon initiation of the program, Foresite will receive and hold bare laminate to be used in the monitor program for the specified assembly. Foresite will secure the integrity of the PCB's by sealing them in Kapak bags until required by the monitor interval.

Foresite will ship two bare PCB's to the customer (build site) at the trigger interval. These PCB's will be identified as "Process Monitor Samples" (marking method to be determined with customer). Foresite will notify customer when samples have been sent.

Customer executes a scheduled build including the two monitor samples. Customer pulls a finished random unit from build and sends the three assemblies to Foresite. No special procedures or handling precautions are to be taken with these monitor samples to accurately represent the daily activities of the production facility. Shipping and packing instructions will be given to customer.

The following information must be provided to Foresite with each monitor batch:
  • notification to Foresite that monitor samples have been sent (phone, fax, e-mail)
  • identification on outside of package (MONITOR SAMPLES)
  • packing list identifying contents (assembly number) and P.O. reference
  • lot code information customer coding previously defined
  • date these samples were manufactured (plant identification may be required)
  • information regarding any change in sequences from established baseline
Foresite will conduct the defined testing upon receipt of samples
  • Testing time completion established at beginning of program
  • Foresite personnel will observe all ESD handling requirements
  • All product will be returned to customer-designated contact
Foresite will issue a Monitor Report for each lot tested
  • Contents of Monitor Report identified at beginning of program
Customer-specific information must be provided to Foresite at start of program:
  • Contact name responsible for all aspects of monitor program (builds/reports)
  • Phone numbers (office, cell, pager, fax)
  • Customer shipping number (FedEx, UPS)
For the Monitor Program sequence, click here.
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