INTRODUCTION FOR CLEANROOM TECHNOLOGY FOR THE MANUFACTURING INDUSTRY
A cleanroom is an environment, typically used in manufacturing or scientific research, that has a low level of environmental pollutants such as dust, airborne microbes, aerosol particles and chemical vapors. More accurately, a cleanroom has a controlled level of contamination that is specified by the number of particles per cubic meter at a specified particle size. To give perspective, the ambient air outside in a typical urban environment contains 35,000,000 particles per cubic meter in the size range 0.5 μm and larger in diameter, corresponding to an ISO 9 cleanroom, while an ISO 1 cleanroom allows no particles in that size range and only 12 particles per cubic meter of 0.3 μm and smaller.
Cleanrooms can be very large. Entire manufacturing facilities can be contained within a cleanroom with factory floors covering thousands of square meters. They are used extensively in semiconductor manufacturing, biotechnology, the life sciences and other fields that are very sensitive to environmental contamination.
COURSE OVERVIEW
This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from services, business processes and industrial applications. The integration of maintenance is also addressed. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments.
COURSE OBJECTIVES
This training program is designed to provide an understanding of engineering-related problems related to the industry globally and a clear sense of what is required to effectively structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem-solving initiative within their organization.
LEARNING OUTCOMES
On successful completion of this course, the participant should be able to:-
- Understand the benefits and implications of a cleanroom and relate the concepts to the overall business mission and objectives.
- Think about his/her organization as a collection of processes, with inputs that determine the output.
- Use the concepts of cleanroom engineering problem-solving to evaluate the capability of a process or organization.
- Recognize the engineering problem-solving model used to improve processes.
- Recognize the organizational factors that are necessary groundwork for a successful engineering problem-solving program.
- Integrate cleanroom engineering problem-solving program efforts with other process improvement initiatives.
METHODOLOGY
- The latest educational methods and strategies will be utilized.
- The course is designed to maximize delegate participation.
- Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
- The course shall be conducted through lectures, case studies, group discussions and exercises to reinforce participants’ learning.
LEARNING BENEFITS
At the end of the programme, participants will be able to:-
- develop a working knowledge of the various classes of cleanroom;
- differentiate between the different classes of cleanroom;
- understand better the design, construction, operations, and maintenance requirements of cleanrooms;
- implement strategies and methodologies to create an effective cleanroom maintenance programme ;
- enhance their knowledge and skills to identify and address operational problems at all levels;
- implement maintenance plans that are cost-effective and aligned with the organisation’s strategic goals;
- improve performance by developing detailed specifications with service partners;
- establish an effective maintenance team.
LEARNING OBJECTIVES
The objective of this programme/course is to introduce participants to the various aspects of cleanroom technology, to improve and develop further the participants’ appreciation of the design and maintenance aspects, and also on how to overcome problems, etc. associated with cleanrooms.
WHO SHOULD ATTEND
Facilities engineers, maintenance engineers, design engineers, production and manufacturing engineers, process engineers, process designers, plant engineers, technicians and anyone involved in cleanroom systems and would like to widen their knowledge.
COURSE FORMAT
The course consists of a formal content presentation interspersed with content quiz sessions. The presenter’s style involves intensive participant participation.
COURSE CONTENT
Day 1
SESSION 1 – OVERVIEW OF CLEANROOM TECHNOLOGY
The need for a cleanroom, history of cleanrooms, cleanroom in the semiconductor and pharmaceutical industries, overview of the wafer fabrication process, the cleanroom as a system and unit operations.
SESSION 2 – CLEANROOM CONTROLLED ENVIRONMENT CONCEPTS
Cleanroom basics, particulate standards, gas and vapour standards, contamination.
SESSION 3 – MICRO CONTAMINATION (PARTICULATE).
The nature of particulate contamination, particulate contamination flow, particulate contamination sources, particulate transport and retention, and contamination monitoring/identification for particulate contamination.
SESSION 4 – CREATING A CLEANROOM
Construction materials, construction practices, air flow basics, typical cleanroom layout/configurations, designing for cleanroom class level
SESSION 5 – FACILITIES AND SERVICES
Electrical systems, power conditioning, compressed air, wet side and dry side air.
SESSION 6 – VIBRATION
External vibration (natural and man-made), internal vibration
Day 2
Plant Visit and a Practical Session. To Observe and Study:-
- The air conditioning system in a typical building;
- The water supply system in a typical building;
- The other facilities are in a typical building.
SESSION 7 – CLEANROOM CODES AND LEGISLATION
Fire protection and smoke removal.
SESSION 8 – ULTRA-PURE WATER
The uses of ultra-pure water, raw water constituents, and water quality standards.
SESSION 9 – MATERIAL USAGE IN A CLEANROOM ENVIRONMENT
Bulk chemical storage and distribution systems, hazardous production materials, safe storage, handling and use of wet chemicals and gases, personal protective equipment, furniture, cleaning equipment and cleaning chemicals, etc.
SESSION 10 – WASTE TREATMENT
Acid waste neutralization plant, hydrofluoric and phosphoric acid waste treatment.
SESSION 11 – PEOPLE AND CONTAMINATION
Apparel, the use of apparel, work practices and general behavior (sneezing, open wounds, eating, drinking, smoking, etc.), excessive movement/motion, etc.
SESSION 12 – QUESTION & ANSWER SESSION
