Semiconductor Case Study
Semiconductor Mount Assembly
Overview
The customer is a global leader in the semiconductor industry, specializing in supplying chipmakers with equipment, software, and related services essential for mass-producing lithography systems used in etching patterns on silicon.
Problem
Straton was contracted to construct a complex mechanical assembly under extremely tight deadlines. The project required finalizing an incomplete design provided by the customer and implementing a pragmatic approach to ensure completion within 8 weeks.
The design required multiple materials, including stainless steel, titanium, Peek, and aluminum. Tolerances were stringent, with flatness requirements of less than .002 inch and critical hole locations specified within .0005-inch accuracy.
Solution
Straton’s Engineering Group played a crucial role in supporting the customer by finalizing the design and assessing feasibility to meet performance goals within the specified delivery timeframe.
Effective Project Management
Aligning efforts across various departments was crucial in synchronizing activities within the company, encompassing engineering, machining, quality control, and final shipping. This collaborative strategy guaranteed smooth execution of the project from inception to completion, fulfilling technical specifications and meeting delivery deadlines.
Efficient Production Optimization and Quality Assurance Strategies
Raw materials and purchased hardware were reviewed and adjusted to more common sizes, which streamlined the procurement process and facilitated expedited delivery schedules. Machining operations were optimized using "lights out" machining tools and techniques, effectively reducing machining time and enhancing efficiency.
Enhanced Quality Control Efficiency
On the shop floor, Coordinate Measuring Machines (CMMs) played a crucial role by providing real-time data to the Quality Department. This enabled faster in-process checks and improved throughput of components, ensuring quality standards were met without delays.
Streamlined In-house Operations: Cleaning, Assembly, and Shipping Container Management
In-house operations managed component cleaning and assembly, maintaining control over the production process. Additionally, a custom shipping container was delivered ahead of schedule, allowing for immediate packing of components post-assembly. This proactive approach contributed to meeting project timelines and customer expectations efficiently.
Outcome
The customer expressed immense satisfaction with both the final product and its early delivery.
