80-90% Yield Increase
with Inline Plasma Cleaning Solutions
A global automotive and automotive electronics manufacturer* overcame low yields and micro-gap plasma issues by migrating from manual batch systems to a fully automated quad-lane plasma cleaning solution.
*Anonymous for privacy purposes
The Challenge
The customer is a global manufacturer of automotive and automotive electronics components. They were operating manual batch plasma systems but needed to scale up to meet increasing volume demands. A critical technical issue - their current plasma process was failing to reach into micro gaps in the substrate structure - this was causing defects, and their existing machines were not capable of handling this problem.
- Using manual batch systems that could not keep up with the growing production volume requirements of the automotive industry.
- The current batch plasma was not able to penetrate efficiently into the micro gaps in the substrate structure, leading to defects in the final product. The existing machines were not designed to handle this issue.
- Low yields caused by the inefficiency of the manufacturing process, impacting production output and cost-effectiveness.
- The customer needed to migrate from manual processes to in-line automatic systems to meet their production targets.
Before & After Plasma
Before
- Using manual batch systems and wanted to migrate to in-line automatic systems to meet volume demands.
- Plasma was failing to penetrate into micro gaps in substrate structure and their machines were not capable of handling this.
- Low yields due to the inefficiency of the manufacturing process.
After
- Custom-designed plasma cleaning process, from batch to an automated quad-lane system.
- Process moved from manual to fully automated.
- All the complex structure of the substrate was treated by the plasma insuring high surface energy.
- Significant increase (80-90%) in output and yield.
The Process
Evaluation & Testing
A thorough evaluation and testing phase was conducted to prove the plasma recipe and treatment would be effective for the customer's specific substrates. Lab-based testing was performed by measuring water contact angle values to validate the surface treatment results.
Hardware Customisation
Once the recipe was proven, SCI improved upon our standard inline solution to provide the necessary throughput and meet the specific technical requirements of the customer's process - including solving the inefficient plasma distribution issue that had plagued the previous equipment.
Single-Lane System Installation (2019)
A single-lane, single-chamber in-line automatic system was installed, replacing the manual batch process. This marked the customer's transition to a fully automated plasma cleaning workflow.
Dual-Lane Expansion & Degassing
As the customer sought to further increase output, SCI supplied a dual-lane plasma cleaning system to boost efficiency, along with a degassing machine that automated the previously manual degassing process.
Quad-Lane Automated System
The final upgrade: a quad-lane, dual-chamber automated plasma system was installed. This system unlocked a further level of efficiency and yield, delivering the 80-90% improvement in output that transformed the customer's production capability.
Technology Used
In-Line Automatic Plasma Cleaning Systems
The solution evolved through multiple SCI in-line systems - from a single-lane to a quad-lane configuration. In-line systems are designed for high-volume production environments, offering SMEMA-compliant automation and seamless integration into existing manufacturing lines.
Explore our in-line plasma systems →Each upgrade from SCI brought a step change in our production capability. Moving from manual batch to a fully automated quad-lane system was transformational for our output and yield.- Customer's Manufacturing Engineering Team
Facing a Similar Challenge?
Whether you're in automotive, medical devices, or electronics - our plasma solutions can help you achieve the yield and quality targets your process demands.
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