Link Magazine: BOZ Group Improves Lead Time with a Cleanroom and ProCleanroom Expertise

Source: LINK magazine 

BOZ Group in Bergen op Zoom sought a partner to meet the growing demand from high-tech customers for cleaner products, and to do so with shorter lead times. ProCleanroom provided the company with a customized solution.

‘We truly hold companies by the hand’

BOZ Group operates in various markets where the demand for high-quality finishes is continuously increasing, both in terms of capacity and quality. Director Corné van Opdorp sought a solution that allowed for low-particle working conditions to future-proof his production. A year later, a full-fledged, serious cleanroom with a floor area of no less than 150 m² is in place.

Low-Particles
‘A lot is happening in the field of low-particles environments in the high-tech sector,’ says van Opdorp. ‘There is a growing demand, from various markets, but especially in the semiconductor industry there is a demand for more capacity. And if you commit to that, you must also ensure that your process is well-organized.’ Van Opdorp started researching the possibilities of bringing the entire process in-house. ‘We already do quite a bit for these markets, but the cleaning and packaging part was still outsourced to third parties. That is manageable in itself, but the lead times are long and the employment agencies that do this are not located in our region. That results in extra logistics.’

Trust
He invited various parties to discuss the possibilities, and the choice was quickly made for ProCleanroom from Eersel. The involvement and the feeling created trust immediately. ‘We want to build up the knowledge ourselves and rely on the expertise of the supplier. ProCleanroom took us on the journey and we had the feeling that they would really take the load off our shoulders. Because if you have less experience yourself, it is nice if someone can present you with the whole picture.’

‘We are taking a big step towards closer collaborations with customers who demand more complexity’

Director Niels Ferguson of ProCleanroom: ‘We truly hold companies by the hand. We look at workflow, purity requirements and desired capacity. Based on this, the most efficient layout are determined. Moreover, we look ahead to the future. Can the capacity or even the entire cleanroom be expanded? We are unique due to the complete unburdening, from designing and building the space, to the furnishings, accessories and consumables.’

Customization

Every cleanroom is custom-made. ‘We start with an extensive inventory, which is necessary for the best end result. Every cleanroom is designed according to the lean principle, with the aim of delivering a cleanroom that performs as efficiently as possible. The delivered solution is a very high-quality PanelBloc cleanroom, which consists of completely flat walls, floors and ceilings with the highest fire class, leak tightness and insulation values on the market. All equipped with a special coating that ensures maximum cleanliness.’ Ferguson explains that this finish ensures that particles adhere less well to the surface. When cleaning, a particle is absorbed by a cloth or made airborne, where it is removed by the overpressure in the room.

Layout
BOZ and ProCleanroom together looked at the desired workflow, which includes the size of the products. By visualizing this well, you can design the cleanroom in such a way that the work can be carried out as efficiently as possible. Fit for purpose, Ferguson calls it. ‘During this research, we make a layout, based on the desired purity specifications – in this case ISO class 6 in the main room. This makes that room suitable for cleaning, packaging and assembling products with a purity level according to grade 2 and 4 specifications.’ Before construction could begin, the floor had to be leveled and a supporting structure was realized in the hall. Van Opdorp takes us to the work floor. He talks about the inspection room of the cleanroom. ‘That inspection room can be completely darkened and then you can use UV light to check components for contamination. The equipment and equipment for this room were also supplied by ProCleanroom.’

Monitoring
The room is equipped with a cleanroom monitoring system that regulates and continuously monitors the conditions as required. If it is not worked with during the weekend, the cleanroom can regulate itself for that. ‘Sustainability is important and we therefore look very closely at the dimensioning of the cleanroom and the need at the moment. With this monitoring system, you can look in remotely and you can adjust components such as the fan-filter motors as energy-efficient as possible. And you can also see if any service needs to be performed.’ The system is set up for remote functionality, has data logging and is suitable for a closed-loop control with particle counters for continuous monitoring and control of the cleanliness of the cleanroom. ‘Because the whole thing is plc-based, you can go in all directions with IO. The cleanroom is flexible and suitable for a possible implementation of grade 2 vacuum and grade 1 processes in the future’, says Ferguson.

Between the ears
‘Although we work with a fixed and well-trained team for the cleanroom, we have maximized internal awareness and all employees have followed a course. Because you need the commitment and so it is important that everyone gets an insight into what it is all about. Not only the product, but also the process, the effect of lubricants and coolants, make-up and food. And also the separation of products’, says van Opdorp. That turned out to be a real eye-opener. The move towards cleaner working is now also being used in many more places outside the cleanroom. He is happy with ProCleanroom’s approach. ‘Everything is delivered very completely. We had limited experience ourselves, so this guidance was very pleasant. The furnishing was also supplied by them, from the UV lamps to the furniture. We also take the clothing, gloves and cleaning products, as well as service and maintenance. So BOZ now has one partner for everything about the cleanroom. This also includes the annual validations to determine whether the cleanroom still meets its ISO classification.’

Distinctive
By now taking care of this cleaning and packaging in-house, the failure costs have decreased. What used to be rejected, such as a small scratch, can now be quickly remedied. ‘If you do it, you have to do it well,’ says van Opdorp. ‘It is a fantastic addition to our company. With this, we can expand our customer profile, reduce the risk profile and we make a higher quality in-house. We are taking a big step towards closer collaborations with customers who demand more complexity. And with that, we differentiate ourselves once again.’

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