A Tier-1 client audit identified particulate contamination on PCBs after the milling process, exceeding allowable cleanliness thresholds. Formal engineering and process resolution was required to maintain compliance and preserve client relationship.
Executing hardware intervention inside a high-utilization production environment: designing and integrating a custom-engineered tray and vacuum modification without degrading cycle times, compromising milling tolerances, or creating ergonomic issues for operators.
I led the end-to-end execution across three areas: engineering validation to confirm the modification eliminated dust while maintaining mechanical tolerances; project governance to synchronize installation with production schedules; and change management to train operators and update work instructions for the new hardware.
The audit non-conformance was closed with zero recurring issues. The solution was benchmarked as Best Practice and rolled out across all milling-dependent products in the facility — resulting in measurable improvement in assembly cleanliness and client satisfaction.