When it comes to high-precision optics, SwissOptic is one of the first names that comes to mind. Read on to find out how the company has boosted its production capacity with 16 new assembly cells in cleanroom class ISO 5, while at the same time meeting the stringent requirements of the semiconductor industry.
SwissOptic manufactures optical components and complex assemblies in cleanrooms for various industries. Based in Heerbrugg, Switzerland, the company has been putting its trust in our solutions for over 20 years. The full-service supplier of OEM solutions for the field of metrology, the semiconductor industry and medical technology is already using numerous item applications – from work bench systems and linear technology to machinery enclosures. When the optics specialist wanted to expand its cleanrooms, it quickly became clear that we were the best partners for this project, too. “We were already very familiar with the flexible modular system based on item aluminium profiles, so we asked whether they could help us put in place new workstations,” explains Mark Rüdisser, Head of Facility Management at SwissOptic. “For the production of components for the semiconductor industry, we needed workstations that can be flexibly adapted and meet the stringent requirements of cleanroom class ISO 5.” The previous work benches were outdated and could not be adapted to different work processes.
System solutions for cleanrooms
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Flexibility and precision in the cleanroom
SwissOptic presented us with clearly defined requirements – create more work and production areas to boost production capacity without impacting ongoing operations. In addition, the costs and renovation outlay should be kept to a minimum. Our solution was to create 16 functional assembly cells in cleanroom class ISO 5 that consist of partial enclosures based on our aluminium profiles and integrated work bench systems. These mini-environments provide the perfect working environment for manufacturing, testing and cleaning complex optomechanical assemblies for the semiconductor industry. This work involves the use of both optical and high-precision mechanical components, which have to be positioned and adjusted with millimetre precision using special jigs and fixtures.
The mini-environments provide the perfect working environment for manufacturing, testing and cleaning complex optomechanical assemblies for the semiconductor industry.
The workstations within the cells are designed in such a way that temperature variations, vibrations and shocks are prevented. What’s more, no particles larger than 0.025 mm can contaminate the workstation – a decisive factor for the quality and durability of the manufactured products. To ensure they are free of particles, SwissOptic examines each assembly optically using specialist microscopes.
Ingenious design for the highest requirements
Each of the 16 assembly cells follows a standardised design. Every cell features a height-adjustable work bench, a mobile rack with four shelves and a movable side trolley made from item components. The partial enclosures are around 2.70 m wide, 2.40 m high and 2.40 m deep. The basic frame consists of Profiles X 8 and Profiles XMS. The panels in the cells are made of easy-to-clean glass. Integrated cable routing ensures safe cable management, as the cables are hidden inside the profile frame, away from dust. “The item Fixing System secures the panels and is particularly suitable for use in cleanrooms because it connects the basic profile, cover and seal perfectly with each other, creating surfaces that are easy to clean,” says Michael Hasler, head of sales at item Switzerland. Four filter fan units (FFUs) are also integrated into the ceiling of each cell. These ensure that the air inside the cells streams from the ceiling to the floor in a laminar flow, which stops particles settling on workpieces or work surfaces. As a result, each cell forms a self-contained unit – a cleanroom within a cleanroom, so to speak. If necessary, they can be moved to other places in the production area for added flexibility.
The item Fixing System is particularly suited for cleanrooms because it connects the basic profile, cover and seal perfectly with each other.
It is particularly important to note that only certain materials are suitable for cleanrooms. Outgassing, volatile organic compounds and lubricants that do not meet the high cleanliness requirements can affect product quality. We therefore had to ensure that we only used cleanroom-compatible materials. For example, certain materials such as silicones and specific plastics could not be used from the outset. Since the solutions incorporate height-adjustable work benches, the lubricants used in these also had to meet the relevant requirements. All open profile grooves had to be sealed with appropriate cover profiles to prevent dust from collecting and other contaminants from forming.
Installation during ongoing operations
Before final installation, SwissOptic used a digital model to test the functionality of the item enclosures in combination with the FFUs. The subsequent installation of the partial enclosures proved to be a logistical challenge, as the work had to be carried out during ongoing operations.
We started with a test project in a separate cleanroom. After a successful test, the enclosures were preassembled in our production facility and then transported to the final location. “This worked really smoothly, because we collaborated closely with the team at item,” says Rüdisser. “It was the only way we could ensure that ongoing operations weren’t disrupted.” All in all, the process from delivery to commissioning in autumn 2022 lasted just a few months.
Thanks to excellent collaboration, the entire process went very smoothly without interrupting ongoing operations.
Improved working conditions and production processes
Thanks to the new mini-environments, SwissOptic has not only increased its production capacities, but also improved working conditions in key ways. The assembly cells offer employees ergonomic and flexible working environments where it is possible to carry out different processes within the same cell. Previously, certain work processes could only be carried out at specific work benches, but now SwissOptic is benefiting from an enormous boost in flexibility.
The production processes themselves were also optimised. By implementing a lean concept, it was possible to improve the positioning of tools and the digitalisation of the work benches. “The standardised basic equipment in all 16 cells makes the work of our employees significantly easier,” says Rüdisser. “item provided us with perfect support through every phase.”
With the concept of a cleanroom within a cleanroom, the optics specialist has increased its production capacities, while also meeting the stringent requirements for manufacturing sensitive assemblies in a high cleanroom class, thus safeguarding the quality of its products at all times. We are proud to have worked together with SwissOptic to develop a customised solution that is flexible, efficient and future-proof.
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