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Effective, consistent cleaning processes for mission-critical hardware are a must.  Everyone involved in either initial assembly or field/depot repair and maintenance worries about cleaning process performance; and any change in the process makes everyone uneasy. Changes cannot be avoided.  Cleaning agents and process fluids, even cleaning equipment, are often modified to meet safety/environmental regulations; some chemicals simply become unavailable.  BFK Solutions has extensive experience in aerospace and military applications; and we are acutely aware of the need for rugged, reliable processes for military hardware. Both Barbara and Ed Kanegsberg have a background in aerospace.  We work with major aerospace organizations, with suppliers to aerospace, and with the military. 

Examples of activities include

Critical cleaning process design and review
Process feasibility
Specification conformance
Process selection criteria
Process equipment comparison, downselect, buy-off
Supply chain audits
Specification conformance
New mil-specs
Compliant cleaning processes for legacy systems
Education/training programs
Brainstorming, resolving conflicts among grumpy engineers
Safety/environmental regulatory harmonization

Optimized Performance, Cleaning Prior to Heat Treatment

An aerospace group had to improve the physical and performance characteristics of a magnetic shield as part of competitive demonstration project.  Technical management became aware that enhanced critical cleaning, not just heat treatment, was a key to superior competitive performance.  BFK Solutions assessed sources of contamination, employee work practices, existing cleaning processes, and the heat treatment facility.  Given the number of contamination sources, we developed exhaustive cleaning processes that the client instituted.  The performance of the magnetic shield surpassed minimum requirements and was superior to the level achieved by the competition.

Cleaning Process, Supply Chain, Process Flow Improvement

The client was setting up new cleanroom facilities for military hardware assembly. BFK Solutions provided support in optimizing the new cleanroom, improving the cleaning processes, and reducing particulate and thin film contamination.  Our activities included site visits, education programs, cleanroom audits, and reviews of suppliers.  We assessed cleaning practices by in-house personnel.  We developed approaches to process flow that maximized the use of expensive cleanroom real estate.  We improved the cleaning validation/monitoring process to provide more sensitivity and a more favorable employee exposure profile.   Because we facilitated communication between Operations and Engineering, some of the valid approaches to cleaning developed by assemblers were adopted and documented (i.e. made legal).  In addition, we worked with the supply chain to achieve more effective cleaning processes at early stages of assembly. 

Cleanroom Contamination

Unexplained, intermittent high particle levels in several cleanrooms used for a critical military program were unacceptable. This posed performance/reliability risks. The number of manufacturing variables made determining the cause of the problem difficult.   We conducted a site audit and worked with the team to determine causes and to quickly resolve the problem.  

Technical Programs

Those in aerospace and the military are in a “perfect storm.”   They face the aggravation of achieving a superior product while being buffeted by higher performance requirements, more stringent regulations, and cost-competitive issues. They have to cover all the bases.  For a smoother approach to navigating these waters, BFK Solutions has conducted in-house educational programs for many aerospace companies. These programs are designed with specific educational goals. Some workshops have been geared to the needs of chemical engineers and analysts in Materials and Processes.  Others have been directed toward the questions and requirements of more diverse groups in Engineering and Operations.  Examples of frequently requested topics include process design, acceptance testing (including surface and extractive analysis), monitoring, and cleanroom contamination.  Because inspections and brainstorming are typically integrated into the programs, we are often able to resolve process issues very rapidly.   

JS3

The Joint Service Solvent Substitution Working Group (JS3) includes representatives from all branches of the military, NASA and the Defense Logistics Agency (DLA). The group has a goal of goal of eliminating the use of hazardous air pollutants (HAPS) and minimizing use of Volatile Organic Compounds (VOCs) while maintaining the quality of mission-critical hardware.  The group encourages a coordinated, collaborative, and practical approach. BFK Solutions is proud to participate in JS3 activities.