In the world of manufacturing, especially in sectors like automotive, aerospace, and electronics, the concept of technical cleanliness is critical. Therefore it should be already taken into consideration while project management. Yet, it’s often overlooked until issues arise. This oversight can lead to costly failures, defects, and inefficiencies. VDA 19, a key standard in this domain, provides a comprehensive framework for managing technical cleanliness in the production environment.
Technical Cleanliness – what is it?
Technical cleanliness refers to the absence of contaminants—such as particles, fibers, and residues—on and within products and components. These contaminants, even when microscopic, can compromise the functionality, safety, and longevity of a product. For example, a small particle in a hydraulic system can lead to valve blockage, causing system failure.
Cleanliness control – serves to record as fully as possible the contamination of particles resulting from the production process, occurring on the important surfaces of the checked part.
Source: VDA 19.1 Inspection of Technical Cleanliness, second revised edition, March 2015
VDA 19 – The Benchmark for Technical Cleanliness
VDA 19, developed by the German Association of the Automotive Industry (Verband der Automobilindustrie), is the go-to standard for assessing and managing technical cleanliness. It is divided into two parts:
- VDA 19 Part 1: Inspection of Technical Cleanliness
This part focuses on the methods and processes for analyzing technical cleanliness. It covers everything from sample collection to analysis methods, providing a detailed guide on how to detect and measure contamination. The primary objective is to ensure that the cleanliness level meets the specified requirements for the component or system. - VDA 19 Part 2: Technical Cleanliness in Assembly
This part deals with maintaining technical cleanliness during the assembly process. It emphasizes the importance of a clean production environment, proper handling, and the use of cleanliness-compatible tools and equipment. This proactive approach helps in preventing contamination rather than just detecting it after the fact.
Technical Cleanliness – Key Principles of VDA 19
1. Sampling and Analysis
VDA 19 outlines strict procedures for sampling and analyzing contaminants. The standard emphasizes the need for representative sampling, which means that samples should accurately reflect the contamination level of the entire batch or production run. This can involve different techniques, such as spraying, rinsing, ultrasonic cleaning or shaking, depending on the component and contamination type.
2. Contamination Limits
One of the critical aspects of VDA 19 is the definition of contamination limits. These limits are typically specified by the OEMs (Original Equipment Manufacturers) and are based on the function and criticality of the component. VDA 19 helps in determining whether the contamination level is within acceptable limits, ensuring that the part will perform reliably in its intended environment.
3. Cleanliness-Compliant Assembly
Maintaining cleanliness during assembly is crucial. VDA 19 Part 2 offers guidelines on how to design and maintain assembly environments to minimize contamination risks. This includes controlling the flow of materials and personnel, using cleanroom techniques, and ensuring that tools and fixtures are free from contaminants.
4. Continuous Improvement
Technical cleanliness is not a one-time effort but a continuous process. VDA 19 encourages regular monitoring and analysis to identify trends in contamination levels. By doing so, manufacturers can implement corrective actions and improve their processes over time, leading to better product quality and reliability.
Implementing VDA 19 in Your Facility
To effectively implement VDA 19, consider the following steps:
- Training and Awareness: Ensure that your team understands the importance of technical cleanliness and the requirements of VDA 19. This includes training on proper handling, cleaning, and inspection techniques.
- Facility Assessment: Evaluate your current production environment to identify potential sources of contamination. This may involve auditing your assembly lines, storage areas, and handling procedures.
- Establishing Procedures: Develop and document procedures for sampling, analysis, and cleanliness maintenance in line with VDA 19. Make sure these procedures are consistently followed and regularly reviewed.
- Regular Monitoring: Implement a schedule for regular cleanliness inspections and audits. Use the data collected to refine your processes and address any issues that arise.
- Collaboration with Suppliers: Work closely with your suppliers to ensure that they also adhere to VDA 19 standards. Contaminants can be introduced at any stage of the supply chain, so it’s crucial to maintain cleanliness from the start.
Technical Cleanliness – The Benefits of Adhering to VDA 19
By following the guidelines set out in VDA 19, manufacturers can reap several benefits:
- Meeting safe-product requirements: For some products like ECU in automotive industry it is crucial to assure safety by eliminating the risk of particle contamination and electrical shortcut
- Improved Product Quality: Reduced contamination leads to fewer defects and higher reliability, which translates to better product quality.
- Cost Savings: Preventing contamination-related failures can save significant costs associated with rework, warranty claims, and recalls.
- Customer Satisfaction: Delivering clean, defect-free products enhances customer trust and satisfaction, which is vital in competitive industries like automotive and aerospace.
Let’s sum up!
Technical cleanliness is a critical aspect of manufacturing that can’t be ignored. VDA 19 provides a robust framework for managing cleanliness, from initial sampling to final assembly. By implementing these standards, manufacturers can ensure that their products meet the highest quality standards, ultimately leading to better performance, safety, and customer satisfaction.
In an industry where even the smallest particle can cause significant problems, maintaining technical cleanliness isn’t just a best practice—it’s a necessity.
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Knowledge must have a solid foundation in order to avoid information noise. Therefore, the article was based on the following literature:
VDA 19.1 Inspection of Technical Cleanliness, second revised edition, March 2015
VDA 19.2 Technical Cleanliness in assembly, 2010
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