Cost reduction is no longer just a part of the overall continuous program; it is the critical requirement for survival.

In today’s turbulent economy, each day brings new challenges in the manufacturing sector unlike anything most of us have experienced in our lifetimes. Even the best run companies are battling dwindling bottom lines and potential reductions in resources. The outlook is no different for critical or cleanroom manufacturing. Cost reduction plans are mandatory and tools must be identified and employed to drive down manufacturing costs while not negatively impacting the process or final product quality. The Cleanroom Wiper Usage Audit is just such a tool.

Focusing on cleanroom manufacturing environments, outside of raw materials, cleanroom consumables can and often do represent the largest spend for the company. Within the cleanroom consumables category, wipers typically account for a majority of the cost. Depending on the size of the operation and processes performed, annual wiper costs can range from the thousands to hundreds of thousands of dollars.

Performed properly, the Cleanroom Wiper Usage Audit can provide a roadmap for improved methods, increased process performance, improved product quality, and most importantly reduced manufacturing costs. By combining knowledge of the manufacturing environment and processing requirements and a knowledge of wiping materials and their performance characteristics with a proven analysis methodology, the Cleanroom Wiper Usage Audit can be a powerful tool. A powerful tool that often is offered as a free service by wiper manufacturers for their customers.

THE METHOD
Through a systematic analysis method, the audit will provide a clear understanding of the manufacturing environment, processing techniques, key process parameters, wiper usage quantities, wiper usage techniques, and wiper material requirements. From this analysis methodology, knowledge of wiping materials and their performance characteristics, proper wiping techniques, and potential packaging configurations can be applied to provide a total solution for the most effective manufacturing cost reduction. While many approaches may be used to conduct a wiper audit, the one presented here will be based on the DMAIC principles associated with Six Sigma methodology: Define, Measure, Analyze, Improve, Control.