Design and steps to implementation of lead-free manufacturing

Abstract

Lead is no longer used in paints or gasoline due to the harmful effects caused from internal consumption and inhalation of lead. Unfortunately, the steps taken to reduce or control the harmful usage of lead in these cases were a reactive rather than a proactive solution. The electronics manufacturing industry now faces a similar situation. Over 80% of the lead used today can be found in the automobile batteries. This means the electronics manufacturing industry does not account for a very large percentage of the total lead usage, but it is the way these devices are someday discarded that is of concern. Lead automobile batteries present a minimal amount of risk to the general public because that lead is contained and it has a well-established recycle system. Electronic devices containing lead are finding their way into landfills and a concern is that the lead may eventually migrate into the drinking water systems. Although there are no cases of such yet, many manufacturers and legislatures would prefer to eliminate the possibility of harm to the general public and the environment. With personal computers and various types of electronic devices becoming more available to the general public, the amount of electronic waste that is dumped into landfills will increase. This will also increase the possibility of lead migration into the water systems. The elimination of lead in electronic devices has now become the trend and an industry wide conversion appears imminent. The question is no longer if lead-free, but rather, when lead-free. Therefore, manufacturers must now consider the key characteristics of successful lead-free implementation if they are to remain competitive. The purpose of this paper was to explore the key characteristics to consider when implementing to a lead-free electronics manufacturing system. XYZ Company was the participating company in this study and was evaluated by using the characteristics determined above. At the time of this research, XYZ had expressed great interest in exploring lead-free manufacturing and an eventual implementation. The results of the study showed various key characteristics to consider when implementing a lead-free manufacturing system. It examined the selection of lead solders and components, evaluated current and new manufacturing equipment, and detailed the differences in inspection and training. In conclusion, suggestions for successful steps to lead-free implementation were offered to assist XYZ Company in planning for future implementation. Furthermore, suggestions were offered for further similar studies.