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NYS Governor's Awards for Pollution Prevention html - Lockheed Martin

Lockheed Martin Ocean, Radar & Sensor Systems, Syracuse

Background

Ocean, Radar & Sensor Systems (OR&SS) in Syracuse is Lockheed Martin's premier site for airborne and ground-based radar as well as sonar and undersea systems. It employs approximately 2,200 as part of the world's largest defense electronics business. Primary operations include electronics manufacturing, microelectronics manufacturing, systems assembly and systems integration.

A cross-functional Pollution Prevention Team comprised of design and process engineers, manufacturing, finance and environmental management personnel was established to analyze each operation that use ozone depleting substances (ODSs) and chlorinated fluorocarbons (CFCs). One operation, the soldering and cleaning of electronic assemblies, was selected by the Team as an opportunity to eliminate and/or substitute these chemicals for less hazardous materials.

Methodologies and Procedures

Precision Application

Analysis of this process revealed the excessive use and imprecise application of solder flux. This required repeated and extensive cleaning of electronic assemblies. The Team realizes that precisely applying solder flux at the beginning of the process would reduce not only the amount of flux used, but also the quantity and toxicity of solvents required to later clean the components. This would equate to an increase in first-time-pass yield rates during cleanliness inspections and a decrease in rework and cycle times.

To improve flux application, several options were evaluated with varying levels of success. The best alternative found was the precision A"flux-pen" applicator, which provides the most consistent delivery of flux to soldering locations by controlling the volume of flux dispensed.

Cleaning

Next, the Team explored several less toxic but equally effective alternatives to existing cleaners. Operators use the "tidy-pen," a precision cleaning tool containing terpene, to assess its ability to remove excess flux. The tidy-pen was judged an excellent tool for removing small amounts of flux.

Finally, a comparable substitute for Freon 113 was needed for the final cleaning of the circuit boards. A nonchlorinated substitute, Axarel©, was identified as an acceptable candidate for this step of the operation. To fully implement the substitute, a new non-aqueous cleaning system was purchased for final rinse.

All techniques developed by the Pollution Prevention Team were incorporated into employee training as a new standard for soldering and cleaning. The high visibility of this process improvement provided an opportunity to promote environmental management issues, including pollution prevention initiatives and waste generation and handling concerns.

Benefits

More precise and less time consuming soldering techniques resulted from the elimination of solvents and degreasers. Concurrently, a more exact process resulted in a lower percentage of components being rejected during testing and inspection.

The resources dedicated to managing air emissions, waste solvents and solvent-contaminated debris have been significantly reduced. In addition, TRI toxic air emissions reporting for Freon 113 were eliminated.

The initiative resulted in a 100 percent reduction in solvent and waste disposal from $6,824 in 1990 to $0 in 1995.

Elimination of chlorinated solvents realized an annual savings of $42,000 after implementation of the program in 1990.

A total of $1,628,566 in savings has been realized from raw materials and disposal costs for the 1990-95 period.

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This page was last modified March 8, 1999


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