Optimizing Coating Parameters to Minimize Waste in TIM PTM 7000 Production for Electronic Components

Abstract

This research aims to reduce the defect rate in the coating process for production Thermal Interface Material (TIM) PTM 7000, essential in electronic components. A surge in demand of 321% in the first quarter of 2024, compared to the previous year, presented challenges in quality control and competitiveness. Initial assessments revealed an average defect rate of 7.8%, primarily due to thickness inconsistencies. Utilizing Engineering Design of Experiments (DOE), the study identified bulk viscosity and coating temperature as critical factors, while coating speed shows minimal impact. Adjusting these parameters reduces the defect rate to 0.017% over five months post-implementation, with process performance indices improving from 0.778 to 1.67. The findings underscore the importance of controlling process parameters to enhance product quality and long-term stability. This research provides a systematic approach to defect reduction, supporting high-quality manufacturing in the electronics industry with quantitative insight into capability indices Ppk = 3.07 and Cpk = 2.36.