The client is a German technology group with 12,000 employees worldwide. In Hesse, the company produces components for medical device implants that are used in the human body. The interim manager took on the task of developing and stabilizing a special soldering process. In this process, ceramic components just a few millimetres in size are hermetically soldered into a metal frame. The components serve as an interface between the inside of the device and the human body.
Process analysis, quality assurance and implementation of new processes
Known suppliers specializing in such soldering processes had not met the desired quality criteria for this soldering interface. The interim manager faced two main challenges in this project:
The technical side of this assignment had to be mastered. Firstly, this meant developing the soldering process in the shortest possible time and providing the components for a large customer order on time. This also included checking the microscopically small soldering results using special equipment such as X-ray microscopes, ultrasound devices, scanning electron microscopes and leak testers.
The employees involved in the development project, who had previously searched in vain for solutions, had to be convinced of the new procedure. The new process also had to be established within the company.
Suitable process parameters for soldering process defined after series of tests
The interim manager first analyzed the existing soldering process and then developed new criteria for the temperature behavior during soldering. He defined a new position for the workpieces in the soldering oven and designed a shield for the components to be soldered to protect them from the radiant heat of the oven. This made it possible to define suitable process parameters for the soldering process after just a few test series.
Production process optimized and new markets opened up with new technology
Together with the development team, he refined the process. The result was repeatable, high-quality solder joints that could also be transferred to other geometric shapes of the workpieces. The company was now able to produce large quantities of consistently good components with very little waste. As a result, the technology group was not only able to supply its customers on time, but also win new orders based on this globally unique technology.
