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Stellar Microelectronics: Making Micro a Big Deal
By Annie Eitman, Business Development Administrator, Stellar Microelectronics, Inc., Valencia, CA M
iniaturized neuro-stimulators, mission- critical satellite assemblies, retinal implant devices, and control systems for a
Mars Rover — unrelated items, yet they share a common source. Stellar Microelectronics, Inc., a full service Electronics Manufacturing Services provider, specializes in building highly complex, high reliability components that go places where space is at a premium and failure is not an option. Walking into Stellar’s expansive, ultra-white
facility can be an eye-popping experience. First- time visitors are often amazed by the sheer size of the production floor. The 140,000 square foot building includes a world-class manufacturing and testing laboratory, a 100,000 square foot surface mount and PCB assembly area, a 15,000 square foot Class 100K clean room, as well as offices for engineering and operations.
Military Die Processor The company was founded in 1974 as a die
processor for the emerging military market. At that time, it specialized in Multichip Packaging (MCP), later adding Multi Device Subassemblies (MDS), Chip-on-Board (COB), and other assembly capabilities. By the 1990s, the company had devel- oped and patented integrated power substrate technologies and secured high-speed and RF design capabilities. In 2003, the company was acquired by
biotechnology philanthropist Alfred E. Mann. Stellar’s customer base quickly grew to include medical and industrial customers seeking precise and durable electronic assembly services. As the company’s popularity increased, it became appar- ent that an expansion was necessary. An extensive
Generous-size production facility also houses large clean room.
high production efficiency. One of the new building’s key strengths is
providing processing capability with immense flex- ibility of scale. The manufacturing area easily adjusts to accommodate new production lines. Equipment is modular for quick changes. Electrical power and other supply lines are routed through the floor, accessible through hatches spaced at key intervals. To guard against manu- facturing delays due to factory downtime, all major
investment in SMT automation soon followed, with the new facility opening in 2008. The new building improves on prior opera-
tions through lessons learned. Experience instilled the need for a more fluid and flexible manufactur- ing process. As a result, the new facility offers fea- tures to meet every possible customer require- ment, incorporating all available ways to achieve
equipment is duplicated. The factory is equipped with a wide variety of
analytical, test, repair, rework, and inspection equipment to support microelectronic and SMT assembly lines. All equipment, work stations, floor and personnel are grounded for Electro-Static Discharge (ESD) protection. Air ionizers are used for critical processes involving Ultra-Static Sensitive electronics. Temperature and humidity are strictly controlled in both the clean room and the extensive PCB assembly area. Foreign Object Debris (FOD) mitigation programs in all manufac- turing areas are enforced.
Reducing Cycle Time Engineers skilled in Design-for-Manufacture
(DFM) enhance the production process by reducing cycle time and improving quality. These engineers work in conjunction with manufacturing personnel to continually improve all aspects of production. This increases the efficiency of the facility and the functional quality of the end product, delivering a higher return on investment to clients. Program managers and quality personnel echo these effi- ciencies by adapting lean and Six Sigma method- ologies. An advanced database management pro- gram tracks the manufacturing process right down to the component level, proactively managing potential issues such as supply shortages or con- flicts in delivery deadlines. The company’s agile organizational structure
supports automated enterprise resource planning (Oracle ERP), product lifecycle/configuration man- agement (via Agile PLM), program management, material logistics, rapid response prototyping, and
Continued on next page
April, 2012
TRUST MATTERS.
WHO’S RELYING ON YOUR CAMERA CHOICE? Real people—you and your customers—are. That’s why, at Basler, trust is as crucial to our business as technology. Count on Basler for::
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