Static-Dissipative Flooring Proves Wise Choice for Atlanta Company

When Automated Logic designed its new headquarters building near Atlanta, selecting the flooring in the manufacturing area was an important decision. The flooring had to withstand the wear-and-tear of foot and cart traffic and serve as a quality-improvement function: to drain away static electricity that could damage the sensitive electronics products the company manufactures.

Automated Logic makes and sells building automation hardware and software used in commercial buildings, industrial plants, schools, government facilities and health institutions. In 1994, the company began planning to build a larger facility three miles north of its previous location. The 30,000-square-foot building, 25% larger than the old one, would house the administrative offices, research and development, manufacturing and a self-contained training facility.

As an electronics manufacturer, Automated Logic faces the challenge of controlling static electricity generated through ordinary handling in the manufacturing process. In its old facility, the company controlled static through traditional methods such as covering worksurfaces with static-protective mats and requiring workers to wear wrist straps that kept them grounded.

Even with these safeguards, the company was aware of occasional defects in products during the testing, or burn-in, phase. Engineers attributed many of these defects to static damage that most likely occurred in the final assembly where workers were very mobile and had little opportunity for proper grounding.

For the new facility, engineers knew that any additional or improved static controls could not add handling time to the manufacturing process. Because all Automated Logic products are made to order during a limited time, any extra step in processing would slow production and increase costs. For example, if increased handling time added only $.50 to the cost of a unit, processing costs for the year would go up by about $18,500.

Consequently, engineers narrowed their options to static-protective flooring. This special flooring would divert static charge from people and materials into grounding strips tied into the metal structure of the building. Covering the entire factory floor would provide basic protection when workers and parts were constantly moving. Because of the large amount of voltage workers can create, they would still wear heel straps to keep in constant contact with the static-protective flooring.

Static-protective flooring costs more than regular flooring. But because they were constructing a building that needed new flooring anyway, engineers realized they could pay a little more to get static protection. Most importantly, the flooring option would allow the manufacturing process to flow unimpeded, with no increase in handling time.

After talking to other companies that had installed similar flooring, Automated Logic engineers selected 3M tiles, particularly because of the no-wax feature. This flooring maintains excellent electrical properties and a high gloss finish with no waxing.

With that in mind, Automated Logic chose the 3M 8410 Static Dissipative Floor Tiles to cover the entire 9,000-square-foot surface of the manufacturing area. The contractor attached grounding strips to the building’s metal frame and laid the tiles in the traditional way using 3M conductive adhesive. No special floor preparation or equipment was needed.

The company moved into the new facility in April 1995. Since that time, the floor in the manufacturing area has never been waxed and shows no sign of needing it. By not having to wax the floor, the company saves approximately $24,000 a year. That is, Automated Logic pays only $6,000 a year for maintenance compared to $30,000 a year quoted for upkeep of other static-protective flooring.

From the beginning, the flooring has served its primary function of draining static charge. The company has observed a 90% reduction in defective parts in electronics products before shipment. By eliminating the need for retest and reburn-in (12 hours of labor and testing time for each of 50 batches), the company saves about $15,700 a year.

Overall, the new flooring has reduced static problems and improved product quality with no increase in labor or processing time. Its no-wax feature has kept maintenance costs low, and its bright, white appearance has contributed to the employees’ perception of a pleasant work environment.

About the Authors

John Burris is the manufacturing engineer and Scott Brannan is the production manager at Automated Logic, 1150 Roberts Blvd., Kennesaw, GA 30144-3618, (770) 429-3000.

February 1997