SenDEC implemented new lead-free machinery to product products that meet RoHS standards.

When SenDEC, a contract electronics manufacturer, became aware that the European Parliament was going to ban the sale or use of products made with lead in the European Union, it wasted no time in preparing its operations for the change. The European directive is called the Restriction of Hazardous Substances (RoHS) and became effective July 1, 2006. Fairport, N.Y.-based SenDEC knew that even if its customers didn’t ship to Europe, other countries would soon adopt the same restrictions, as well, so it devised a strategy to help customers deal with the mandate.   

“Just like the CFC changes in the ‘90s, we knew the change to lead-free would be inevitable,” says John Stryker, director of quality assurance. “We got to work right away. We learned about what the new requirements would be, which helped us determine what to implement, how to implement the new equipment and understand the new material and budget requirements.”

The equipment covered by RoHS includes large and small household appliances, IT and telecommunications equipment, electronic tools, toys, sports equipment and monitoring and control instruments. SenDEC is in the middle of the supply chain for these products, so it worked with both its suppliers and customers to ensure everyone was on board.

SenDEC’s process of going lead-free included:

• Teaming up with its bare board suppliers, solder paste manufacturers and component distributors to qualify and approve lead-free pastes as well as printed circuit board materials and processes  
  
• Investing in and installing new surface-mount reflow ovens and a dedicated wave solder machine that would process and utilize only RoHS-compliant materials
• Conducting trial runs on its equipment and processes
  
• Implementing a new system to quickly distinguish between a lead-free component and a leaded one
  

“We relied on our suppliers a lot,” Stryker says. “They were ready early, so they had many of the kinks worked out. As a result, we were ahead of the curve, so we were prepared when our customers were ready to change. It required a companywide educational program.”

SenDEC’s next steps were to help its customers become compliant and to adapt its own system to meet customers’ needs. Many customers thought they would be exempt from RoHS, but they were at the mercy of their component suppliers, so they had to either make changes to be RoHS compliant or make a lifetime buy of the leaded parts.

“Changing to a RoHS-compliant operation is not a super simple transition, which is why some customers are hesitant to change right now,” says Mike Campoli, SenDEC’s supply chain manager. “You need new designs of the products and have to make changes in the manufacturing. It is all about profits – our customers are not going to make profits on both leaded and unleaded products, so they have to make a decision on which way they want to go. It’s not a matter of if you want to make the changes, it’s when.”

The primary goal of going lead-free is to reduce landfill waste and keep toxic materials from getting into the earth. Working with lead-free components is also much better for the health of employees in prototype and manufacturing operations.

“Now you are seeing more companies develop their own standards for lead-free products, which is great for the entire supply chain,” Campoli says. “The more companies designing at RoHS standards, the better. Carestream Health, Kodak’s former health group, is one example of where you can find lead-free production, but you will see even more soon.”