Dear Lord,
We have had similar challenges with customer requirements related to ionic testing. You have determined that you cannot get a reliable result from testing at the stage where the adhesive has been applied. That option is out.
Assuming that Hege's logical plan wouldn't fly with your customer, here's what I would do:
1. Figure out where, upstream in the process, you can perform the cleanliness test to get a reliable result and generally be representative of the assembly process (most components installed).
2. Do an assessment of what risks downstream processes pose in adding/creating ionic contamination to the assembly.
3. Mitigate those risks. This may be done through mandating use of nitrile gloves for handling, review and update of manual cleaning process, etc.
4. Present to your customer as "This is what we can do to meet your requirements." not "Can we do this....?".
Cheers,
Joe
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