How Athena Manufacturing Solves Complex Cleanroom Assembly Challenges

At Athena Manufacturing, our mission isn’t simply to manufacture high-quality parts. What we’re really passionate about is forging true partnerships with our customers—and providing a full-service manufacturing experience that can save them time, money, and maybe even a few headaches.

That mindset was the driving force behind our decision to invest in a new 4,000-square-foot ISO 6 cleanroom last year. With much of our business rooted in the semiconductor industry, we knew this capability would create immediate value for our customers.

And that’s precisely what happened.

Not long after we completed the cleanroom, we were able to take on a much larger scope of work for one of our long-term semiconductor customers—handling not just their precision machining and sheet metal fabrication needs, but also their full cleanroom assembly. The result was a 75% reduction in assembly time, significant cost savings, and a smoother, more efficient build from start to finish.

Why This Semiconductor Frame Was So Difficult to Build

For almost a decade, the team at Athena has manufactured the parts for this complex assembly, which requires 1,000 unique components and a bill of materials that exceeds 2,500 total parts for each frame.

Before our cleanroom installation, this customer assembled the frames in-house, using a mix of Athena-made parts, externally sourced components, and mechanical and electromechanical subassemblies. Each unit took them a full week to complete, partially due to redundant steps such as installing and uninstalling components during various stages of the assembly process.

Recognizing the inefficiencies in their current system, the customer approached Athena with a challenge: could we take on these frame assemblies and reduce the time, labor, and overhead they currently require?

How We Streamlined the Entire Cleanroom Assembly Process

Our team knew we had the capabilities to streamline the manufacturing and assembly of these cleanroom assemblies, but we couldn’t be sure about the precise savings until we got to work. Our team loves a good challenge, so digging into this complex assembly and strategizing ways to improve the manufacturing processes around it was right in our wheelhouse.

Once we could look at the project holistically, we determined that instead of continuing with a fragmented workflow, we could streamline the cleanroom assembly process by integrating the mechanical assemblies directly into our production process. This decision eliminated the need to disassemble and reassemble the frame, cutting hours of non-value-added work from the process.

We also leaned heavily on our Lean practices, including KANBAN systems, Kaizen improvements, and a just-in-time supply chain approach supported by long-term agreements with our vendors. This process reduced the part count from a 1,000+ piece bill of material into a single, consolidated deliverable.

From a Full Week to Just 16 Hours per Assembly

When our customer was managing assemblies in-house, the process took them about a week to complete. With the improvements we were able to put in place, each cleanroom assembly now only takes 16 hours from start to finish.

Our supply chain played a key role in this efficiency gain. By setting up stocking programs, we reduced procurement strain and ensured timely access to every component.

Not only did the customer immediately notice how much faster we could produce their frames, but they also noticed the cost savings. The efficiency improvements we made to the assembly process, along with our Lean processes, meant that we could make these assemblies much more economically, without sacrificing quality, compliance, or the delivery schedule.

As a bonus, we also piloted a real-time tracking program with this customer, giving them complete visibility of each frame throughout the manufacturing process. This program provides greater transparency and has built even deeper alignment between our teams, as well as greater confidence in Athena as a long-term partner.

From Component Supplier to True Manufacturing Partner

At Athena Manufacturing, we’re committed to being more than a parts supplier. Our one-stop-shop approach allows us to take on complex builds from start to finish—saving our customers time, reducing risk, and adding value at every stage.

What began as a standard component relationship grew into a fully integrated manufacturing solution, and the results speak for themselves. With over 25 years of precision sheet metal and machining expertise, as well as our cleanroom and electromechanical capabilities, we’re equipped to handle even your most demanding assembly needs.

Are you looking for a cleanroom assembly partner who can simplify your process and deliver real results?

Request a quote today, and let’s get started.