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2003

First Year of IC Production. 2001. 2003. 2005. 2007. 2009. 2011. 2013. 2015. 2017. DECISION SUPPORT TOOLS FOR OPERATIONAL IMPROVEMENT Tools for understanding components of cycle time and trade-off between cycle time and equipment utilization and hot lots

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2003

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  1. First Year of IC Production 2001 2003 2005 2007 2009 2011 2013 2015 2017 DECISION SUPPORT TOOLS FOR OPERATIONAL IMPROVEMENT Tools for understanding components of cycle time and trade-off between cycle time and equipment utilization and hot lots Tools/algorithms/models for wafer release (start) policies based on bottleneck monitoring Tools/algorithms/models for forecasting demand and capacity-demand integration Tools to accurately predict and analyze individual lot cycle times to ensure On-Time-Delivery (OTD) Tools/algorithms/models for optimized operator and technician staffing levels and developing optimal training/cross-training plans Integrated techniques for coordination with supply chain management efforts (fab/sort/assy/test/distribution) Tools for determining optimum quantities and timings of operations resources (such as Reticle and Spares quantities) Tools for determining optimal Non-product wafer plans Tools/algorithms/models to measure actual capacity loss components due to operators and technicians EXECUTION TOOLS FOR OPERATIONAL IMPROVEMENT Real-time scheduling and dispatching algorithms integrated with AMHS - must consider operations resources, labor, Non product wafer, status of equipment (PM) and factory Planning systems integrated with real-time scheduling and dispatching systems Real-time optimization of operator and technician activities Spares usage optimization and tracking and control capability Real-time factory supply chain management & real-time control capability 2002 2004 2006 2008 2010 2012 2014 2016 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm Applies for 450 mm 300 mm 300 mm 450 mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution. Applies for 450 mm 300 mm 450 mm

  2. 2001 2003 2005 2007 2009 2011 2013 2015 2017 2002 2004 2006 2008 2010 2012 2014 2016 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 450mm 450mm 450mm 450mm 450mm 450mm 450mm 450mm 450mm 450mm 450mm 300mm 300mm 300mm 300mm 300mm 450mm 450mm 450mm 450mm 300mm 300mm 300mm 300mm 300mm 300mm 450mm 450mm 450mm 450mm First Year of IC Production Cost Reduction by Standards & Interoperability Standard interfaces for wafer and carrier handling, communications interfaces, material handling, facilities systems (utilities, drains and exhaust), operations and equipment maintenance. Equipment manuals, schematics, drawings, and specifications accessible and browseable using mainstream Internet technology, internet standards, and user-interfaces. OEE Improvement Proliferation of in-situ monitoring and recipe adjustable parameters. Statistical analysis and feedback control improvements, enable all logs & parameter related data to leave tool in an orderly manner; permit controlled remote interruption of processes at a step/recipe level; allow remote systems to take chambers in the middle of lot processing without impacting other chamber’s process. Smarter embedded tool controller, precise wafer handling & particulate control, eliminate dwell-time between wafer handling moves and increase processing wafer/hour rate. Self-diagnostic & remote diagnostic supported by fault detection/classification, run to run control and integrated metrology Single-wafer level tracking and control. More Efficient Equipment Designs Recycle/re-use more water Separate waste streams at the tool Heat load removal from tool by usage of process cooling water versus HVAC systems High efficiency power distributions systems in the tool (use higher voltage, not current) Spares Cost Reduction Increased modularization, permit change out and remote service to minimize downtime, optimized PM frequency, consumables modular system components Ramp-up Cycle-time Reduction Qualification period reduction (more pre-qualification at supplier site) Installation period reduction (quicker assembly on-site) Multiple-Generation (node) Upgradability High exchangeability of chamber modules, parts and fittings Common equipment base, frame and modules, Modular equipment control systems Carrier level and Wafer level integrated Flow and Controls Type1: Sorter and Metrology integrated with Stockers Type 2-1: Connected EFEM type equipment Type 2-2: Expanded EFEM type equipment Type 2-3: Continuous EFEM type equipment 300mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

  3. 2001 2003 2005 2007 2009 2011 2013 2015 2017 2002 2004 2006 2008 2010 2012 2014 2016 300 mm 300 mm 300 mm 300 mm First Year of IC Production EASE OF IMPLEMENTATION /QUICK RAMPUP / MAINTENANCE Simple system component modules with automated or zero field hardware alignment and positioning capability (cleanroom support structure, teaching, and adjustment not required) Easily extended transport system rail Automated software configuration (HW independent structure and parameter setting) Dynamic (high volume transfer load) simulation test and automatic transfer capability estimation (throughput and carrier delivery time) Automated preventive/predictive maintenance, calibration, fine tuning, software upgrade (uninterrupted) and e-Diagnostics MATERIAL TRANSPORT SYSTEM CONFIGURATIONS High throughput vehicle based direct transport system with by-pass capability Large scale, high throughput conveyors and next generation vehicles MATERIAL HANDLING STORAGE SYSTEM CONFIGURATIONS Central storage systems for low use non-production lots using zero fab floor space. Conveyor based storage system for using zero fab floor space. Modular field upgradeable stockers which are expandable to very large capacity TRANSPORT LOAD IDENTIFICATION & TRACKING METHODS Carrier identification system for separate tracking of empty carrier and lid Wafer ID reading to support 450mm wafer tracking MATERIAL HANDLING CONTROL CAPABILITY Integrated material control system for interbay and intrabay control Intelligent vehicle traffic management control for direct transport system and advanced reticle transportation integration Flexible lot size transport, capable of handling split and merge. (Note: same size carrier with variety of multiple lots) 300 mm 300 mm 300 mm 300 mm 450 mm 450 mm 300 mm 300 mm 300 mm 450 mm 300 mm 450 mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

  4. 2001 2003 2005 2007 2009 2011 2013 2015 2017 2002 2004 2006 2008 2010 2012 2014 2016 300 mm 300 mm 450 mm 450 mm 450 mm First Year of IC Production INTEGRATED FLOW AND CONTROL SYSTEMS [1] Carrier Level (Stocker, Sorter, and Metrology Integration) Integrated stocker, sorter, and metrology equipment into single unit with standard intrabay operational model including exception handling and standard interfaces for easy equipment add-on capability Wafer Level (Connected EFEMs (Equipment Front-End Modules)) EFEMs with standard hardware and software interfaces Integrated operational model; using connected EFEMs and including wafer staging and exception handling Wafer Level (Extended EFEMs) Extended EFEMs with high-speed wafer transfer robot and standard equipment hardware and software interfaces for easy equipment and load port add-ons Integrated operational model; using equipment throughput matching algorithms and including robust wafer dispatcher and exception handling Wafer Level (Continuous EFEMs) Ultra high speed wafer transport system and stockers with high speed wafer sorting capability (lot to wafer transition between stocker and transport) and standard interfaces System level controller with wafer level dispatcher 450 mm INTERFACE STANDARDS DEVELOPMENT Interface standards development for storage, transport, carriers, and equipment 300 mm 300 mm 300 mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

  5. 2001 2003 2005 2007 2009 2011 2013 2015 2017 2002 2004 2006 2008 2010 2012 2014 2016 300mm 300mm 300mm 450mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 300mm 450mm 300mm 300mm 450mm 300mm 300mm Research and Standards Development Development Underway Qualification/Pre-Production First Year of IC Production • Improve Factory Effectiveness • Cycle Time and Throughput • Real-time dispatching and direct transport with integration of Dispatcher, MES, AMHS, equipment availability and yield data • FICS that support multiple recipes/lots per carrier • E-Diagnostics to support automated preventative/predictive maintenance, calibration, fine tuning, software upgrades for production and AMHS equipment • Highly Reliable Systems • Fault tolerant computer systems with transparent hardware switching for failures (minimal to no impact) • Software application fault detection & monitoring • Low Maintenance Systems • Software applications capable of dynamic upgrades (minimal to no impact) • Databases capable of dynamic upgrades (minimal to no impact) • Automatic/Dynamic AMHS software (MCS) reconfiguration • Integration testing and volume testing of overall factory systems (incl AMHS) through simulators or emulators • Flexible Manufacturing Systems • Scalable system performance • Web capable interfaces for factory systems • Wireless/portable user interfaces • IMPROVE FACTORY YIELD • Recipe management for all assembly production equipment • Equipment Engineering Fault Detection and Control (FDC) • Standards-based historical and summary data storage/analysis products • Standards-based detailed wafer-level and chamber-level data tracking • Standards-based configurable/downloadable FDC models • Standards-based FDC signals from equipment to host • Standards-based Host-issued FDC control commands • Equipment Engineering (EE) Run-to-Run Control • Standards-based Modular Applications w/ Open Interfaces • Standards-basedMES recipe interaction • Standards-based Recipe Adjustment (process/control job) • Standards-based Metrology data collection via EE interface • Standards-basedWafer-level and Chamber-level Process data collection via EE interface • Equipment Engineering (EE) Integrated Metrology • Standards-based Metrology/process data collection via EE interface • Standards-based FICS to GEM interface for integrated process/metrology control • Standards-based Recipe and Model selection/download for integrated process/metrology • Real-time yield management systems to correlate test/probe and process data to automatically determine process problems • ACCOMMODATE PROCESS AND • PRODUCT COMPLEXITY • Integrated FICS to facilitate data searches and information correlation on process and operational data • Integrated MCS for interbay/intrabay control • Integrated FICS to support cross-site processing • Business-level software systems integrated with FICS • FACTORY SYSTEMS (FS) REUSE • Replace SECS/GEM with mainstream-based standards • Collaboration/Prototyping to decrease Standards cycle time • INCREASING PURITY • REQUIREMENTS • FOR PROCESS AND MATERIAL • Improve systems to monitor and control chemical, safety and environmental items 300mm 300mm 300mm 300mm 300mm This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

  6. 2001 2003 2005 2007 2009 2011 2013 2015 2017 2002 2004 2006 2008 2010 2012 2014 2016 First Year of IC Production Facility Cost Reduction Use benchmarking to develop standard performance metrics and best practices for facility construction, operation, reliability and equipment installation Develop Standard facility designs and specifications that reduce unique custom factory designs allowing earlier design packages for construction Develop more robust design tools Provide better quality utility requirements for production equipment Design tools for clean maintenance to ensure isolation is maintained during routine maintenance operations Develop Power and water reduction protocols in conjunction with production equipment manufacturers Reduce move-in size of production equipment to minimize aisle widths Improve factory layout density/ vertical layout optimization Standardize measuring and reporting of utility utilization at production equipment Efficient Production Equipment Installation Develop More Accurate Factory Models Develop Flexible Factory Designs that allow installation, removal, and reconfiguration of production equipment over the life of the factory Develop Production Equipment Installation Standards using Predictable/Consistent tool connection for utilities, drains, exhaust and interconnects Ensure early and accurate identification of production equipment installation demand requirements (eg. pressure, loads, flows, connection size) Design Production Equipment to operate within facility infrastructure systems capabilities Design support equipment to fit production equipment footprint determined by prime manufacturing area Improve production equipment documentation and change management Reduce makeup air & exhaust requirements Facility Solutions for ESH Requirements Transition to higher efficiency (voltage) power distribution Maintain or reduce radiation exposure in the facility (EUV Impact) Recycle/Retreat water and waste streams Investigate ROI and incentives for alternative power solutions Transition from air to more efficient liquid cooling systems in cooperation with production equipment manufactures Develop Risk Assessment tools for understanding economic impact to EHS design and measurement incentives Provide cost effective point of use and/or factory wide abatement technologies 300mm 450mm 300mm 450mm 300mm 450mm 450mm 300mm 300mm 300mm 300mm 300mm 450mm 300mm 300mm 450mm 300mm 450mm 300mm 450mm 300mm 450mm 450mm 300mm 300mm 450mm 300mm 300mm 450mm 300mm 300mm 300mm 300mm 300mm 450mm 300mm 300mm 450mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

  7. First Year of IC Production 2001 2003 2005 2007 2009 2011 2013 2015 2017 Standards Based Equipment and FICS Test equipment and FICS solutions with standardized software control interfaces (Revised SEM) Prober equipment and FICS solutions with standardized software control interfaces (Revised SEM) Handler equipment and FICS solutions with standardized software control interfaces (Revised SEM) Test equipment and FICS solutions with standardized result data Test equipment and FICS solutions with standardized test program formats and interfaces 2002 2004 2006 2008 2010 2012 2014 2016 450mm 450mm 450mm 300mm 450mm 300mm 300mm 300mm 450mm 300mm Research Required Development Underway Qualification/Pre-Production This legend indicates the time during which research, development, and qualification/pre-production should be taking place for the solution.

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