Welcome to the ISMI NGF & 450mm Industry Briefing - Sematech

Welcome to the ISMI NGF & 450mm Industry Briefing - Sematech Welcome to the ISMI NGF & 450mm Industry Briefing - Sematech

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SEMICON West 2008 Accelerating Manufacturing Productivity Welcome to the ISMI NGF & 450mm Industry Briefing Copyright ©2008 SEMATECH, Inc. SEMATECH, and the SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, ISMI, Advanced Materials Research Center and AMRC are servicemarks of SEMATECH, Inc. All other servicemarks and trademarks are the property of their respective owners.

SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

<strong>Welcome</strong> <strong>to</strong> <strong>the</strong> <strong>ISMI</strong><br />

<strong>NGF</strong> & <strong>450mm</strong> <strong>Industry</strong> <strong>Briefing</strong><br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Accelerating Manufacturing Productivity<br />

Introduction &<br />

Opening Remarks<br />

Scott Kramer<br />

VP, Manufacturing<br />

Technology<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Meeting Outline<br />

• Purpose<br />

– Maintain industry communication regarding <strong>ISMI</strong> programs related <strong>to</strong> <strong>NGF</strong><br />

and <strong>450mm</strong>.<br />

– Promote supplier participation in industry collaboration forums and <strong>ISMI</strong><br />

supplier engagement.<br />

– Inform industry of emerging needs and expectations related <strong>to</strong> equipment<br />

and fac<strong>to</strong>ry productivity for next generation fabs and <strong>450mm</strong> transition.<br />

• Expected results<br />

– Attendees will gain more insight in<strong>to</strong> <strong>the</strong> current status and future direction<br />

of <strong>ISMI</strong> programs. The <strong>Briefing</strong> is expected <strong>to</strong> stimulate interest and<br />

participation where opportunities exist for supplier engagement with <strong>ISMI</strong>.<br />

July 16, 2008 3


Meeting Agenda<br />

• (10) <strong>Welcome</strong> and Opening Remarks – S. Kramer<br />

• (35) <strong>NGF</strong> Session – O. Ro<strong>the</strong><br />

– <strong>NGF</strong> Program overview<br />

– <strong>NGF</strong> Guidelines priorities<br />

– Overall productivity and cost goals<br />

– Productivity modeling and metrics<br />

– Outlook 2009 and Beyond<br />

– Key messages<br />

• (35) <strong>450mm</strong> – T. Abell<br />

– <strong>450mm</strong> Program overview<br />

– Guidelines updates<br />

– Interoperability Test Bed results<br />

– Silicon studies<br />

– Supplier engagement summary<br />

– Outlook 2009 and Beyond<br />

– Key messages<br />

• (10) Closing remarks and Q&A – J. Draina<br />

July 16, 2008 4


Accelerating Manufacturing Productivity<br />

<strong>ISMI</strong> Overview<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


<strong>ISMI</strong> Worldwide Cooperation<br />

• Members represent over half of world<br />

semiconduc<strong>to</strong>r sales<br />

July 16, 2008 6


<strong>ISMI</strong> Mission - Accelerating<br />

Manufacturing Productivity<br />

<strong>ISMI</strong> provides productivity solutions for current and<br />

future challenges in <strong>the</strong> manufacturing plants of our<br />

membership, so that our members will achieve best in class<br />

productivity levels.<br />

We will accomplish this by providing platforms for<br />

collaboration among our members and directing<br />

development activities in key areas identified by our<br />

members.<br />

July 16, 2008 7


Next Generation Fac<strong>to</strong>ry Vision Realization<br />

<strong>450mm</strong><br />

<strong>450mm</strong> Fac<strong>to</strong>ry Integration<br />

Test Bed<br />

<strong>450mm</strong> Fac<strong>to</strong>ry Integration<br />

Guidelines & Standards<br />

<strong>450mm</strong> Silicon Wafer<br />

<strong>450mm</strong><br />

Readiness<br />

<strong>NGF</strong><br />

Software Infrastructure<br />

SWP/Small lot-size Fac<strong>to</strong>ry<br />

Availability Improvement<br />

FWD/Set-up Reduction<br />

300mm Classic<br />

Foundation<br />

• Complementary forward-compatible paths for <strong>NGF</strong> and <strong>450mm</strong><br />

– Realization of <strong>450mm</strong> is built upon coordinated improvements from <strong>NGF</strong> and<br />

<strong>450mm</strong> activities <strong>to</strong> efficiently utilize industry resources<br />

• Collaboration is a critical success fac<strong>to</strong>r: Inside and Outside <strong>ISMI</strong><br />

July 16, 2008 8


Productivity Overview<br />

• Member companies all agree – higher productivity is a<br />

must, always<br />

• There are multiple solutions possible<br />

• <strong>ISMI</strong> philosophy – accelerate productivity improvement<br />

– Be impatient<br />

– Do not delay or hesitate<br />

– Consider all information and possible solutions<br />

• Introduction and timing of any productivity improvements<br />

are determined by markets<br />

– Decisions by informed buyers and sellers<br />

– Free and open<br />

– Level playing field<br />

July 16, 2008 9


Meeting Agenda<br />

• (10) <strong>Welcome</strong> and Opening Remarks – S. Kramer<br />

• (35) <strong>NGF</strong> Session – O. Ro<strong>the</strong><br />

– <strong>NGF</strong> Program overview<br />

– <strong>NGF</strong> guidelines priorities<br />

– Overall productivity and cost goals<br />

– Productivity modeling and metrics<br />

– Outlook 2009 and beyond<br />

– Key messages<br />

• (35) <strong>450mm</strong> – T. Abell<br />

– <strong>450mm</strong> Program overview<br />

– Guidelines updates<br />

– Interoperability Test Bed results<br />

– Silicon studies<br />

– Supplier engagement summary<br />

– Outlook 2009 and beyond<br />

– Key messages<br />

• (10) Closing remarks and Q&A – J. Draina<br />

July 16, 2008 10


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

<strong>ISMI</strong> Next Generation Fac<strong>to</strong>ry<br />

Program <strong>Briefing</strong><br />

Olaf Ro<strong>the</strong><br />

<strong>NGF</strong> Program Manager<br />

July 16, 2008<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


<strong>ISMI</strong> <strong>NGF</strong> Program Mission<br />

• Continuously refine, communicate and realize <strong>the</strong> next generation<br />

fac<strong>to</strong>ry vision and “19 point Fac<strong>to</strong>ry Guidelines”<br />

• Address global and infrastructure aspects of both hardware and<br />

software development, targeting new capabilities in equipment and<br />

fac<strong>to</strong>ry productivity<br />

• Enable retrofit of both new and improved capabilities in<strong>to</strong> existing 200<br />

and 300mm fac<strong>to</strong>ries as a high priority<br />

• Integrate a step-wise and coordinated waste reduction approach <strong>to</strong><br />

realize equipment and fac<strong>to</strong>ry productivity improvements targets<br />

• Provide a complementary forward-compatible approach of 300mm<br />

<strong>NGF</strong> <strong>to</strong> <strong>450mm</strong> <strong>to</strong> address <strong>the</strong> needs of our various member<br />

constituencies and minimize <strong>the</strong> R&D expenditure by <strong>the</strong> industry<br />

• Deliver <strong>NGF</strong> productivity improvements by 2012, in accordance with<br />

<strong>the</strong> ITRS, <strong>to</strong> realize <strong>the</strong> necessary cycle time and cost reduction and <strong>to</strong><br />

stay on Moore’s Law<br />

July 16, 2008 12


<strong>ISMI</strong> <strong>NGF</strong> 2008 Program Objectives<br />

• Key supplier engagement and coordination for major<br />

equipment improvement<br />

– First Wafer Delay, Availability & Predictability, Quality<br />

Data Access and Usage<br />

• Identify requirements <strong>to</strong> implement small lot<br />

manufacturing and single wafer processing<br />

• Identify productivity improvements<br />

necessary <strong>to</strong> implement fully continuous<br />

processing<br />

• Address requirements for advanced material<br />

delivery and fac<strong>to</strong>ry control systems <strong>to</strong> take<br />

full advantage of <strong>the</strong> equipment/fac<strong>to</strong>ry<br />

productivity improvements<br />

July 16, 2008 13


<strong>ISMI</strong> <strong>NGF</strong> Program Overview<br />

<strong>NGF</strong> Target for 2012 centered at<br />

- 50% Cycle Time Reduction<br />

- 30% Cost Reduction<br />

ITRS, Moore’s Law,<br />

IDM Requirements<br />

19 Point Guidelines<br />

<strong>ISMI</strong> CIP Program<br />

NPW<br />

FWD<br />

<strong>ISMI</strong> <strong>NGF</strong> Program<br />

EDA<br />

EEQA<br />

SLS<br />

ECM<br />

What Else ?<br />

DQ<br />

PPM<br />

VM<br />

July 16, 2008 14


19 Point Guidelines and <strong>NGF</strong> Projects<br />

• Member Company Prioritization in 2007<br />

• Supplier Perspective on Priorities<br />

• Very Good Correlation<br />

1. Maximum <strong>450mm</strong> carrier capacity and specification for early pro<strong>to</strong>types<br />

2. Front Opening <strong>450mm</strong> wafer carriers<br />

3. Carriers designed for efficient purging with standardized purge locations<br />

4. MHS Design <strong>to</strong> assume infrequent, anomaly manual handling only<br />

5. Design allowing au<strong>to</strong>mated reticle transport<br />

6. Standardized interfaces - equipment mainframe: process chambers<br />

7. Standardized locations for low-cost buffers on <strong>to</strong>ols (beyond loadports)<br />

8. Equipment <strong>to</strong> be Predictive Maintenance friendly<br />

9. Equipment maintenance and operation in parallel<br />

10. “Smart Idle” mode for equipment<br />

11. Facility adap<strong>to</strong>r plates<br />

12. Equipment first wafer delay reduction<br />

13. Single Wafer or Mini-batch (vs. Batch) processing <strong>to</strong>ols<br />

14. Equipment design for flexible capacity increments<br />

15. Enable continuous processing of material<br />

16. Wafer-level instruction at any time before processing<br />

17. Single Point of Control for fac<strong>to</strong>ry system command/control<br />

18. Equipment <strong>to</strong> provide quality data <strong>to</strong> enable external moni<strong>to</strong>ring<br />

19. Carrier: Slot integrity flexibility<br />

450 only<br />

MED<br />

LOW<br />

LOW<br />

LOW<br />

HIGH<br />

HIGH<br />

MED<br />

LOW<br />

HIGH<br />

MED<br />

MED<br />

HIGH<br />

MED<br />

MED<br />

HIGH<br />

MED<br />

Equipment<br />

Centric<br />

PPM<br />

SLS<br />

EDA<br />

DQ<br />

VM<br />

EEQA<br />

ECM<br />

FWD<br />

July 16, 2008 15


<strong>NGF</strong> Strategic Outlook 2009 – 2013<br />

2008 2009 2010 2011 2012 2013<br />

Cost and Cycle Time Improvement Strategies<br />

)<br />

Minimized Cycle Time and Cost<br />

Equipment Availability & Predictability<br />

Fac<strong>to</strong>ry Predictability<br />

Advanced Material Control & Delivery<br />

Projects<br />

Advanced Fac<strong>to</strong>ry System<br />

Command & Control<br />

July 16, 2008 16


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

2008 Results – Metrics &<br />

Simulation<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Metrics and Target Definition<br />

• Collaboration with <strong>the</strong> Joint Productivity Working<br />

Group in Metrics, Simulation & Economics<br />

– Metrics breakdown for cycle time and cost<br />

– Common metrics definition<br />

– Identification of productivity contribu<strong>to</strong>rs<br />

• Metrics Breakdown<br />

– Top down quantification of improvement for<br />

each metric using simulation guidance<br />

• <strong>ISMI</strong> Projects: PPM, EEQA, ECM, FWD<br />

– Target definition<br />

– Measurement of results<br />

– Bot<strong>to</strong>m up feasibility verification<br />

July 16, 2008 18


Productivity and Cost Goals<br />

Breakdown Approach<br />

Metrics Targets Contribu<strong>to</strong>rs<br />

Cost Modeling<br />

and Fac<strong>to</strong>ry Simulation<br />

Cycle Time<br />

Cost<br />

Equipment Metrics<br />

Availability……………………….xx%<br />

Predictability ……………………xx%<br />

…<br />

…<br />

Fac<strong>to</strong>ry Metrics<br />

Utilization………………………..xx%<br />

WIP………………………………xx%<br />

Capacity………………………....xx%<br />

…<br />

…<br />

…<br />

PPM<br />

EEQA<br />

ECM<br />

DQ<br />

EDA<br />

FWD<br />

SLS<br />

VM<br />

Setup Time / FWD<br />

MTTR<br />

Time <strong>to</strong> diagnose MTBF<br />

Parts delivery<br />

Unscheduled <strong>to</strong> scheduled<br />

downtime<br />

Variance of Repair<br />

Deterministic PM ….<br />

AMHS predictability<br />

Mean delivery time<br />

Scheduling & dispatch<br />

cascading<br />

Chamber dedication<br />

Downtime predictability<br />

Single wafer manufacturing<br />

NPW<br />

Small Lot Size ….<br />

Cost Metrics<br />

Fixed…………………………….xx%<br />

Variable…………………………xx%<br />

??<br />

??<br />

Depreciation<br />

Maintenance<br />

Fab Capacity<br />

Materials<br />

NPW<br />

Labor ….<br />

July 16, 2008 19


Productivity and Cost Goals - Targets<br />

Fac<strong>to</strong>r Target Cycle Time Cost<br />

2007 Data From To 25-Wafer 12-Wafer 25-Wafer 12-Wafer<br />

Cost Modeling<br />

and Fac<strong>to</strong>ry Simulation<br />

Cycle Time Option<br />

Availability 87% 91% 7.6% N/A -1.7% N/A<br />

First Wafer Delay<br />

Setup<br />

Batch SWP<br />

2008 Data<br />

MIN MIN LOTS<br />

Availability 87% 91%<br />

First Wafer Delay<br />

Setup<br />

Batch SWP<br />

MIN MIN LOTS<br />

8.3 6.2<br />

2.1% N/A -1.8% N/A<br />

9.2 6.9<br />

6/2 1 19.1% 51.4% -3.3% -15.3%<br />

8.3 6.2 10.5% 12.8% 4.6% 4.4%<br />

9.2 6.9<br />

6/2 1 7.8% 29.3% -0.3% 0.5%<br />

Cascading<br />

LOTS<br />

1,2,4 1,2 35% 39% 1.7% 1.6%<br />

NPW 12% 10% 1.8% 1.5%<br />

Overall 46% 62% 7.5% 8.0%<br />

July 16, 2008 20


300mm <strong>NGF</strong> Program Addendum<br />

Cycle Time vs Wafer Cost Change<br />

Wafer Cost Change<br />

25%<br />

20%<br />

15%<br />

10%<br />

5%<br />

0%<br />

-5%<br />

-10%<br />

-15%<br />

-20%<br />

-25%<br />

-30%<br />

-35%<br />

Increased Benefit for <strong>NGF</strong> High Mix with<br />

additional Cascading and NPW Initiatives<br />

Currently identified opportunities<br />

of<br />

*<br />

improvement<br />

*<br />

Similar Benefit for <strong>NGF</strong> High Mix with<br />

SWP/SLS & +5%EA, +25% FWD<br />

<strong>ISMI</strong> <strong>NGF</strong> Program<br />

Target in accordance<br />

with ITRS<br />

Cycle Time Reduction<br />

Fur<strong>the</strong>r refinement and<br />

investigation underway<br />

-40%<br />

-70% -65% -60% -55% -50% -45% -40% -35% -30% -25% -20% -15% -10% -5% 0% 5%<br />

Cycle Time Change<br />

Wafer Cost Reduction<br />

<strong>ISMI</strong> <strong>NGF</strong><br />

Program<br />

High Mix<br />

Baseline<br />

(712 <strong>to</strong>ols)<br />

July 16, 2008 21


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

2009 Outlook and Beyond<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Outlook 2009 and Beyond<br />

Improved equipment productivity, lower cycle time, small lot size and<br />

single wafer manufacturing require significant fac<strong>to</strong>ry operations<br />

improvements <strong>to</strong> leverage <strong>the</strong>ir full benefit<br />

• Equipment Availability & Predictability<br />

– Continued focus on equipment productivity improvement<br />

• PPM, EEQA, EDA/DQ<br />

• Supplier pilots, fac<strong>to</strong>ry integration and solutions<br />

• Fac<strong>to</strong>ry Predictability<br />

• Advanced Material Control & Delivery<br />

• Advanced Fac<strong>to</strong>ry System Command & Control<br />

– Investigate productivity improvement areas in fac<strong>to</strong>ry operations<br />

• Cascading<br />

• AMHS<br />

• Scheduling & dispatch<br />

• Decision support systems<br />

• Network communications for command & control<br />

• Equipment changes related <strong>to</strong> areas above<br />

July 16, 2008 23


Manufacturing Improvement and<br />

Waste Reduction<br />

• How <strong>to</strong> improve waste reduction activity?<br />

• One reduction brings about many effects!<br />

• One effect needs many efforts for waste reduction!<br />

Stabilization of equipment<br />

OEE improvement<br />

Variation control for fine pattern<br />

Cycle time reduction<br />

Material expense reduction<br />

Yield enhancement<br />

Waste of equipment utilization<br />

Waste of maintenance<br />

Waste of poor achievement of<br />

product performance<br />

Waste of order fulfillment delay<br />

Waste of over production<br />

Waste of material over<br />

consumption<br />

This slide by courtesy of NEC<br />

July 16, 2008 24


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

<strong>NGF</strong> Key Messages<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


<strong>NGF</strong> Key Messages<br />

• <strong>ISMI</strong> <strong>NGF</strong> target remains 50% cycle time and 30% cost<br />

improvement<br />

• <strong>NGF</strong> program has identified more productivity<br />

improvement opportunities, enabling both cycle time and<br />

cost improvements at <strong>the</strong> same time<br />

• Equipment productivity improvement projects have<br />

progressed <strong>to</strong> a stage of active supplier engagement (ECM,<br />

FWD, PPM, EEQA)<br />

– PPM embraced as currently most promising project, with EDA/DQ<br />

usage by suppliers and IDM’s as fundamental enabler<br />

– Testing of software and EDA functionalities critical for enabling and<br />

implementing new <strong>NGF</strong> capabilities<br />

July 16, 2008 26


<strong>NGF</strong> Key Messages<br />

• <strong>ISMI</strong> addresses fac<strong>to</strong>ry operations and environment as<br />

next step with continued focus on equipment productivity<br />

improvements<br />

– Approach <strong>to</strong> waste reduction becomes a strategic part of<br />

productivity improvement<br />

– Retrofit of new capabilities in<strong>to</strong> existing fac<strong>to</strong>ries highly desirable<br />

• <strong>ISMI</strong> is committed <strong>to</strong> continued communication and<br />

collaboration between suppliers and IDMs<br />

• The identification of additional leverages will enable fur<strong>the</strong>r<br />

productivity improvements beyond <strong>the</strong> reported results<br />

July 16, 2008 27


For more Information…<br />

This presentation material will be made available for<br />

download at <strong>the</strong> SEMATECH public website:<br />

www.ismi.sematech.org<br />

Meetings and News – Past Meeting Proceedings – <strong>ISMI</strong><br />

<strong>Industry</strong> <strong>Briefing</strong>s<br />

To initiate individual discussions with <strong>the</strong> <strong>ISMI</strong> Team, please<br />

contact:<br />

– Olaf Ro<strong>the</strong>, <strong>NGF</strong> Program Manager<br />

(olaf.ro<strong>the</strong>@ismi.sematech.org)<br />

– Brad Van Eck, <strong>NGF</strong>R Project Manager<br />

(brad.van.eck@ismi.sematech.org)<br />

July 16, 2008 28


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

<strong>ISMI</strong> <strong>450mm</strong><br />

Program <strong>Briefing</strong><br />

Tom Abell<br />

450 Program Manager<br />

July 16, 2008<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.<br />

Portions of this document contain <strong>ISMI</strong><br />

Confidential Information as marked


<strong>ISMI</strong> <strong>450mm</strong> Program Mission<br />

and Objectives<br />

Mission:<br />

• Enable cost-effective <strong>450mm</strong> transition through coordination and<br />

development of infrastructure, guidance, and industry readiness<br />

2008 Objectives:<br />

1. <strong>450mm</strong> wafer availability <strong>to</strong> enable <strong>450mm</strong> development<br />

2. Timely coordination and support of <strong>450mm</strong> transition projects and<br />

strategic industry activities<br />

3. Creation of testable Next Generation Fac<strong>to</strong>ry Architecture guidelines<br />

and coordination of standards <strong>to</strong> accelerate <strong>450mm</strong><br />

4. Pro<strong>to</strong>type testing of <strong>450mm</strong> Fac<strong>to</strong>ry Integration Interoperability<br />

challenges<br />

July 16, 2008 30


<strong>ISMI</strong> <strong>450mm</strong> Program Structure for 2008<br />

<strong>450mm</strong> Transition Program<br />

Si Wafer Readiness<br />

• Supplier Engagement<br />

• ESH Challenges<br />

• Economic Moni<strong>to</strong>ring<br />

• <strong>Industry</strong> Collaboration<br />

• Si supplier readiness<br />

• Si Bank and wafer testing<br />

Fac<strong>to</strong>ry Integration Guidelines and Standards<br />

• Guideline development<br />

• Standards coordination<br />

Fac<strong>to</strong>ry Integration Interoperability Test Bed<br />

• Pro<strong>to</strong>type wafer handling and fac<strong>to</strong>ry<br />

interface facility and testing<br />

July 16, 2008 31


<strong>ISMI</strong> <strong>450mm</strong> Strategic Planning<br />

• <strong>ISMI</strong>’s <strong>450mm</strong> strategic roadmap targets<br />

capabilities required for 2012 pilot line<br />

• Enabling components of this target include:<br />

– Fac<strong>to</strong>ry Integration test data for robust standards<br />

– Guidance on equipment and fac<strong>to</strong>ry aspects<br />

– Test wafer generation and metrology capability<br />

– Equipment demonstration guidance<br />

– Improvement of silicon quality and availability<br />

July 16, 2008 32


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

Guidelines Update and<br />

Interoperability Test Bed<br />

Results<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Fac<strong>to</strong>ry Integration Guideline<br />

Summary<br />

The <strong>450mm</strong> Guidelines and Standards team has<br />

developed significant clarifying detail in H1’08 in <strong>the</strong><br />

following areas:<br />

• <strong>450mm</strong> Carrier Design (<strong>ISMI</strong> Unified GL’s #2 and #3)<br />

– Purge retention, carrier ID, carrier “run card” pocket, carrier<br />

vibration, wafer pitch/carrier height<br />

• <strong>450mm</strong> Wafer Handling (<strong>ISMI</strong> GL #2)<br />

– Wafer backside contact area & carrier constraint zones<br />

• <strong>450mm</strong> Material Handling Guidelines (<strong>ISMI</strong> GL #4)<br />

– Manual handling design for carrier<br />

Clarification <strong>to</strong> guidelines will be discussed at <strong>the</strong> <strong>ISMI</strong><br />

<strong>450mm</strong> Guidelines and Test Bed Project Report-Out<br />

following this <strong>Briefing</strong> from 3:00~6:00 P.M.<br />

July 16, 2008 34


SEMI IPIC Inputs :<br />

Testing/Evaluation Areas of Interest<br />

Inputs <strong>to</strong> <strong>ISMI</strong> for consideration in testing/evaluation of pro<strong>to</strong>types/test bed in<br />

areas that are of interest <strong>to</strong> 450 IPIC TF<br />

– KC pin and groove interface due <strong>to</strong>:<br />

• Carrier weight<br />

• Pin shape and Groove shape design compatibility<br />

• Theta/lead-in for carrier seating<br />

– Validate wafer pitch and wafer pickup, set down, extraction volume, etc.<br />

based on blue ballot definitions/parameters:<br />

• 1st step: Initial feasibility of <strong>the</strong> values in <strong>the</strong> blue ballot, especially for wafer<br />

pitch<br />

• 2nd step: Direction on how <strong>to</strong> account for long term variations of carriers and<br />

<strong>to</strong>ols?<br />

– <strong>ISMI</strong> share <strong>the</strong> test setup/conditions when <strong>the</strong> data is published:<br />

• Type of end-effec<strong>to</strong>r, range of end-effec<strong>to</strong>rs, etc.<br />

• The more information about <strong>the</strong> parameters <strong>the</strong> better we are in a position <strong>to</strong><br />

confirm <strong>the</strong> assumptions in <strong>the</strong> blue ballot, i.e., end-effec<strong>to</strong>r variation, wafer<br />

deflection, etc.<br />

<strong>ISMI</strong>’s Interoperability Test Bed is working closely with <strong>the</strong> SEMI IPIC Task Force <strong>to</strong><br />

enable data-based standards<br />

July 16, 2008 35


<strong>ISMI</strong> Carrier Metrics and Testing<br />

Items<br />

Wafer <strong>to</strong> End<br />

effecter<br />

clearance<br />

FOUP critical<br />

dimensions<br />

Weight and CG<br />

Transport Flange<br />

Backside Wafer<br />

Support<br />

25 Wafer<br />

Capacity<br />

Hardware currently at <strong>the</strong><br />

<strong>ISMI</strong> Test Bed under test<br />

Removable<br />

manual<br />

handles<br />

Carrier ID<br />

Purging<br />

Wafer Pitch<br />

Door Interoperability<br />

Conveyor Rails<br />

Info pads<br />

Kinematic<br />

couplings<br />

July 16, 2008 36


EFEMs / Loadport Metrics and<br />

Testing Items<br />

Wafer<br />

rotation<br />

and sag<br />

End Effec<strong>to</strong>r<br />

thickness and sag<br />

Precise,<br />

accurate &<br />

repeatable<br />

placement<br />

Pitch<br />

Budget<br />

EFEMs max<br />

thru-put<br />

FIMS Std.,<br />

door opening<br />

cycle time<br />

& req’d<br />

closure force<br />

Carrier<br />

purging<br />

Capability<br />

RFID Exclusion<br />

Space<br />

Hardware currently at <strong>the</strong> <strong>ISMI</strong><br />

Test Bed under test<br />

ESD Prevent<br />

= Ω Grounding<br />

Slot integrity<br />

& material<br />

redirect mode<br />

BOLTS Std.<br />

Dimensions<br />

Loadport Std.<br />

Dimensions<br />

July 16, 2008 37


Joint <strong>ISMI</strong> & ITG-Japan Statement<br />

• <strong>ISMI</strong>’s Interoperability Test Bed (ITB) and <strong>the</strong> Japan<br />

Interoperability Test Group teams (ITG-J) have agreed <strong>to</strong><br />

develop a constructive and cooperative relationship related <strong>to</strong><br />

<strong>450mm</strong> fac<strong>to</strong>ry integration standards.<br />

• This relationship will combine <strong>the</strong> strengths of both<br />

organizations <strong>to</strong> focus on standards related <strong>to</strong> <strong>450mm</strong> carriers,<br />

loadports, EFEMs and AMHS.<br />

• Both efforts intend <strong>to</strong> provide complementary test reports <strong>to</strong> <strong>the</strong><br />

related standard committees and/or task forces using common<br />

test methods <strong>to</strong> enable data-based <strong>450mm</strong> standardization.<br />

• We believe that <strong>the</strong> <strong>ISMI</strong> ITB and ITG-Japan efforts can benefit<br />

from each o<strong>the</strong>r and advance industry knowledge for <strong>450mm</strong>.<br />

July 16, 2008 38


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

Silicon Studies<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Polysilicon Sag Comparison <strong>to</strong> Single<br />

Crystal<br />

<strong>450mm</strong><br />

Polycrystalline<br />

Silicon<br />

300mm<br />

925µm<br />

START<br />

925µm<br />

CUT<br />

300mm<br />

775µm<br />

GRIND<br />

Single Crystal<br />

Silicon<br />

Sag = 84 µm<br />

Polycrystalline<br />

Silicon<br />

Sag = 85 µm<br />

COMPARE<br />

Same support<br />

configuration<br />

• Sag of polysilicon wafers are representative of single crystal<br />

• <strong>450mm</strong> tests will occur once single crystal wafers are obtained<br />

July 16, 2008 40


<strong>450mm</strong> Support Method Effect on Sag<br />

FULL PERIPHERY SUPPORT<br />

CANTILEVER SUPPORT<br />

Center<br />

950μm<br />

Bowl shape<br />

500μm<br />

430μm<br />

Saddle shape<br />

850μm<br />

• Wafer sag is highly dependent on wafer support and wafer thickness<br />

• Data on actual pro<strong>to</strong>type FOUP supports will be collected within <strong>the</strong><br />

<strong>ISMI</strong> Test Bed<br />

July 16, 2008 41


Si Wafer Bank – <strong>450mm</strong> Poly Wafers<br />

Inven<strong>to</strong>ry # of Loans # of Wafers Loaned # Available<br />

97 11 70 27<br />

Testing Examples<br />

• Wafer Sag • Wafer Handling • Shipping • Wafer Pitch • Shock / Vibration<br />

Statement<br />

Statement<br />

of<br />

of<br />

Work<br />

Work<br />

(SOW)<br />

(SOW)<br />

•<br />

•<br />

# of<br />

of<br />

Wafers<br />

Wafers<br />

•<br />

•Loan<br />

Loan Length<br />

Length<br />

•<br />

•<br />

Test<br />

Test<br />

Plans<br />

Plans<br />

<strong>ISMI</strong><br />

Approval<br />

Ship<br />

Wafers<br />

Test<br />

Results<br />

Return<br />

Wafers<br />

Polysilicon wafers are available for loan <strong>to</strong> suppliers from <strong>ISMI</strong><br />

Contact: Michael Bishop, michael.bishop@ismi.sematech.org<br />

July 16, 2008 42


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

Supplier Engagement<br />

Summary<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


2008 Production Equipment<br />

Supplier Engagement Activity<br />

• High-level engagement with process and metrology<br />

supplier management<br />

– Description of <strong>ISMI</strong> <strong>450mm</strong> program structure, progress and<br />

plans for 2008<br />

– Understand suppliers concerns, plans and needs<br />

• Various types of meetings <strong>to</strong> engage effectively<br />

– Individual supplier meetings for information sharing<br />

>20 suppliers met and scheduled<br />

– Periodic workshops on Guidelines and Test Bed progress <strong>to</strong><br />

keep interested suppliers informed of new developments and<br />

data<br />

– Continue briefings at major forums (SEMICON West, <strong>ISMI</strong><br />

Symposium, SEMICON Japan, etc.)<br />

July 16, 2008 44


Overview of Individual Production<br />

Equipment Supplier Engagements<br />

• Suppliers briefed on <strong>ISMI</strong> <strong>450mm</strong> program and<br />

requested continued interaction and updates<br />

• Discussed concerns on business issues<br />

• Requests for information about timing, technology<br />

node and equipment performance requirements<br />

• Requests for <strong>ISMI</strong> <strong>to</strong> coordinate test wafer<br />

generation and metrology availability<br />

• Some suppliers have already done detailed<br />

studies on <strong>450mm</strong> technical challenges<br />

• Proposals for early <strong>to</strong>ols have been received<br />

July 16, 2008 45


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

2009 Outlook and Beyond<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


2009 Outlook & Beyond<br />

• Silicon development and testing activities will shift <strong>to</strong> single<br />

crystal for process test and production grade wafers<br />

• Expanded scope of Interoperability Test Bed activities,<br />

continued guideline clarification, and interaction with SEMI<br />

task forces<br />

• Increased scope of <strong>450mm</strong> EHS analysis<br />

• Investigation of <strong>450mm</strong> operational challenges<br />

• Expanded interactions with process and metrology<br />

suppliers <strong>to</strong> enable equipment development<br />

– Discuss evolving business concerns<br />

– Discussions on equipment performance requirements<br />

– Test wafer generation and metrology capability<br />

July 16, 2008 47


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

Key Messages<br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Key Messages<br />

• Samsung, tsmc and Intel are committed <strong>to</strong> <strong>the</strong> <strong>450mm</strong><br />

wafer size transition and are working with <strong>ISMI</strong> <strong>to</strong> realize a<br />

2012 pilot line target date.<br />

• Development of <strong>450mm</strong> silicon wafers is progressing from<br />

sintered mechanical handling test wafers <strong>to</strong> single crystal<br />

wafers in 2008<br />

– 100 mechanical handling test wafers have been delivered <strong>to</strong> <strong>ISMI</strong><br />

for measurement and ITB testing<br />

– 5 different thicknesses have been received and are being<br />

measured for mechanical properties<br />

– Wafers are available for loan and have been loaned<br />

– Sag of polysilicon wafers are comparable <strong>to</strong> single crystal<br />

July 16, 2008 49


Key Messages (continued)<br />

• <strong>ISMI</strong>’s Interoperability Test Bed is underway on fac<strong>to</strong>ry<br />

interface testing<br />

– Suppliers have signed contracts for demonstrations of pro<strong>to</strong>type<br />

hardware in <strong>ISMI</strong>’s Austin lab with more under discussion.<br />

– Pro<strong>to</strong>type hardware has been received at <strong>ISMI</strong> and is under test<br />

– Test Bed User’s Group discussing interoperability challenges<br />

– Agreement <strong>to</strong> work with Japan’s Interoperability Test Group<br />

• Clarifications <strong>to</strong> 19-Point Unified Guidelines that relate <strong>to</strong><br />

<strong>450mm</strong> are being provided for improved understanding<br />

and early discussion of challenges<br />

– Constructive two-way exchanges with SEMI IPIC Task Force<br />

– Information and proposals reviewed with individual suppliers and<br />

ESG<br />

– <strong>ISMI</strong> Report Out will follow this <strong>Briefing</strong> at 3:00 P.M.<br />

July 16, 2008 50


Key Messages (continued)<br />

• <strong>ISMI</strong> is assessing <strong>the</strong> Environmental, Health and Safety<br />

related challenges for <strong>450mm</strong> realization<br />

– Environmental challenges, carrier handling, ergonomics and fall<br />

protection<br />

• <strong>ISMI</strong> is engaging with <strong>the</strong> industry and suppliers in several<br />

ways at different levels on <strong>450mm</strong><br />

– <strong>Briefing</strong>s and workshops at industry forums<br />

– Continued interactions in SEMI Standards forums<br />

– Expanded engagement with production equipment suppliers<br />

– Continued engagement with fac<strong>to</strong>ry interface and silicon<br />

infrastructure suppliers<br />

July 16, 2008 51


For more Information…<br />

• This presentation material will be made available<br />

for download at <strong>the</strong> SEMATECH public website:<br />

www.ismi.sematech.org<br />

Meetings and News – Past Meeting Proceedings –<br />

<strong>ISMI</strong> <strong>Industry</strong> <strong>Briefing</strong>s<br />

• To initiate individual discussions with <strong>the</strong> <strong>ISMI</strong><br />

Team, please contact:<br />

– Tom Abell, <strong>450mm</strong> Program Manager<br />

(<strong>to</strong>m.abell@ismi.sematech.org)<br />

– Denis Fandel, <strong>450mm</strong> Project Manager<br />

(denis.fandel@ismi.sematech.org)<br />

July 16, 2008 52


SEMICON West 2008<br />

Accelerating Manufacturing Productivity<br />

Conclusion<br />

Questions and Answers<br />

Joe Draina<br />

Direc<strong>to</strong>r, <strong>ISMI</strong><br />

Copyright ©2008<br />

SEMATECH, Inc. SEMATECH, and <strong>the</strong> SEMATECH logo are registered servicemarks of SEMATECH, Inc. International SEMATECH Manufacturing Initiative, <strong>ISMI</strong>, Advanced Materials Research Center<br />

and AMRC are servicemarks of SEMATECH, Inc. All o<strong>the</strong>r servicemarks and trademarks are <strong>the</strong> property of <strong>the</strong>ir respective owners.


Q & A<br />

July 16, 2008 54


For more Information…<br />

• This presentation material will be made available<br />

for download at <strong>the</strong> SEMATECH public website:<br />

www.ismi.sematech.org<br />

Meetings and News – Past Meeting Proceedings –<br />

<strong>ISMI</strong> <strong>Industry</strong> <strong>Briefing</strong>s<br />

• To initiate individual discussions with <strong>the</strong> <strong>ISMI</strong><br />

Team, please contact:<br />

– Olaf Ro<strong>the</strong><br />

(olaf.ro<strong>the</strong>@ismi.sematech.org)<br />

– Tom Abell<br />

(<strong>to</strong>m.abell@ismi.sematech.org)<br />

July 16, 2008 55

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