Advanced Silicon Processing & Manufacturing Techniques

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MODULE PROFILE

Module Number: 7

Title: Production Management

Delivered by: Heriot-Watt University

Module Credits: 15

Assessment Weighting:

  • Pre-residential work: 3
  • Post-residential work 7
  • Examination: 10

Convenor:

  • Dr Lynn Baxter, Heriot-Watt University

Lecturers/Tutors:
Internal:

  • Dr Lynn Baxter

External:

  • Professor Anthony Walton, University of Edinburgh
  • Dr Tom Stevenson, University of Edinburgh
  • Dr Ian Graham, University of Edinburgh

Industrial:

  • Mr Andy Stables, Freescale Semiconductors
  • Mr A McGibbon, National Microelectronics Institute
  • Mr Robin Thompson, Raytheon
  • Mr Jim Canning, National Seniconductor
  • Dr David MacNicol, 3tplus

Industrial Advisors:

  • Mr Andy Stables, Freescale Semiconductors
  • Mr Jim Canning, National Seniconductor

Aim:

The aim of this module is to introduce delegates to the principles of production management and provide descriptions of the equipment and tools that underpin the infrastructure for the processing that takes place within the cleanroom. Software tools for data analysis and simulation of production economics will be described

Learning Objectives:

On successful completion of this module, delegates will have:

  • an understanding of the principles of design and the operation of a silicon IC manufacturing facility.
  • become familiar with the use of CIM, factory simulation and COO software tools.
  • knowledge of the strategies for efficient distribution of process gases/chemicals and the safe disposal of by?products.
  • an understanding of the environmental issues involved in the handling and usage of gases/chemicals.

Assessment: Pre-residential sessions:

  • Assignments 15%
  • Post-residential sessions: assignments 35% Examination: (supervised) 50%

Background to the Module:

The design and efficient operation of a modern IC manufacturing plant, requires a detailed understanding of the process flow and control methods of the fabrication process. In this module computer software and the associated CAM systems will be utilised to simulate the flow of wafers during IC manufacture. Cost-of-ownership models and CAM software that are widely used in the IC fabrication industry will also give the participant the opportunity to use commercial factory simulation tools.

Pre-requisite Knowledge:

Text in the process of being drafted

Delivery & Assignments:

Copies of the lecture notes and other relevant literature will be provided along with associated electronic courseware. All documentation will be downloadable from restricted access pages on the World Wide Web or in paper-based format.

  • Pre-residential sessions:
    • A study pack will be sent to Delegates
    • Directed reading
    • Exercises
  •  

  • Residential week (35 hours contact time)
    • Lectures
    • Laboratory work using computer packages
    • Tutorials/case studies/factory visits
    • Exercises

     

  • Post-residential sessions:
    • Advanced tutorial questions
    • Written report (2000-4000 words)
    • Supervised examination (3 questions out of 5, 2 hours)

SYLLABUS

  • Lectures 26 hours
  • Laboratory sessions/case studies 8 hours

The breakdown of lectures covering the following topics is under development in preparation for delivery 2003, but will cover:

  • Production economics, WIP, cycle time, CIM systems and factory simulation.
  • Implementation of SPC in a wafer fab.
  • Implementation of Taguchi methods in a wafer fab.
  • Data analysis systems (e.g. RS/1, Cornerstone, SAS).
  • Yield management methods.
  • Technology evolution and roadmaps: economic and management implications.
  • Cost of ownership models.
  • Wafer handling, automation and SECS.
  • Cleanroom design, services and material distribution systems.
  • Equipment monitoring and optimisation, TPM.

Laboratory Sessions:

Laboratory sessions using industry standard software is a major component of this course. The simulation exercises will be run on the extensive network of Unix workstations within Heriot-Watt University.

Recommended Texts:

  • Toyota Production System, Ohio, T. Productivity Press, ISBN 0915299143
  • The Goal: A Process of Ongoing Improvement, Eliyahu Goldratt , Jeff Cox, ISBN 0566074184
  • Twentyfirst Century Manufacturing: Creating Winning Business Performance, Thomas G Gunn, O Wright Publications, ISBN 093924652X

Conference & Journal Papers:

'Reification and Representation in the Implementation of Quality Improvement Programmes', Baxter, Lynne F, Hirschhauser, Constanze, International Journal of Operations & Production Management, Volume 24 No: 2, 2004

TIMETABLE

NB: Details of module content, timetable and lecturers may be subject to change

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Module 7

 

   
Monday
Tuesday
Wednesday
Thursday
Friday
09.00 - 10.00

Introduction to the Module

 

The Cleanroom

 

Information Management

Fab Dynamics:
Throughput/ Bottleneck Management

Fab Dynamics:
Headcount/People Management

10.00 - 11.00

Global manufacturing and supply chains. Current Best Practice
Fab design
Information Management in Practice

Work in Process Management

Productivity
11.00 - 11.15
COFFEE
COFFEE
COFFEE
COFFEE
COFFEE
11.15 - 12.15
Strategic manufacturing objectives for Fabs: SIA roadmaps
Fab Layout
Japanese Production Management Techniques (1)

Materials Flow in Proctice

Managing Change & Innovation (1)

12.15 - 13.00
Mapping Supply Chains & Processes
Preventative Maintenance
Japanese Production Management Techniques (2)
Performance Management
Managing Change & Innovation (2)
13.00 - 14.00
LUNCH
LUNCH
LUNCH
LUNCH
LUNCH
14.00 - 15.00

The Changing Semiconductor Supply Chain

Production Planning

Factory Tour
Cycle Time Reduction
Future Dirtections
Wrap-up Session
15.00 - 15.15
TEA
TEA
ditto
TEA
TEA
15.15 - 16.15
Design for Manufacture
Capacity Management
Factory Tour
Simultaneous Engineering
Course Ends
16.15 - 17.15
Identification of Topics & Problems
to be addressed during the week
Simulation Exercise
Debrief
Value Analysis
19.30 COURSE BANQUET
Enquiries and further information from:

Mrs Sandra Peace
IGDS Programme Co-ordinator,
IGDS Office
School of Electronics & Physical Sciences
University of Surrey
Guildford
Surrey
GU2 7XH UK

Tel +44 (0)1483 686 138
Fax +44 (0)1483 686 139
e-mail: s.peace@surrey.ac.uk
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