Managing CI in a New Work Environment Profiler Automation … · Analog Devices Confidential...

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Managing CI in a New

Work Environment –

Profiler Automation Case

Study & Learnings Patrick Kavanagh – Manufacturing Supervisor IPD

Patrick Kennedy – Manufacturing Team Member

Sept FY17

AGENDA

► Introduction to Analog Devices

► Orange Fab – Move from Development to Production – What Bugs you ?

► Continuous Improvement – Profiler Automation – Pat Kennedy

► Observations & Lessons Learnt

► Questions

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Analog Devices Confidential Information.

©2016 Analog Devices, Inc. All rights reserved.

Global Front End Internal Operations and Technology

ADI Limerick Campus – 41Years in Ireland

European Research &

Development Centre

Limerick Manufacturing

Facility

IPD

5

ADI Markets – Products & Customers

WHITE FAB

ORANGE FAB

Wafer Level

Processing

For Signal Chain

Technology

Fully Isolated Lines

Limerick Manufacturing Facility

8FAB

8” IPD + KGD FAB

Limerick Manufacturing Facility

Analog Devices Proprietary and Confidential Information

Orange Fab IPD – What we do

► i Coupler products are used for voltage isolation between circuit components. They allow two parts of

a circuit to interact and pass information and communicate while operating at different voltage levels

► Started as a Development fab

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Significant output ramp

How we tackled our approach to this project.

In reviewing different approaches to implementing this project, it was determined to be within the

scope of the existing Engineering group and so an in-house solution was developed in conjunction

with the Engineering & Manufacturing teams.

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Automated solution to

measurement issues on profiler

tool in IPD.

Patrick Kennedy


©2016 Analog Devices, Inc. All rights reserved. 11

Meet the Team

►Project Sponsor – Martin O Halloran

►Project Support – Jason O Neill

►Team:

Patrick Kennedy

Mike Osiak

Patrick Kavanagh

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Introduction – My background

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► I have worked for Analog devices for the past 13 years.

► My role as a manufacturing team member ( MTM) in the defect area until 2015 (White

Fab)

► I Was in the defect WorkCentre with a responsibility for quality and visual inspection &

tool setups.

► Transferred down to IPD area in 2015 to support ramp up.

► Daily duties involve working across a variety of areas in a cross functional environment.

► I am currently a member of the ongoing Continuous Improvement team in IPD.

► This idea came from my observations of the engineers and the setups that they were

doing on a tool in one of my areas. ( The Profiler )

► I was confident that I could implement a solution to ongoing work practices that could

improve the utilization of the profiler tool.

Background Information on our project.

► What is a Profiler Tool?

The KLA-Tencor HRP is tool is used to check the “profile” of the surface of a wafer.

Typical measurements are taken of thickness/stack height of polyimide post cure and also copper and gold

roughness post electroplating in the IPD area.

► Taking Measurements: Current Approach

An MTM manually takes measurements when completing checks.

Average time taken 25min per lot.

► Automating Measurement:

As part of continuous improvements in the Manufacturing areas and to further enhance data collection

methods, an automated measurement solution on the Profiler tool was considered in the IPD area.

This will significantly reduce time spent collecting data at the tool.

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KLA-Tencor HRP

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► Measures Step Height

► Multiple Materials

► Limited automation capability

► Accuracy Critical

► Manual Operation

► 25 mins per Lot

Human Hair

70um – 80um

Our Fishbone Diagram – Brainstorming sessions.

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Describe the Goals and Secondary Measures

Goals

Goal 1 : Implement a setup on the Profiler tool to ensure all jobs are automated

Goal 2: Target time saving of 20hrs per week

Goal 3: Capture new process in a controlled document

Goal 4: Train all users on new system by Q317

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Benefits of Data Automation

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Benefits

Of Automation Tool Efficiency

Increase system

capability Improved

utilisation of

MTM’s time

Improve cycle

time

Increase job

satisfaction

levels

Eliminate risk

Conclusion: Implementing an automated measurement solution the Profiler Tool

provides multiple benefits and improves the overall efficiency of the fab operation.

We Developed A High Level Plan

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Define system requirements

Setup automatic jobs with

engineering support

Implement and pilot test

Gather learnings and update system

as required

Implement Phase 2 : Update Spec to

reflect new measurement procedures

Communicate project to users and train users

We Reviewed the Results and Secondary Measures

►Results.

Goal: Implement a setup on the Profiler tool to ensure all jobs are automated

Result 1: Automate data collection step on Profiler tool

Goal:15 – 20hrs saved per week

Result 2: last week 58hrs work went through our automated setups. .

Goal: Capture new process in a controlled document

Result 3: Standardise and document process

Goal: All users trained on new system

Result 4: Training

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Reflection And Next Steps

►Managing CI in a New Work Environment our lessons learned

Very worthwhile & interesting project to undertake.

Good optimisation of existing resources.

Positive feedback from all groups shared learning experience

Great cross collaboration across groups – Manufacturing/ Engineering/Equipment.

Met with the general manager at a weekly op ex meetings

We know we have a wealth of new talent and new ideas in IPD

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