Operation Efficiency Best
Ji-Fu KungAssociate Vice President
12” Manufacturing GroupsMay 27 2015
UMC © 2013
Agenda
Manufacturing Profile Manufacturing Excellence Automotive Product Readiness Summary
2
Manufacturing Profile
UMC © 2013
Fab 12A Expansion
• P5/6 Construction completed • 50K wafers/month for 28nm
and below• State-of-the-art green fab
design
4
RDRDP1/P2P1/P2P3/P4P5/P6P5/P6
P7/P8P7/P8
RDP1/P2P3/P4P5/P6
P7/P8
• UMC R&D Center• Hefty Manufacturing
UMC © 2013
United Semi JV – Xiamen, China• First Taiwan foundry
to invest 12” Fab in China
• USD 6.2B Investment• 50K wpm, starting from
40nm and 55nm• UMC Ownership:
• 6/9 board seats• Management, Technology
and Operation
• Construction Underway• Production Start: Q4, 2016
Access vast China Market5
UMC © 2013
UMC/MIFS (Mie Fujitsu) Partnership• Relationship
• Established as co-foundry partners
• JV in Mie 300mm wafer fab, to expand its business globally as a pure-play foundry company
• Technology• 40nm low-power technology licensing
6
UMC © 2014
7
UMC’s 12” Expanding Geography
• Centrally located in Asia for efficient logistics and economy of scale
• Mitigate geographic risk
• Serve local market
Mie Fab Collaboration
Xiamen Fab Joint Venture
Tainan Fab 12A Phases 1-5
Singapore Fab 12i
UMC © 2014
8
Comprehensive Technology Portfolio
Logic/MS
RF
BCD
Updated Nov, 2014
CIS
eNVM
HV
.6um .5um .35um .25um .18um .15um .13um.11um
90nm80nm
65nm55nm
40nm 28nm 14nm
Available Developing JDP/Customization
10nm
MEMS
RF SOI uLP option
UMC © 2014
9
Selected as a DJSI Global Component for Seven Straight Years
Selected as a DJSI Global Component for Seven Straight Years
Recycle, Reduce and Reuse Approach to
Sustainability
Recycle, Reduce and Reuse Approach to
Sustainability
Participation in Global Carbon Footprint
Program
Participation in Global Carbon Footprint
Program
Building a Sustainable Future
UMC © 2013
Manufacturing Profile Summary
Sustainability
TechnologyCapacity
10
Manufacturing Excellence
UMC © 2013
12
• Awards of Taiwan Ministry of Economic Affair QIT Competition Since 2008
• 1st Place - 4 times• 2nd Place - 5 times• 3rd Place - 1 times
Soft Power to Cohesiveness and Quality
UMC © 2014
13
Quality Ctrl.
Equipment Automation
Facility Monitor
Auto. Material HandlingSystem
ManufacturingExecution System
DataAnalytics
Change Mgmt.
Dashboard Monitor
Production Ctrl.
Production Info.
System
Inte
rfac
e Fa
b C
ontr
ol
Fab
Man
agem
ent
Manufacturing Systems
• Fast response time, • Real-time data• Overall efficiency enhancement
• Optimized/Verified APC• High yield & quality • Low wastage
• Volume increase • Cycle time reduction
UMC © 2014
14
Manufacturing Optimization by Prediction
• Integrate online data• Predict WIP profile • Optimize dispatching
schedule
• Increase volume• Ensure on time delivery• Accelerate Time to Market
for Customer
Predictive Scheduling
Prediction
Optimization
BottleneckProcess Step n-1
Process Step nProcess Step n-2Process Step n-3
Real Time Dispatching
UMC © 2014
15
Effectiveness of MESMachine to Man Ratio
Unit : Quarter
Unit : QuarterCycle Time
UMC © 2014
16
Tool Management System
• Early equipment abnormality detection and prevention
• Tool performance prediction and Auto process Tuning
• Tools / Recipes Change Qualification
Robust Tool Management Model
Tool Management
Faul
t Det
ectio
n &
C
lass
ifica
tion
PM M
anagement &
PMQ
ATool Matching
R2R Control
Virtual Metrology
Recipe Mgmt
UMC © 2014
17
Effectiveness of Tool Management System
With the comprehensive tool management systems, we outpace benchmark in yield
UMC © 2013
18
First foundry in Taiwan certificates ISO 15408 Common Criteria EAL-6.
Security protection to Customers from design to manufacturing, from IP to silicon
Save costly time & resources of Customers’ security products certification
Fab 12i in Singapore, Q2’15
Highest Manufacturing Security Commitment
Validity : 2014/11/5 ~ 2016/11/4
ISO15408 EAL-6Taiwan (12A)
18
UMC © 2014
19
ProductionPhaseTransfer/Pilot Phase
Seamless Transition from R&D to Fab
Division
Qual. Lots Start
Process Qual. Passed
Product Qual. Passed
Phase
APQP •Planning •Product and process validation •Production
FabDevelopment Team
Verification/Validation PhaseProposal/Development
Phase
Check Point
Check list CTMR Voice, Process/Device Maturity,
Reliability & Production Readiness
UMC © 2014
20
Rapid DD Improvement Learning Curve
Node N
Node N+1Nor
mal
ized
DD
Rat
io
Time Line of DD Leaning by Quarterly
Node N+1 thr rapid DD learning Methodology
UMC © 2014
21
Efficient New Tech. Platform Porting
Gap Analysis: Raw material, Tool and Recipe and FMEA
1st Q
Matching: Physical & Electrical
3rd Q
5th QProduct Verification: Function,Yield & Reliability
6th Q Mass Production
Porting within 6Q
UMC © 2014
Successful Porting Stories
Project Kickoff
1stQ
2ndQ
3rdQ
4thQ
5thQ
6thQ
Matching & Process
Qual
Product Verification
& Qual
Gap analysis
Mass Production
J-F E-N U-4
22
Automotive Product Readiness
23
UMC © 2014
24
AUTO Quality Mindset & Culture
Board
Manager
Employee
Top-down
AUTO Quality Policy
Commitment of “Quality Principle”
MindsetEducation
Certification
UMC © 2014
25
Comprehensive Technology for AUTO IC
Logic/MS
RF
PMIC
Updated Sep, 2014
CIS
eNVM
HV
.6um .5um .35um .25um .18um .15um .13um.11um
90nm80nm
65nm55nm
40nm 28nm 14nm
Available Developing JDP/Customization
10nm
MEMS
Automotive Product
• 28/45nm ~0.5um AUTO in production
UMC © 2014
26
UMC Automotive Operation Package
System Management
• Identification• Data retention• PCM• 8D report• MRB• Early Alert• Audit
Outlier Control
• Tighten SPC• Preferred tools• Defect
scanning • Tighten WAT • AVI• Q-Time Control• Rescreen• Rework
DPPM Reduction
• SYL• SBL• PAT
UMC © 2014
27
Auto control
Auto
Non-Auto
Automotive Practice
UMC Generic Platform, 0.18um BCD/AEC-Q100 Grade-0
product Mass Production since 1Q’15
Pro
duct
DD
Time
UMC © 2014
Summary
28
2011
2009
2014
Qualcomm: UMC/Fab12i Outstanding Service Award
Parade: UMC/Fab8CD Manufacture Excellence Award
MediaTek: UMC/Fab12iBest Foundry Award
2012
XIX: UMCBest Supplier Award
ATMEL: UMC Top Rated Foundry Supplier
Lantiq: UMCBest Supplier Award
FARADAY: UMC/Fab 12i Partnership Award
2013 Lantiq: UMCBest Supplier Award
NXP: UMC/Fab12i Outstanding Manufacturing SupportSanDisk: UMC/Fab12i
Appreciation Award
XIX: UMC/Fab12AOutstanding Contribution to XIX
ATMEL: UMC Top Rated Foundry Supplier
XIX: UMC 2014Best Partner Quality Award
Thank You!
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