Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
This research is to develop a new approach to accelerate capacity increment from unexpected additional demand at semiconductor fabrication by 10%. The issue is from unpredictable demand at short notice to increase capacity by 10% in future period or as high as 35%historically. Current improvement...
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| Format: | Thesis |
| Language: | English |
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| Online Access: | http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/61624/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/61624/2/Full%20text.pdf |
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| Summary: | This research is to develop a new approach to accelerate capacity increment from
unexpected additional demand at semiconductor fabrication by 10%. The issue is from
unpredictable demand at short notice to increase capacity by 10% in future period or as
high as 35%historically. Current improvements practice for capacity increment such as
increase in equipment throughput, availability and manufacturing efficiency will take up
to six months to be effective are not able to solve this issues. This is due to the
processing steps that range from 300 to 1000 with cycle time 30 to 90 days. Plus, the
new improvements from equipment usually need data to verify electronically to
understand the impact from the product quality and reliability. The traditional
improvements from equipment are still relevant for medium or long-term solution.
Another approach for capacity increment is through investing in new or refurbished
equipment. Investing new equipment required Capital expenditure (CAPEX) range from
USD 20 to 30 million for additional capacity of 1,000 wafers per month. This huge
investment will takes up from 10 up 14 months for equipment ready to support
production and only afford by big scale companies. Newly popular strategy is to do
outsourcing to another fab, but again, initial stages needs six to nine months for product
to qualify for production, however when the outsourcing fab is qualified and fully
loaded, it is not guaranteed to absorb additional loading. Thus, make this research topic
valuable and significant for the situation current economic trends. The new approach is
based on the philosophy of borrowing the future capacity into current time when
immediate capacity increment is needed. As the capacity usually determine by total
number of processing steps that need to process at the constraint equipment, this
research concluded that the higher re-entrance steps caused lower the capacity of a fab
at exponential trend. Through similar approaches taken from specification from SEMI
and others literature the baseline capacity successfully developed at 22,511 wafers per
month. Therefore in this case to increase the capacity at a time, it needs lowered reentrance
steps, by recalculating the capacity not based plan order demand but by using
preferred WIP to reduce the impact from exponential impact. In order to this, the cycle
time and the equipment output needs to be integrated in production systems for real
time validation and the information then needs to store into databases and integrated
with simulation model for the system to be able identify immediately for the WIP that
able to help to increase the capacity with high accuracy planning. The data collection
and the simulation models used commercial software from Applied Material which is
Advance Productivity Family and AutoshedAP, that proven in this research at 97%
accuracy for 30 days output WIP forecasting. The simulation results in the models
successfully demonstrated accelerate capacity increment by 21%, and actual
implementation of capacity increment by 33% and the research meets its original
objective. |
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