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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Main Author:	Mohd Azizi, Chik
Format:	Thesis
Language:	English
Subjects:	Semiconductors Semiconductors industry Capacity increment Semiconductor fabrication
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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spelling	my-unimap-616242019-09-03T09:36:33Z Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry Mohd Azizi, Chik Professor Dr. Uda Hashim 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. Universiti Malaysia Perlis (UniMAP) 2015 Thesis en http://dspace.unimap.edu.my:80/xmlui/handle/123456789/61624 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/61624/1/Page%201-24.pdf 509447e00f8d3d30d53e203cf51ac92f http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/61624/2/Full%20text.pdf c106d34eb3e203eeff8444ec35c963bf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/61624/3/license.txt 8a4605be74aa9ea9d79846c1fba20a33 Semiconductors Semiconductors industry Capacity increment Semiconductor fabrication Institute of Nano Electronic Engineering
institution	Universiti Malaysia Perlis
collection	UniMAP Institutional Repository
language	English
advisor	Professor Dr. Uda Hashim
topic	Semiconductors Semiconductors industry Capacity increment Semiconductor fabrication
spellingShingle	Semiconductors Semiconductors industry Capacity increment Semiconductor fabrication Mohd Azizi, Chik Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
description	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.
format	Thesis
author	Mohd Azizi, Chik
author_facet	Mohd Azizi, Chik
author_sort	Mohd Azizi, Chik
title	Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
title_short	Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
title_full	Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
title_fullStr	Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
title_full_unstemmed	Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry
title_sort	developing incremental capacity during seasonal demand for technologies beyond 90 nm in semiconductor fabrication industry
granting_institution	Universiti Malaysia Perlis (UniMAP)
granting_department	Institute of Nano Electronic Engineering
url	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
_version_	1747836847552200704

Developing incremental capacity during seasonal demand for technologies beyond 90 NM in semiconductor fabrication industry

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