Qualifying A New Equipment for Enhanced Productivity and Safety

Semiconductor Manufacturing Efficiency / Increase productivity / Increase safety / CRB compliance

Content Table

• Introduction- Semiconductor manufacturing
  An Introduction to Semiconductor Manufacturing Efficiency
  
• Overview
  Qualification of equipment for semiconductor Manufacturing Efficiency
  Goals of our client
  Our approach
  Results
  
• Context
  Initial situation of our client in Semiconductor Manufacturing
• Practical overview on how qualified backup equipment enhances efficiency
  
• Our Approach
  Attaining Semiconductor Manufacturing Efficiency under CRB Compliance
  Execution of the qualification of standard applications Semiconductor Manufacturing Efficiency
  In-depth analysis: Microscopic Analysis and Result Validation
  Reporting and Data Analysis for Semiconductor Manufacturing Efficiency

• Results
  Semiconductor Manufacturing Efficiency Results

Introduction- Semiconductor manufacturing

The IC industry accounts for approximately 1.8% of global anthropic emissions.

According to reports, improving manufacturing efficiency, lowering emissions, and improving safety standards are C-level priorities for many semiconductor industries.  

In line with a similar objective , in this article, we share our experience of qualifying an equipment, while assuring quality and compliance with recognized regulatory body CRB.

The integration of a qualified backup equipment can significantly reduce the strain on operational resources by providing reliable and efficient alternatives in case of equipment failure or maintenance. This ensures uninterrupted production and reduces the need for frequent solvent swaps, ultimately boosting productivity and reducing costs associated with downtime.

By introducing a qualified backup equipment, semiconductor manufacturers can swiftly switch operations to the backup system during equipment maintenance or troubleshooting, mitigating the need for extended hold lots and minimizing the impact on the production line. This proactive approach ensures smoother production flow, accelerates time-to-market, and enhances the company’s competitive edge in the market.

Overview

Qualification of a new equipment for Semiconductor Manufacturing Efficiency

Goals of our client                      

• Reduce the chemical swaps by the qualification of a new backup equipment.
  With this:
  • Reduce the workload of operations due to the chemical swap
  • Reduce planned hold lots required due to the present chemical swap.

Our approach

• Verify that the equipment operationality within specified parameters.
• Evaluate the equipment’s performance in real-world scenarios.
• Perform Statistical analysis for valuable insights.
• Prepare a comprehensive qualification report.

Results

• Reduction of Workload in operations and solvent swaps.
• Better compatibility compared to the previous equipment.
• Quality assurance of the product along with accomplished environmental and safety compliance.

Context

Initial situation of our client

1. High workload
2. High demand for solvent swaps
3. High hold lots- These hold lots can induce: disruption in the production schedule, increase cycle time, impact overall efficiency.

One of the primary objectives of qualifying a new backup equipment is to

• alleviate the workload burden on operations
• minimize solvent swaps.

In this pursuit, the qualification of a new backup equipment emerged as a game-changer practice!

Our Approach

-) Attaining Semiconductor Manufacturing Efficiency under CRB Compliance

The Change Review Board (CRB) plays a vital role in managing and approving changes in the semiconductor industry. The project was adhered closely to the CRB-approved guidelines to ensure a controlled and standardized approach.

This involved a meticulous evaluation of the new equipment’s specifications, compatibility with existing processes, and impact on product quality. By following these guidelines, it was guaranteed that all necessary applications and procedures were thoroughly reviewed.

Hence, meeting the required standards!

-) Execution of the qualification of standard applications Semiconductor Manufacturing Efficiency

In the semiconductor industry, numerous applications must be qualified to ensure quality in their products. Each standard application of the project was processed with the new equipment. Ensuring, it’s validity!

-) In-depth analysis: Microscopic Analysis and Result Validation

In-depth analysis was conducted to assess the performance of the new equipment. Involving careful examining the samples produced by both the previous tool and the newly qualified equipment. By comparing the results, we could identify any variations in product quality, yield, or defects.

Our goal was to ensure that the new equipment perfectly matched the capabilities of its predecessor.

-) Reporting and Data Analysis for Semiconductor Manufacturing Efficiency

Transparency and clear communication were crucial throughout the qualification process. Comprehensive reports were prepared to document the findings, observations, and recommendations. These reports not only served as a record of the progress but also provided a reference for future evaluations.

Results

Based on a thorough analysis and microscopic examination, it was confirmed that the new equipment produced the same level of quality as its predecessor. This outcome was a testament to the careful planning, meticulous execution, and adherence to CRB guidelines throughout the qualification process.

Overall, by leveraging the new equipment, the semiconductor company gained advantages such as

• enhanced productivity
• improved efficiency
• increased process reliability

As the competition grows, regulations tightens and demands surge, efficient manufacturing can be one of the deciding factors that gives one firm an edge over the other!