Development and Simulation Assessment of Semiconductor Production System Enhancements for Fast Cycle Times

Long cycle times in semiconductor manufacturing represent an increasing challenge for the industry and lead to a growing need of break-through approaches to reduce it. Small lot sizes and the conversion of batch processes to mini-batch or single-wafer processes are widely regarded as a promising means for a step-wise cycle time reduction. Our analysis with discrete-event simulation and queueing theory shows that small lot size and the replacement of batch tools with mini-batch or single wafer tools are beneficial but lot size reduction lacks persuasive effectiveness if reduced by more than half. Because the results are not completely convincing, we develop a new semiconductor tool type that further reduces cycle time by lot streaming leveraging the lot size reduction efforts. We show that this combined approach can lead to a cycle time reduction of more than 80%

Smart Sustainable Manufacturing Systems

With the advent of disruptive digital technologies, companies are facing unprecedented challenges and opportunities. Advanced manufacturing systems are of paramount importance in making key enabling technologies and new products more competitive, affordable, and accessible, as well as for fostering their economic and social impact. The manufacturing industry also serves as an innovator for sustainability since automation coupled with advanced manufacturing technologies have helped manufacturing practices transition into the circular economy. To that end, this Special Issue of the journal Applied Sciences, devoted to the broad field of Smart Sustainable Manufacturing Systems, explores recent research into the concepts, methods, tools, and applications for smart sustainable manufacturing, in order to advance and promote the development of modern and intelligent manufacturing systems. In light of the above, this Special Issue is a collection of the latest research on relevant topics and addresses the current challenging issues associated with the introduction of smart sustainable manufacturing systems. Various topics have been addressed in this Special Issue, which focuses on the design of sustainable production systems and factories; industrial big data analytics and cyberphysical systems; intelligent maintenance approaches and technologies for increased operating life of production systems; zero-defect manufacturing strategies, tools and methods towards online production management; and connected smart factories

Design and Management of Manufacturing Systems

Although the design and management of manufacturing systems have been explored in the literature for many years now, they still remain topical problems in the current scientific research. The changing market trends, globalization, the constant pressure to reduce production costs, and technical and technological progress make it necessary to search for new manufacturing methods and ways of organizing them, and to modify manufacturing system design paradigms. This book presents current research in different areas connected with the design and management of manufacturing systems and covers such subject areas as: methods supporting the design of manufacturing systems, methods of improving maintenance processes in companies, the design and improvement of manufacturing processes, the control of production processes in modern manufacturing systems production methods and techniques used in modern manufacturing systems and environmental aspects of production and their impact on the design and management of manufacturing systems. The wide range of research findings reported in this book confirms that the design of manufacturing systems is a complex problem and that the achievement of goals set for modern manufacturing systems requires interdisciplinary knowledge and the simultaneous design of the product, process and system, as well as the knowledge of modern manufacturing and organizational methods and techniques

Prognostic Algorithms for Condition Monitoring and Remaining Useful Life Estimation

To enable the benets of a truly condition-based maintenance philosophy to be realised, robust, accurate and reliable algorithms, which provide maintenance personnel with the necessary information to make informed maintenance decisions, will be key. This thesis focuses on the development of such algorithms, with a focus on semiconductor manufacturing and wind turbines. An introduction to condition-based maintenance is presented which reviews dierent types of maintenance philosophies and describes the potential benets which a condition- based maintenance philosophy will deliver to operators of critical plant and machinery. The issues and challenges involved in developing condition-based maintenance solutions are discussed and a review of previous approaches and techniques in fault diagnostics and prognostics is presented. The development of a condition monitoring system for dry vacuum pumps used in semi- conductor manufacturing is presented. A notable feature is that upstream process mea- surements from the wafer processing chamber were incorporated in the development of a solution. In general, semiconductor manufacturers do not make such information avail- able and this study identies the benets of information sharing in the development of condition monitoring solutions, within the semiconductor manufacturing domain. The developed solution provides maintenance personnel with the ability to identify, quantify, track and predict the remaining useful life of pumps suering from degradation caused by pumping large volumes of corrosive uorine gas. A comprehensive condition monitoring solution for thermal abatement systems is also presented. As part of this work, a multiple model particle ltering algorithm for prog- nostics is developed and tested. The capabilities of the proposed prognostic solution for addressing the uncertainty challenges in predicting the remaining useful life of abatement systems, subject to uncertain future operating loads and conditions, is demonstrated. Finally, a condition monitoring algorithm for the main bearing on large utility scale wind turbines is developed. The developed solution exploits data collected by onboard supervisory control and data acquisition (SCADA) systems in wind turbines. As a result, the developed solution can be integrated into existing monitoring systems, at no additional cost. The potential for the application of multiple model particle ltering algorithm to wind turbine prognostics is also demonstrated

Semantic data integration for supply chain management: with a specific focus on applications in the semiconductor industry

Supply Chain Management (SCM) is essential to monitor, control, and enhance the performance of SCs. Increasing globalization and diversity of Supply Chains (SC)s lead to complex SC structures, limited visibility among SC partners, and challenging collaboration caused by dispersed data silos. Digitalization is responsible for driving and transforming SCs of fundamental sectors such as the semiconductor industry. This is further accelerated due to the inevitable role that semiconductor products play in electronics, IoT, and security systems. Semiconductor SCM is unique as the SC operations exhibit special features, e.g., long production lead times and short product life. Hence, systematic SCM is required to establish information exchange, overcome inefficiency resulting from incompatibility, and adapt to industry-specific challenges. The Semantic Web is designed for linking data and establishing information exchange. Semantic models provide high-level descriptions of the domain that enable interoperability. Semantic data integration consolidates the heterogeneous data into meaningful and valuable information. The main goal of this thesis is to investigate Semantic Web Technologies (SWT) for SCM with a specific focus on applications in the semiconductor industry. As part of SCM, End-to-End SC modeling ensures visibility of SC partners and flows. Existing models are limited in the way they represent operational SC relationships beyond one-to-one structures. The scarcity of empirical data from multiple SC partners hinders the analysis of the impact of supply network partners on each other and the benchmarking of the overall SC performance. In our work, we investigate (i) how semantic models can be used to standardize and benchmark SCs. Moreover, in a volatile and unpredictable environment, SC experts require methodical and efficient approaches to integrate various data sources for informed decision-making regarding SC behavior. Thus, this work addresses (ii) how semantic data integration can help make SCs more efficient and resilient. Moreover, to secure a good position in a competitive market, semiconductor SCs strive to implement operational strategies to control demand variation, i.e., bullwhip, while maintaining sustainable relationships with customers. We examine (iii) how we can apply semantic technologies to specifically support semiconductor SCs. In this thesis, we provide semantic models that integrate, in a standardized way, SC processes, structure, and flows, ensuring both an elaborate understanding of the holistic SCs and including granular operational details. We demonstrate that these models enable the instantiation of a synthetic SC for benchmarking. We contribute with semantic data integration applications to enable interoperability and make SCs more efficient and resilient. Moreover, we leverage ontologies and KGs to implement customer-oriented bullwhip-taming strategies. We create semantic-based approaches intertwined with Artificial Intelligence (AI) algorithms to address semiconductor industry specifics and ensure operational excellence. The results prove that relying on semantic technologies contributes to achieving rigorous and systematic SCM. We deem that better standardization, simulation, benchmarking, and analysis, as elaborated in the contributions, will help master more complex SC scenarios. SCs stakeholders can increasingly understand the domain and thus are better equipped with effective control strategies to restrain disruption accelerators, such as the bullwhip effect. In essence, the proposed Sematic Web Technology-based strategies unlock the potential to increase the efficiency, resilience, and operational excellence of supply networks and the semiconductor SC in particular

PV Status Report 2012

Photovoltaics is a solar power technology to generate Electricity using semiconductor devices, known as solar cells. A number of solar cells form a solar "Module" or "Panel", which can then be combined to solar systems, ranging from a few Watts of electricity output to multi Megawatt power stations. The unique format of the Photovoltaic Status Report combines international up-to-date information about Research Activities with Manufacturing and Market Implementation Data of Photovoltaics. These data are collected on a regular basis from public and commercial studies and cross-checked with personal communications. Regular fact-finding missions with company visits, as well as meetings with officials from funding organisations and policy makers, complete the picture. Growth in the solar Photovoltaic sector has been robust. Yearly growth rates over the last decade were on average more than 40%, thus making photovoltaics one of the fastest growing industries at present. The PV Status Report provides comprehensive and relevant information on this dynamic sector for the public interested, as well as decision- makers in policy and industry.JRC.F.7-Renewable Energ

Attaining Knowledge Workforce Agility in a Product Life Cycle Environment using Real Options

The product life cycle (PLC) phenomenon has placed significant pressures on high-tech industries which rely heavily on the knowledge workforce in transferring cutting-edge technologies into products. This thesis examines systems where market changes and production technology advances happen frequently and unpredictably during the PLC, causing difficulties in predicting an appropriate demand on the knowledge workforce and in maintaining reliable performance. Knowledge workforce agility (KWA) is identified as a desirable means for addressing the difficulties, and yet previous work on KWA is incomplete. This thesis accomplishes several critical tasks for realizing the benefits of KWA in a representative PLC environment, semiconductor manufacturing. Real options (RO) is chosen as the approach towards exploiting KWA, since RO captures the essence of KWA-options in manipulating knowledge capacity, a human asset, or a self-cultivated organizational capability for pursuing interests associated with change. Accordingly, market demand change and workforce knowledge (WK) dynamics in adoption of technology advances are formulized as underlying stochastic processes during the PLC. This thesis models KWA as capacity options in a knowledge workforce and develops a RO approach of workforce training, either initial or continuous, for generating options. To quantify the elements of KWA that impact production, the role of the knowledge workforce in production and costs in obtaining KWA are characterized mathematically. It creates necessary RO valuation methods and techniques to optimize KWA. An analytical examination of the PLC models identifies that KWA has potential to reduce negative impacts and generate opportunities in an environment of volatile demand, and to compensate unreliable performance of knowledge workforce in adoption of technology advances. The benefits of KWA are especially important when confronting highly volatile demand, a low initial adoption level, shrinking PLCs, a growing market size, intense and frequent WK dynamics, insufficient learning capability of employees, or diminishing returns from investments in learning. The thesis further assesses RO, as an agility-driven approach, by comparing it to a chase-demand heuristic and to the Bass forecasting model under demand uncertainty. The assessment demonstrates that the KWA attained from the RO approach, termed RO-based KWA, leads to a stably higher yield, to a persistently larger net present value (NPV), and to a NPV distribution that is more robust to highly volatile demand. Subsequently, a quantitative evaluation of KWA value shows that the RO-based KWA creates a considerable profit growth, either with uncertainty in demand or in the WK dynamics. In evaluation, RO modeling and the RO valuation are identified to be useful in creation of KWA value especially in highly uncertain PLC environments. This thesis illustrates the effectiveness of the numerical methods used for solving the dynamic system problem. This research demonstrates an approach for optimizing KWA in PLC environments using RO. It provides an innovative solution for knowledge workforce planning in rapidly changing and highly unexpected environments. The work of this thesis is representative of studying KWA using quantitative techniques, where there is a dearth of quantitative studies in the literature

Knowledge management within a multinational knowledge led company

The semiconductor industry relies on knowledge sharing and collaboration between its employees and amongst subsidiary companies to remain competitive in an ever changing, market driven environment. Practise has changed from workers supplying labour to workers supplying knowledge. Technology improvements and investment in automation have provided companies the platform to generate, codify, harness and exploit knowledge as a means of improving organisational performance. This research explores knowledge dynamics in the organisation and specifically looks at knowledge sharing within a subsidiary and among subsidiaries in a multinational corporation. The corporation in question operates its manufacturing facilities as competing business units. The purpose of the research was to establish if this method of organising business units provides the overall corporation with a competitive advantage, or if competing business units inhibits performance preventing or restricting the potential for a competitive advantage for the corporation. To determine how knowledge is shared within the organisation a series of semi-structured interviews were conducted. Senior managers and professional staff across a number of disciplines were interviewed. Knowledge sharing within functional area departments, collaboration between functional area departments, knowledge systems and compliance to knowledge systems were used as determinants to establish the extent of the knowledge dynamic in the subsidiary. The relationship between knowledge sharing and how it impacted the “bottom line” performance of the subsidiary was also considered in an attempt to quantify the impact knowledge sharing has on performance. To determine how knowledge is shared between subsidiaries, two case studies were conducted. The first case study involved a benchmarking visit to allow two of the corporation’s subsidiaries to compare best practice cost systems with multi-disciplines involved. The second case study involved a cross functional team of technical staff to define a manufacturing facility technical yield roadmap. Significant cost, productivity and yield improvement at the site was attributed to the success of collaborative units established at site. Establishing collaborative units was a precursor to setting up a network within the site to promote knowledge sharing in the organisation. The site was cognisant of the impact of effective knowledge sharing and receptive to sharing knowledge on an informal or formal basis. The site put great stock in codified knowledge and invested heavily in automating knowledge based systems. Many barriers to knowledge sharing were identified including compliance to codified procedures, departmental conflicts, viewing knowledge sharing as a burden, variation across automated systems, conflicts caused by the internet as a knowledge source and logistics due to geographical dispersion. Knowledge-led teams overcame many of these barriers. Success bred success to the extent knowledge sharing has become a business process in the organisation. Knowledge sharing is a two way process. It can be a vehicle for trust, respect and improvement. This research has shown knowledge sharing even within competing business units can produce a competitive advantage. An organisation is an accumulation of knowledge. A knowledge-led collaborative approach provides many benefits: it will advance the company, engage staff at all levels and favourably impact the “bottom line”. Knowledge management differentiated the local site from other corporate subsidiaries with the local site demonstrating “best in class” results on its key performance indicators. Encouragingly, there is ample opportunity to improve performance further once knowledge management is fully embedded as a business process across the organisation