CTI - Proceedings of the 1998 Winter Simulation Conference...

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Proceedings of the 1998 Winter Simulation Conference D.J. Medeiros, E.F. Watson, J.S. Carson and M.S. Manivannan, eds. EFFECTIVE IMPLEMENTATION OF CYCLE TIME REDUCTION STRATEGIES FOR SEMICONDUCTOR BACK-END MANUFACTURING Joerg Domaschke Steven Brown Siemens AG, HL MS Balanstrasse 73 Munich 81541, GERMANY Jennifer Robinson C2MS Productivity Solutions 7171 Buffalo Speedway #639 Houston, Texas, 77025, U.S.A. Franz Leibl Siemens Microelectronics Center Koenigsbruecker Strasse 180 Dresden 01099, GERMANY ABSTRACT Using discrete-event simulation models, a study was conducted to evaluate the current production practices of a high-volume semiconductor back-end operation. The overall goal was to find potential areas for productivity improvement that would collectively yield a 60% reduction in manufacturing cycle time. This paper presents the simulation methodology and findings pertaining to analysis of the Assembly, Burn-In, and Test operations. Many of the recommendations identified can be implemented at no additional cost to the factory. The most significant opportunities for improvement are in the Test area, the system constraint. Additionally, the model is extremely sensitive to changes in operator staffing levels, an accurate reflection of many back-end operations. The model shows that the cumulative impact of these recommendations is a 41% reduction in average cycle time, a significant contribution to the overall goal. 1 INTRODUCTION The application of modeling and simulation for factory performance analysis is in the beginning stages in the semiconductor industry, relative to device and process modeling [ Moore, 1997 ] . However, the National Technology Roadmap now identifies modeling and simulation as critical needs in the area of factory integration [ Semiconductor Industry Association, 1997 ] . The Next-Generation Manufacturing Project Team goes even further in their discussion of pervasive modeling and simulation, predicting that all future production decisions will be made on the basis of modeling and simulation methods [ The Agility Forum, 1997 ] . Modeling and simulation are becoming particularly critical for back-end operations. As yields and efficiencies from wafer fabs continue to increase, more attention is directed towards the ability of semiconductor back-end factories to handle the load with minimum capital expenditures. Throughput, utilization, and cycle time continue to be emphasized as key performance parameters for existing operations and for the complex planning of new facilities. Because static models cannot adequately handle this level of analysis, managers are turning more to simulation. Figure 1 shows a typical semiconductor production flow. Siemens’ Semiconductor Division has recently used a simulation approach to address a classic capacity issue. The Dresden, Germany wafer fab has experienced a
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CTI - Proceedings of the 1998 Winter Simulation Conference...

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