System, method and program for designing a utility facility and method for manufacturing a product by the utility facility

A system for designing a utility facility includes a state analyzer analyzing operational states of tools included in a production line, an extraction module extracting an operational period and a standby period of each of the tools, a calculator calculating changes in a quantity of utilities consumed by the tools in operation and in standby, based on the operational periods and the standby periods, and a facility design module designing at least any of a utility facility for supplying utilities to the tools and a utility facility for disposing of utilities discharged from the tools.

This application is based upon and claims the benefit of priority from prior Japanese Patent Application P2005-263519 filed on Sep. 12, 2005; the entire contents of which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to facility design technology, particularly for a system, a computer implemented method and a computer program product for designing a utility facility, based on utility consumption of a production line.

2. Description of the Related Art

In the case of the related art, quantities of utilities, such as electricity and gases, which are used by tools for the production of products, are calculated by multiplying utility specification for usage of each tool, by corresponding coefficients (load factors), respectively. As is often the case, the utility specifications of each of the tools demand utilities larger than utilities actually consumed during operation. As a result, the total capacity for a designed utility facility is larger than the total quantity of utilities consumed by each of the tools included in the production line during operation.

As is often the case, the load factors are determined based on the experience of persons in charge of facility design. Usually, load factors tend to be surplus so that undersupply of respective utilities does not occur. The quantities of utility demanded, which have been calculated with surplus load factors, respectively, largely deviate from quantities of utilities consumed during actual operation. As a result, a utility facility with an unnecessarily large size is designed.

A utility facility once included in the factory is not capable of low capacity operation by reducing quantities of utilities to be supplied. For such reason, regardless of the quantities of utilities consumed by each of the tools and the number of products processed during actual operation, the utility facility continues operating with the designed quantities of utilities. Accordingly, running costs are kept almost constant. In a case where large utility specifications for usage are calculated, compared with utilities consumed during actual operations, the excessive capacity of the utility facility is large. For example, a production line for wafers, each with a diameter of 300 mm, indicates extremely large utility specifications, and the excessive capacity of a utility would be larger than ever. In this case, running costs become increased, and there also exists a problem from the viewpoint of energy savings when actual consumption is less than designed capacity.

The reduction of quantities has been examined for the quantity of utilities consumed by each of the tools included in the production line. However, the reduction of the quantities of utilities consumed by each of the tools and in the facility is within an excessive surplus set during the design of the utility facility. Thus, it is difficult to estimate how much effect will be achieved by reducing utilities in each of the tools. As a result, the reduced quantities of the utility have not been employed in the design stage of the utility facility.

As for an example similar to the foregoing explanation, the following method has been proposed. In such method, quantities of utilities consumed by each of the tools are calculated by a simulation using a virtual production line, and quantities of utilities to be supplied to a production line are determined. While the foregoing method can be applied to a production line already manufacturing products, the method cannot be applied to a production line in a production planning phase. Moreover, in the case of the foregoing method, a state in which each of the tools is in operation and a state in which the tools are in standby is not discriminated from each other. This makes it impossible to estimate accurate quantities of utilities to be respectively supplied.

SUMMARY OF THE INVENTION

An aspect of the present invention inheres in a system for designing a utility facility. The system includes a state analyzer configured to analyze operational states of a plurality of tools included in a production line for producing products, respectively, each of the operational states being assumed based on production information of the products; an extraction module configured to extract an operational period and a standby period of each of the tools, based on a result of the state analysis; a calculator configured to calculate changes in a quantity or an amount of utilities consumed by each of the tools with respect to time, based on quantities of utilities consumed by each of the tool in operation and in standby during the operational periods and the standby periods; and a facility design module configured to design at least any of a utility facility for supplying utilities to each of the tools and a utility facility for disposing of utilities discharged from each of the tools, based on the changes in the quantity of utilities consumed by the tools.

Another aspect of the present invention inheres in a computer implemented method for designing a utility facility. The method includes analyzing operational states of a plurality of tools included in a production line for producing products, respectively, each of the operational states being assumed based on production information of the products; extracting an operational period and a standby period of each of the tools, based on a result of the state analysis; calculating changes in a quantity of utilities consumed by each of the tools with respect to time, based on quantities of utilities consumed by each of the tools in operation and in standby during the operational periods and the standby periods; and designing at least any of a utility facility for supplying utilities to each of the tools and a utility facility for disposing of utilities discharged from each of the tools, based on the changes in the quantity of utilities consumed by the tools.

Still another aspect of the present invention inheres in a method for manufacturing a product. The method includes analyzing operational states of a plurality of tools included in a production line for producing products, respectively, each of the operational states being assumed based on production information of the products; extracting an operational period and a standby period of each of the tools, based on a result of the state analysis; calculating changes in a quantity of utilities consumed by each of the tools with respect to time, based on quantities of utilities consumed by each tool in operation and in standby during the operational periods and the standby periods; designing at least any of a utility facility for supplying utilities to each of the tools and a utility facility for disposing of utilities discharged from each of the tools, based on the changes in the quantity of utilities consumed by the tools; and manufacturing the products by use of the production line including the utility facility.

Still another aspect of the present invention inheres in a computer program product to be executed by a computer for designing a utility facility. The computer program product includes instructions configured to analyze operational states of a plurality of tools included in a production line for producing products, respectively, each of the operational states being assumed based on production information of the products; instructions configured to extract an operational period and a standby period of each of the tools, based on a result of the state analysis; instructions configured to calculate changes in a quantity of utilities consumed by each of the tools with respect to time, based on quantities of utilities consumed by each of the tools in operation and in standby during the operational periods and the standby periods; and instructions configured to design at least any of a utility facility for supplying utilities to each of the tools and a utility facility for disposing of utilities discharged from each of the tools, based on the changes in the quantity of utilities consumed by the tools.

DETAILED DESCRIPTION OF THE INVENTION

In the following descriptions, numerous specific details are set forth such as specific signal values, etc., to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits have been shown in block diagram form in order not to obscure the present invention in unnecessary detail.

First Embodiment

A system for designing a utility facility according to a first embodiment of the present invention includes a state analyzer11, an extraction module12, a calculator13and a facility design module14, as shown inFIG. 1. The state analyzer11analyzes operational states of a plurality of tools included in a production line for producing products, respectively. Each of the operational states is assumed based on production information of the products. The extraction module12extracts an operational period and a standby period of each of the tools on the basis of the result of the state analysis of the tools. Based on the operational periods and the standby periods, the calculator13calculates changes in a quantity of utilities consumed by each of the tools with respect to time, based on quantities of utilities consumed by each of the tools in operation and in standby. Based on changes in the quantity of utilities consumed by all of the tools with respect to time, the facility design module14designs at least any of a utility facility for supplying utilities to each of the tools and a utility facility for disposing of utilities discharged from each of the tools. As shown inFIG. 1, the state analyzer11, the extraction module12, the calculator13and the facility design module14are included in a central processing unit (CPU)10.

The “production information” includes a product mix which is a production plan for products, process information applied to the manufacturing of the products, information of types and numbers of tools included in the production line, tool operational state information, and the like. The “tool operational state information” includes information on maintenance frequency, time required for the maintenance, mean time between failures (MTBF), mean time to repair (MTTR) and the like with regard to each of the tools. The process information and the tool operational state information are acquired, for example, from information of an existing production line and the like. The “operational period” and the “standby period” are periods in which each of the tools included in the production line is respectively in operation and in standby.

FIG. 2shows an example of a product mix.FIG. 2shows a plan by which x wafers for a product A, y wafers for a product B and z wafers for a product C are intended to be produced each month.

FIG. 3shows an example of the process information.FIG. 3shows that a tool M1is used in a process step SA1for a1minutes, and a tool M2is used in a process step SA2for a2minutes, for the purpose of producing the product A. In a case for semiconductor products, the process steps SA1and SA2are, for example, an etching process, a diffusion region forming process, an interconnect forming process and the like. In addition, tools M1and M2are, for example, a reactive ion etching (RIE) system, an ion implanter, a sputtering system and the like. As shown inFIG. 3, the tool M1is used in the process step SB1for b1minutes, and the tool M3is used in the process step SB2for b2minutes, for the purpose of producing the product B. The tool M2is used in the process step SC1for c1minutes, and the tool M3is used in the process step SC2for c2minutes, for the purpose of producing the product C.

FIG. 4shows an example of the tool information of the tools included in the production line. The production line includes i tools M1, j tools M2and k tools M3(i, j and k are natural numbers).

FIG. 5shows an example of the tool operational state information. The tool M1is placed under maintenance service every day, and the time required for the maintenance service is 90 minutes. The MTBF of the tool M1is 700 hours, and the MTTR of the tool M1is 150 minutes. The tool M2is placed under maintenance service for each 50 lots, and the time required for the maintenance service is 180 minutes. The MTBF of the tool M2is 1200 hours, and the MTTR of the tool M2is 240 minutes. The tool M3is placed under maintenance service every 7 days, and the time required for the maintenance is 90 minutes. The MTBF of the tool M3is 900 hours, and the MTTR of the tool M1is 120 minutes.

The “utilities” are required for manufacturing products in the production line. Examples of the utilities include electricity, pure water, cooling water, a refrigerant for a chiller, solid materials for ion doping, high-pressure air, clean air, dried air, nitrogen (N2) gas, oxygen (O2) gas, hydrogen (H2) gas, helium (He) gas, argon (Ar) gas, other semiconductor material gases, semiconductor material gases liquefied at room temperature, chemical solutions, resists for lithography, materials for applied insulating films, and slurries for chemical mechanical polishing (CMP). Examples of the “semiconductor material gases liquefied at room temperature” include tetraethoxysilane (TEOS), triethoxyarsine (TEOA) and triethyl borate (TEB). Hereinafter, information of quantities of utilities, which are consumed while the tools included in the production line are in operation and in standby, is referred to as “utility information.”

A utility facility includes plants respectively for manufacturing, for supplying, and for disposal treatments and the like on utilities consumed by each of a plurality of tools included in the production line, as well as central supply facilities and disposal treatment facilities. The disposal treatments include exhaust air treatment and wastewater treatment. Examples of the wastewater treatment include neutralization treatments, removal of poisonous metals contained in the wastewater, and treatments and the like for reducing biochemical oxygen demand (BOD) and chemical oxygen demand (COD) of the wastewater. In other words, the utility facility includes the exhaust air facilities and the wastewater facilities. In addition, the utility facility also performs evacuation treatment on each of the tools. The utility facility includes piping for supplying utilities to each of the tools and piping for exhaustion from each of the tools (hereinafter referred to simply as the “piping”) as well as wiring.

FIGS. 6A to 6Dshow examples of the utility information. The abscissas axis of each ofFIGS. 6A to 6Dindicates a lapse of time for which a process is carried out by use of a tool using N2gas. The ordinates axis of each ofFIGS. 6A to 6Dindicates a quantity of N2gas consumed by the tool per unit time.

FIG. 6Ashows examples of quantities of N2gas consumed by the tool M1in operation in the process step SA1. The process step SA1is started at time ta1, and the quantities of N2gas consumed by the tool M1are a quantity Na1from time ta1to ta2, a quantity Na2from time ta2to ta3, a quantity Na1from time ta3to ta4, and zero on and after time ta4.FIG. 6Bshows an example of a quantity of N2gas consumed by the tool M1in standby in the process step SA1. The quantity of N2gas consumed by the tool M1in standby is a quantity Nb1of N2gas, which is constant.

FIG. 6Cshows examples of quantities of N2gas consumed by the tool M2in operation in the process step SA2. The quantities of N2gas consumed by the tool M2in operation are a quantity Nc1of N2gas consumed from time tc1, when the process step SA2is started, through time tc2, a quantity Nc2of N2gas consumed from time tc2through time tc3, a quantity Nc1of N2gas consumed from time tc3through time tc4, a quantity Nc2of N2gas consumed from time tc4through time tc5, and a quantity Nc1of N2gas consumed from time tc5through time tc6. On and after time tc6, a quantity of N2consumed by the tool M2is equal to zero.FIG. 6Dshows an example of a quantity of N2gas consumed by the tool M2in standby in the process step SA2. The quantity of N2gas consumed by the tool M1in standby is a constant quantity Nd1. Every tool can have more than one piece of utility information, which varies by products to products, or processes to processes.

As shown inFIG. 1, a system for designing a utility facility according to the first embodiment of the present invention further includes a memory20, an input unit30and an output unit40. The memory20includes a production information area21, a utility information area22, an analysis result area23, an extraction period area24, a calculated consumption area25and a design result area26.

The production information is stored in the production information area21. The utility information of each of the tools included in the production line is stored in the utility information area22. Information of an operational state of each of the tools, as analyzing by the state analyzer11, is stored in the analysis result area23. Information of an operational period and a standby period of each of the tools, as extracted by the extraction module12, is stored in the extraction period area24. Information of changes in quantities of utilities consumed by each of the tools with respect to time, as calculated by the calculator13, is stored in the calculated consumption area25. A design result of the utility facility is stored in the design result area26.

The input unit30includes a keyboard, a mouse pointer, a light pen, and a flexible disk unit or other equivalent elements. A person responsible for designing the utility facility uses the input unit30to designate input/output data. Moreover, setting an output data format via the input unit30is possible, and inputting an instruction for executing or stopping the design is also possible.

The output unit40includes a display and a printer, which display recipe contents, or a recording unit, which stores information in a computer readable recording medium. A ‘computer readable recording medium’ refers to a medium such as an external storage unit for a computer, a semiconductor memory, a magnetic disk, or an optical disk, which may store electronic data. More specifically, a ‘computer readable recording medium’ may be a flexible disk, a compact disk read only memory (CD-ROM), or a magneto-optics (MO) disk.

Descriptions will be provided below for an example of a method for designing a utility facility by use of the system for designing a utility facility, shown inFIG. 1, with reference to a flowchart shown inFIG. 7.

In step S11, for example, the product mix shown inFIG. 2, the process information shown inFIG. 3, the tool information shown inFIG. 4and production information of products, including the tool operational state information shown inFIG. 5, are stored in the production information area21through the input unit30. The utility information of each of the tools included in the production line is stored in the utility information area22.

In step S12, the state analyzer11reads the production information of products from the production information area21. Based on the production information, the state analyzer11analyzes states of the plurality of tools, for which utilities are to be designed, in the production line. For example, the state analyzer11can refer to the tool information of each of the tools included in a real production line for actually manufacturing products. Thereby, the state analyzer11constructs, in memory reserved in the memory20, a virtual production line including substantially the same functions as the real production line includes. The state analyzer11simulates the real production line by use of the virtual production line, and thereby analyzes respective operational states of the plurality of tools included in the real production line. Specifically, step orders of processing products, time required for each of the processing steps, the types and the numbers of tools included in the production line, maintenance information, and the like are taken into consideration. Thus, the production line is simulated virtually, and subsequently, an operation time of each of the tools is determined. Based on the determined operation time of each of the tools, the state analyzer11analyzes the operational state of each of the tools. The result of the analysis is stored in the analysis result area23.

In step S13, the extraction module12reads the result of the analysis from the analysis result area23. From the result of the analysis, the extraction module12extracts the operational period and the standby period of each of the tools included in the production line.FIG. 8shows an example of the result of the analysis. The abscissa axes inFIG. 8indicate time, and shows the operational period and the standby period of each of the tools M1to M4included in the production line. Continuous lines respectively show periods in which the tools M1to M4are in operation. Dashed lines respectively show periods in which the tools M1to M4are in standby. As shown inFIG. 8, the operational period of the tool M1is a time period from time t2to time t6, and the standby period thereof is a time period from time t1to time t2. The operational period of the tool M2is a time period from time t1to time t6. The operational period of the tool M3is a time period from time t4to time t5, and the standby periods thereof are a time period from time t1to time t4, and a time period from time t5to time t6. The operational period of the tool M4is a time period from time t3to time t6, and the standby period thereof is a time period from time t1to time t3. The information of the operational periods and the standby periods, which have been thus extracted, is stored in the extraction period area24.

In step S14, the calculator13reads the information of the operational periods and the standby periods from the extraction period area24. The calculator13reads the utility information of each of the tools included in the production line from the utility information area22. Based on the information of the operational periods and the standby periods and on quantities of utilities consumed by each of the tools in operation and in standby, which tools are included in the production line, the calculator13calculates changes with respect to time in quantities of utilities consumed by each of the tools during production of products. The calculated quantities of utilities consumed by each of the tools are summed, and thereby changes in quantity of utilities consumed by the whole production line are calculated with respect to time.FIG. 9shows examples of the changes in quantities of utilities consumed with respect to time.FIG. 9shows an average, maximum and minimum values of a quantity of N2gas consumed in the production line from the tenth month through the twelfth month in a case where a time period of the analysis is set at twelve months. The information of calculated changes in quantities of utilities consumed with respect to time is stored in the calculated consumption area25. The calculated changes in quantities of utilities consumed with respect to time can be displayed, as an image, in the output unit40shown inFIG. 1, or can be processed in a similar manner.

In step S15, the facility design module14reads the information of the changes in quantities of utilities consumed with respect to time from the calculated consumption area25. Based on the information of the changes in quantities of utilities consumed with respect to time, the facility design module14designs a configuration of the utility facility. In other words, the facility design module14determines the size of the utility facility for supplying utilities to each of the tools included in the production line, so as to ensure quantities of utilities to be supplied, which are demanded for production of products. For example, the facility design module14determines the capacity, the number, and the like of, a N2plant for supplying N2gas, depending on a total quantity of N2gas demanded by each of the tools included in the production line. In this design stage, the maximum, average and minimum values of each of the quantities of utilities consumed are used respectively in designing each component of the utility facility. For example, based on the average value of the quantity of N2gas consumed, which is shown inFIG. 9, the facility design module14designs a N2gas generator. Additionally, based on the maximum value of the quantity of N2gas consumed, which is shown inFIG. 9, the facility design module14designs an evaporator for evaporating liquid N2and a proper piping bore. The result of the design is stored in the design result area26. The design result which has been stored in the design result area26can be transmitted externally of the system for designing a utility facility through the output unit40. Based on the design result, the utility facility for supplying the utilities to the production line is installed in the production line.

With regard to step S12, the example where the state analyzer11constructs the virtual production line in order to analyze the operational states, respectively, of the tools included in the production line has been described. However, the following process flow may be adopted. The constructed virtual production line is stored beforehand in the memory20. The state analyzer11reads the stored virtual production line, and thus analyzes the operational states, respectively, of the tools.

With regard to step S14, the example where the calculator13calculates the average value, the maximum value and the minimum value of each of the quantities of utilities consumed, which vary with respect to time, has been described. Changes in terms of quantities of utility actually consumed can be more accurately calculated with respect to time by calculating the mode, the median, the variance, and the standard deviation value of each of the quantities of utilities consumed. For example, the modes or the medians can be used instead of the average values. Additionally, values obtained by adding the modes or the medians, respectively, to values obtained by standard deviation multiplied with a number may be used instead of the corresponding maximum values. In this respect, it is desirable that the “a number” should be a real number of three to five.

In the foregoing descriptions, in step S15, the facility design module14determines the size of the utility facility for supplying the utilities to each of the tools included in the production line. However, a designer of the utility facility may determine the size of the utility facility on the basis of the changes in quantities of utilities consumed with respect to time, which has been acquired in step S14.

FIG. 10shows a few examples of the designing of a utility facility including a N2plant for supplying N2gas to a growing production line for semiconductor devices. One is a quantity N1of N2gas which is calculated by use of the related art, and the other is a quantity N2of N2gas which is calculated by use of the system for designing a utility facility shown inFIG. 1. The quantity N1of N2gas is calculated based on quantities of utilities consumed by each tool, which are calculated by use of utility specifications of the tools. The abscissa axes inFIG. 10indicate the numbers of wafers to be processed in the production line. The ordinate axes therein indicate a quantity of N2gas estimated for the production line. The quantity of N2gas is specified in cubic meters per hour (m3/h), for example. As shown inFIG. 10, a quantity N10of N2gas can be supplied by one N2plant. Two N2plants are needed when the quantity of N2gas is in a range of quantities N10to N20. Three N2plants are needed when the quantity of N2gas is in a range of quantities N20to N30. Four N2plants are needed when the quantity of N2gas is in a range of quantities N30to N40. In this case, for example, for the purpose of processing w wafers, the utility facility designed by use of the related art demands four N2plants, whereas the utility facility designed by the system for designing a utility facility shown inFIG. 1indicates three N2plants are enough. Consequently, the design of the utility facility by the system shown inFIG. 1makes it possible to avoid designing a utility facility which has an excessive quantity of N2gas, and to accordingly design an efficient utility facility.

The quantity N3of N2gas, shown inFIG. 10, is an example of the quantities of N2gas which is calculated by the system for designing a utility facility shown inFIG. 1in a case where measures are taken to reduce a quantity of N2gas consumed in the production line. Examples of the measures to reduce the quantity of N2gas consumed in the production line include enhancing efficiency of consumption of N2gas by each of the tools included in the production line. As shown inFIG. 10, the reduction of the quantities of N2gas consumed in the production line from N2to N3makes it possible to estimate the number of N2plants included in the utility facility from three to two in the case where the number of wafers to be processed is w. In other words, the system for designing a utility facility shown inFIG. 1makes it possible to evaluate effects beforehand of the measures to reduce the quantities of N2gas.

The foregoing illustrative descriptions have been provided for the example where the utility facility supplies N2gas to be consumed in the production line for semiconductor devices. The method for designing a utility facility described above can be also applied to the designing of a utility facility for supplying, or for performing disposal treatments on any of semiconductor material gas such as O2and H2other than N2gas, pure water, cooling water and the like. In a case where, for example, a utility facility for supplying electric power is intended to be designed, a transformer capacity is designed based on the calculated average value of a quantity of power consumed, and the trunk line or the size of wiring, is designed based on the calculated maximum value of the quantity of power consumed. When a utility facility for supplying pure water and wastewater treatment is intended to be designed, a primary pure water facility is designed based on the calculated average value of a quantity of pure water consumed, and an ultra pure water facility and sizes of piping bores are designed based on the calculated maximum value of the quantity of pure water consumed.

There is a risk that reduction of a quantity of utility supplied to a tool in operation may affect the performance of the tool. For this reason, it is desirable to preferentially investigate measures in standby to reduce a quantity of utility to be supplied to each tool in standby. The system for designing a utility facility, shown inFIG. 1, calculates quantities of utilities to be consumed by tools in operation and quantities of utilities to be consumed by tools in standby. In other words, the system for designing a utility facility, shown inFIG. 1, makes it possible to evaluate effects of the measures to reduce quantities consumed in standby, which are less likely to affect the performances of the tools.FIG. 11shows an example of changes in the quantity of power consumed in the production line with respect to time. The power consumption change is calculated by the system for designing a utility facility shown inFIG. 1. InFIG. 11, power consumption11A indicates a quantity of power consumed when the production line is in operation, and power consumption11B indicates a quantity of power consumed when the production line is in standby. As shown inFIG. 11, the power consumption11B of power consumed in standby is equivalent to approximately 30% of the power consumption11A of power consumed in operation. Reduction of the power consumption11B of power consumed in standby makes it possible to enhance the effects of the measures to reduce the quantity of power consumed as a whole.

The system for designing a utility facility shown inFIG. 1calculates quantities of utilities consumed by each of the tools included in the production line, and calculates quantities of utilities consumed in each of the processing sequences in the production line. Powers P1to Pn, shown inFIG. 11, represent the quantity of power consumed respectively in each process in standby at time tp (where n is an integer of 2 or more). For example, the processing steps SP1to SPn include a diffusing step, a low-pressure chemical vapor deposition (LPCVD) step, a plasma chemical vapor deposition (PCVD) step and the like in a case where products are semiconductor devices. Determining the quantity of utilities consumed by each of the tools or in each of the processing makes it possible for a process engineer to determine which tool or process consumes large quantity of utilities. As a result, it is possible to efficiently reduce quantities of utilities supplied to the production line.

The calculator13is capable of calculating quantities of utilities per each of a plurality of tool components included in the production line. Therefore, the quantity of utilities consumed can be calculated respectively by tool components included in the tools in common. The “tool components” are pumps, chillers and the like respectively commonly included in the tools.FIG. 12shows quantities of power PE1to PE6consumed by respective tool components El to E6, and the quantities of power PE7consumed by remaining tool components. In the case of the example shown inFIG. 12, the quantities of power PE1consumed respectively by the tool component E1total and the quantity of power PE2consumed respectively by the tool component E2total are larger than the other tool components. Thus, a combination of the totals PE1and PE2consume approximately one-third of the grand total. As a result, the process engineers may decide on a guideline that it is effective to chiefly investigate measures to reduce the quantities of power consumed by the tool component E1and the tool component E2.

The system for designing a utility facility according to the first embodiment of the present invention calculates the average value and the like of each of the changes with respect to time of the quantity of utilities consumed in the production line, based on the operational periods, the standby periods, and the utility information of each of the tool, all of which have been extracted from the production information. The designing of the utility facility on the basis of the changes in the quantity of utilities consumed with respect to time can improve design accuracy values. As a result, the system for designing a utility facility, shown inFIG. 1, can avoid designing a utility facility in which excessive quantities of utilities are supplied, and accordingly design an efficient utility facility which is capable of supplying, and disposing of, utilities. In addition, the system for designing a utility facility, shown inFIG. 1, calculates the quantity of utilities consumed by each of the tools or in each of the process steps. Accordingly, this makes it easy to estimate how much effect will be brought about by measures to cut back the quantity of utilities in each of the tools or in each of the process steps.

The system for designing a utility facility shown inFIG. 1makes it possible to avoid supplying excessive utilities by the utility facility, and to reduce the quantity of utilities to be supplied to the production line. As a result, by manufacturing the products by use of the production line including the designed utility facility, costs of manufacturing the products can be reduced. In a case a utility facility for supplying utilities to the production line for semiconductor devices is designed by the system shown inFIG. 1, the costs of manufacturing semiconductor devices are reduced by use of the production line including tools such as the RIE system, the ion implanter and the sputtering system.

A series of operations for utility facility design shown inFIG. 7may be carried out by controlling the system, shown inFIG. 1, by use of a program algorithm equivalent to that shown inFIG. 7. The program should be stored in the memory20of the system shown inFIG. 1. In addition, a series of operations for designing a utility facility of the present invention may be carried out by storing such a program in a computer-readable recording medium and instructing the memory20, shown inFIG. 1, to read the recording medium.

The foregoing descriptions have been provided for the case where a utility facility for a factory is newly designed. The method for designing a utility facility according to the first embodiment of the present invention can be applied to a case where a production plan of an existing factory is modified.

Descriptions will be provided below for an example of the design of a utility facility where a production plan with a product mix shown inFIG. 13Bis intended to be added to an existing factory. The existing factory produces products based on a production plan with a product mix shown inFIG. 13A.FIG. 13Ashows the product mix of products currently in production.FIG. 13Bshows the product mix of additional products to be manufactured. In other words, the processing of x2wafers and y2wafers, respectively, for the products A2and B2is intended to be added to an existing manufacturing facility which processes x1wafers and y1wafers, respectively, for the products A1and B1, monthly.

FIGS. 14A and 14Brespectively show examples of process information of the products A1, B1, A2and B2.FIG. 14Ashows that, for the purpose of manufacturing the products A1, the tool M10is used in the process step SA11for all minutes, and the tool M20is used in the process step SA12for a12minutes. In addition, for the purpose of manufacturing the products B1, the tool M10is used in the process step SB11for b11, minutes, and the tool M30is used in the process step SB12for b12minutes.FIG. 14Bshows that, for the purpose of manufacturing the products A2, the tool M10is used in the process step SA21for a21minutes, and the tool M20is used in the process step SA22for a22minutes. In addition, for the purpose of manufacturing the products B2, the tool M10is used in the process step SB21for b21minutes, and the tool M30is used in the process step SB22for b22minutes. In this respect, the tools M10, M20and M30are tools included in the production line in the existing factory.

FIG. 15shows an example of tool information of the tools M10, M20and M30. The production line includes l tools M10, m tools M20and n tools M30(l, m and n: natural numbers). In addition,FIG. 16shows an example of tool operational state information.

The process information shown inFIG. 14A, the tool operational state information shown inFIG. 16, and the like can be acquired from the past record of operation of the existing factory.

In step S11in the flowchart shown inFIG. 7, the system for designing a utility facility, shown inFIG. 1a, receives the product mix shown inFIG. 17, as part of the production information. The product mix is obtained by combining the product mix shown inFIG. 13Awith the product mix shown inFIG. 13B. The system for designing a utility facility receives process information shown inFIG. 18, as part of the production information. The system for designing a utility facility receives the tool information, shown inFIG. 15, and the tool operational state information with regard to the tools M10, M20and M30, which is shown inFIG. 16, as another part of production information.

Subsequently, utility facility is designed by the method described inFIG. 7. As a result, the utility facility can be designed with little difference between quantities of utility actually consumed and supplied, and the facility is capable of supplying enough utilities for achieving the growing production plan with the product mix shown inFIG. 17.

Based on the utility facility thus designed, the additional change of the utility facility can be examined by considering the quantity of utilities supplied by the utility facility of the existing factory. For example, a new utility facility to be added to the existing utility facility is designed in order to fill the gap between the quantity of utilities supplied by the existing utility facility and the quantity of new utility demand.

In the method for designing a utility facility according to the modification of the first embodiment of the present invention, changes with respect to time, in total, of the quantity of utilities consumed for producing products of an existing type and products to be added are calculated. The utility facility is designed based on the calculated changes in quantities of utilities to be consumed. For this reason, in the case where a production plan is intended to be added in an existing factory, accuracy of each of the design can be improved. As a result, it is possible to avoid designing a utility facility in which excessive quantities of utilities are provided, and to design an efficient utility facility capable of supplying utilities.

Second Embodiment

A system for designing a utility facility according to a second embodiment of the present invention is different from the system for designing a utility facility shown inFIG. 1in the point that, as shown inFIG. 19, the system according to the second embodiment further includes a piping design module15, a layout information area27and a piping information area28. The other configuration of the system for designing a utility facility according to the second embodiment is the same as the configuration of the system according to the first embodiment.

Layout information of the production line, to which the utility facility supplies utilities, is stored in the layout information area27. The “layout information of the production line” is information for indicating where in a factory each of the tools included in the production line are to be installed.

The piping design module15designs piping through which the utility facility supplies utilities to each of the tools included in the production line. More specifically, the piping design module15determines piping bores, branch points of the piping and the like, based on quantities of utilities supplied to each of the tools and the layout information of the production line. A result of the designing of the piping by the piping design module15is stored in the piping information area28.

Descriptions will be provided below for an example of a method for designing piping through which ultra pure water is supplied from a utility facility100to a production line200for semiconductor devices, as shown inFIG. 20. It is assumed that, in a manner similar to that which has been described with regard to the first embodiment, the utility facility100is designed by the system for designing a utility facility shown inFIG. 19, based on the quantity of ultra pure water consumed in the production line200.

As shown inFIG. 20, the ultra pure water is supplied from the utility facility100to the production line200through a main pipe300. The ultra pure water is returned from the production line200to the utility facility100through a main pipe350. The piping design module15determines the bores, strengths and the like of each of the main pipes300and350, based on the quantity of ultra pure water supplied from the utility facility100.

In the case of the layout of the production line200, a group of tools211to213, a group of tools221to223, a group of tool231, and a group of tools241to248are installed, respectively, in areas in the factory. The piping design module15analyzes the layout information of the production line, and thus arranges sub-main pipes310,320,330and340, respectively, in areas of the group of tools211to213, the group of tools221to223, the group of tool231, and the group of tools241to248. Ultra pure water is supplied to tools211to213through the sub-main pipe310. Ultra pure water is supplied to tools221to223through the sub-main pipe320. Ultra pure water is supplied to tool231through the sub-main pipe330. Ultra pure water is supplied to tools241to248through the sub-main pipe340. As shown inFIG. 20, the sub-main pipes310,320,330and340are branched out from the main pipe300connected to the utility facility100. In addition, the sub-main pipes310,320,330and340are connected to the main pipe350. The main pipe350is connected to the utility facility100. In the case where the production line200is for semiconductor devices, the group of tools211to213, the group of tools221to223, the group of tool231and the group of tools241to248are a wet bench, a CMP system and the like.

The system for designing a utility facility, shown inFIG. 19, calculates the quantity of ultra pure water consumed respectively by the group of tools211to213, the group of tools221to223, the group of tool231and the group of tools241to248. The piping design module15designs the bore, the strength and the like of the sub-main pipe310, based on the quantity of ultra pure water to be supplied respectively to tools211to213. The piping design module15similarly designs the bore, the strength and the like of each of the sub-main pipes,320,330and340, based on the quantity of ultra pure water supplied respectively to tools221to223, tool231, and tools241to248.

The foregoing descriptions have been provided for the method for designing the piping for ultra pure water. The foregoing method for designing piping can be applied to piping to supply each of N2gas, O2gas, H2gas and the like, air exhaust piping, drain piping and electrical wiring. Descriptions will be provided for a method for designing a utility facility by use of the system shown inFIG. 19with reference to a flowchart shown inFIG. 21.

In steps S11to S15, a configuration of the utility facility is designed based on changes in the quantity of utilities consumed with respect to time, in a manner similar to that which has been described with reference to the flowchart shown inFIG. 7. A result of the design is stored in the design result area26.

In step S16, the layout information of the production line is stored in the layout information area27through the input unit30, shown inFIG. 19. It does not matter that the layout information of the production line is stored beforehand in the layout information area27.

In step S17, the piping designing module15reads the result of the utility facility design and the layout information of the production line, respectively, from the design result area26and the layout information area27. The piping design module15analyzes the layout information of the production line. Based on the analyzed layout information of the production line and the quantity of utilities supplied to each of the tools included in the production line, the piping design module15designs the piping. The result of the piping design is stored in the piping information area28.

The piping design result can be transmitted externally of the system for designing a utility facility through the output unit40. Based on the result of the piping design, pipes are installed through which the utility facility supplies utilities to the production line. Other elements are substantially the same as elements of the first embodiment, and the descriptions will be omitted.

The system for designing a utility facility according to the second embodiment of the present invention can accurately design the piping for supplying utilities from the utility facility relative to the quantity of utilities consumed during actual operation to each of the tools included in the production line, depending on the quantity of utilities consumed by each of the tools. As a result, it is possible to avoid a piping design with excessive capacity for supplying utilities to each of the tools, and to avoid increased costs for installing the piping.

Other Embodiments

The foregoing descriptions of the first and second embodiments have been provided for an example where the system for designing a utility facility, shown inFIG. 1, analyzes states of the tools included in a production line, as described in steps S11to S12of the flowchart shown inFIG. 7. The system calculates changes in the quantity of utilities consumed with respect to time, as described in steps S13to S14. It does not matter that the method for designing a utility facility, shown in the flowchart ofFIG. 7, is carried out by use of a first simulator for analyzing the operational states of the respective tools included in the real production line, and a second simulator for calculating the changes in the quantity of utilities consumed with respect to time. In such case, it does not matter that, for example, a result of analysis of the first simulator is manually provided to the second simulator. It does not matter that the result of analysis of the first simulator is transferred to the second simulator online by electrically connecting the first and second simulators with each other.

In addition, the foregoing descriptions of the first and second embodiments have been provided for the example where the production line is for semiconductor products. One may consider that it is easily understood from the foregoing descriptions that the present invention can be applied to the design of a utility facility for supplying utilities to a production line for automobiles, a production line for chemicals, or a production line for building components.