Substrate processing apparatus and control system

A controller that processes a substrate by executing a process recipe for supplying at least a source gas to a process chamber to form a film on the substrate, and a pressure controller that controls the degree of opening of a pressure control valve on the basis of a pressure value detected by a pressure sensor that detects a pressure in a furnace during execution of the recipe and maintains the process chamber to a predetermined pressure. The pressure controller includes a memory that accumulates data acquired from the pressure sensor and pressure control valve, and measures a valve full close time to full close of the pressure control valve during execution of the process recipe and holds the valve full close time in the memory, and the controller acquires the stored valve full close time and confirms whether the acquired valve full close time falls within a threshold range.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2018-064191, filed on Mar. 29, 2018, and Japanese Patent Application No. 2019-011910, filed on Jan. 28, 2019, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

This present disclosure relates to a substrate processing apparatus, a control system, and a method of manufacturing a semiconductor device.

BACKGROUND

Conventionally, as a method of confirming an abnormal state of a pressure control valve, there are a pressure deviation check for confirming follow-up of a pressure monitor at the time of pressure control and a deviation check on the degree of valve opening at the time of control of the degree of valve opening.

In the present circumstances, in a film type that requires a pressure control valve to be opened and closed in a short time to perform pressure control, for example, in a process of forming a film on a substrate such as a semiconductor wafer by alternately supplying a first processing gas (source gas) and a second processing gas (reactant gas) on the substrate, as described in Japanese Patent Application No. 2014-506299, a pressure value is not controlled to a target value, and thus the above-described abnormality check by pressure deviation cannot be applied. Further, the abnormality detection by deviation check of the degree of valve opening is possible but an accurate time from an open state to a close state of the pressure control valve cannot be obtained even if the abnormality is detected.

Further, in a case of recognizing a close time of the pressure control valve by a process control module via a current communication line, a delay time due to the communication line exists as in the comparative example illustrated inFIG. 6, and a time difference from the actual close time of the pressure control valve occurs and the accurate close time cannot be acquired.

SUMMARY

In view of such circumstances, this present disclosure provides a configuration to acquire an accurate close time of a pressure control valve.

According to an aspect of this present disclosure, provided is a configuration including a controller that processes a substrate by executing a process recipe for supplying at least a source gas to a process chamber to form a film on the substrate, and a pressure control controller that controls the degree of opening of a pressure control valve on the basis of a pressure value detected by a pressure sensor that detects a pressure in a furnace during execution of the recipe and maintains the process chamber to a predetermined pressure, and the configuration in which the pressure control controller includes a memory region in which data acquired from the pressure sensor and the pressure control valve is accumulated, and measures a valve full close time to full close of the pressure control valve during execution of the process recipe and holds the valve full close time in the memory region, and the controller acquires the valve full close time held in the memory region and confirms whether the acquired valve full close time falls within a threshold range.

DETAILED DESCRIPTION

(1) Outline of Substrate Processing Apparatus

In a substrate processing apparatus described in the present embodiments is used in a process of manufacturing a semiconductor device, and heats a substrate to be processed with a heater in a state where the substrate is accommodated in a process chamber and applies processing.

An example of the substrate to be processed by the substrate processing apparatus includes a semiconductor wafer substrate (hereinafter simply referred to as “wafer”) on which a semiconductor integrated circuit device (semiconductor device) is built. Further, examples of the processing performed by the substrate processing apparatus include oxidizing, diffusion processing, reflow and annealing for carrier activation and planarization after ion implantation, and film formation processing by thermal chemical vapor deposition (CVD) reaction.

(2) Schematic Configuration of Substrate Processing Apparatus

A configuration example of the substrate processing apparatus according to the present embodiments will be described with reference toFIG. 1.

A substrate processing apparatus10includes a housing12in which main parts such as a process furnace40are arranged. A pod stage18is arranged on a front side of the housing12. A pod16as a transfer container for accommodating a wafer14is transferred and placed on the pod stage18. The pod16has twenty-five wafers14accommodated therein, for example, and is configured to be placed on the pod stage18in a state where a lid (not illustrated) is closed. In other words, the substrate processing apparatus10exchanges the pod16with an external device while using the pod stage18on which the pod16is to be placed.

A pod transfer device20that transfers the pod16is arranged at a position on the front side in the housing12and facing the pod stage18. A rotary pod shelf22acapable of storing the pod16, a stacked pod shelf22bcapable of storing the pod16, and a pod opener24are arranged near the pod transfer device20. The pod transfer device20is configured to transfer the pod16among the pod stage18, the rotary pod shelf22a, the stacked pod shelf22b, and the pod opener24.

The rotary pod shelf22ais arranged in a first shelf region that is a region above the pod opener24and is configured to hold a plurality of the pods16in a placed state. The rotary pod shelf22ais configured by a rotary shelf having a plurality of stages (for example, five stages) of shelf plates. Further, a clean unit including a supply fan and a dustproof filter may be provided near the rotary pod shelf22a, and clean air as a cleaned atmosphere may be circulated from the clean unit.

The stacked pod shelf22bis arranged in a second shelf region that is a region below the pod stage18and is configured to hold a plurality of the pods16in a placed state. The stacked pod shelf22bhas a plurality of stages (for example, three stages) of shelf plates and is configured to have the pods16placed on the respective shelf plates. Further, clean air may be circulated near the stacked pod shelf22b, similarly to the rotary pod shelf22a.

The pod opener24is configured to open the lid of the pod16. Note that a substrate number detector that detects the number of the wafers14in the pod16with the lid opened may be arranged adjacent to the pod opener24.

A transfer chamber50partitioned as one room in the housing12is formed on a back side of the pod opener24in the housing12. A substrate transfer machine28and a boat30as a substrate holder are arranged in the transfer chamber50.

The substrate transfer machine28has an arm (tweezer)32capable of taking out five wafers14, for example. The substrate transfer machine28is configured to be able to transfer the wafer14between the pod16placed at the position of the pod opener24and the boat30by rotating and moving the arm32up and down by driving means (not illustrated).

The boat30is configured to align and stack a plurality of wafers14(about 50 to 175 wafers14, for example) in a horizontal attitude with centers aligned at predetermined intervals in a vertical direction, and hold the plurality of wafers14in multistage in a longitudinal direction. The boat30holding the wafers14is configured to be able to move up and down by a boat elevator as an elevating mechanism (not illustrated).

The process furnace40is arranged in a back-side upper portion in the housing12, that is, above the transfer chamber50. The boat30loaded with the plurality of wafers14is carried into the process furnace40from below.

Next, the above-described process furnace40will be briefly described with reference toFIG. 2.

The process furnace40is provided with a reaction tube41. The reaction tube41is configured by a heat-resistant non-metallic material such as quartz (SiO2) or silicon carbide (SiC) and is formed in a cylindrical shape with an upper end closed and a lower end opened.

A process chamber42is formed in the cylinder of the reaction tube41. The process chamber42is configured such that the boat30as a substrate holder is inserted from below, and the wafers14held in the horizontal attitude by the boat30are accommodated in an aligned state in multistage in the vertical direction. The boat30accommodated in the process chamber42is configured to be rotatable in a state where the plurality of wafers14is mounted while keeping airtightness of the process chamber42by rotating a rotation shaft44by a rotation mechanism43.

A manifold45is arranged below the reaction tube41concentrically with the reaction tube41. The manifold45is configured by a metallic material such as stainless steel, for example, and has a cylindrical shape with an upper end and a lower end opened. The reaction tube41is longitudinally supported from a lower end side with this manifold45. That is, the reaction tube41forming the process chamber42stands in the longitudinal direction via the manifold45to constitute the process furnace40.

A lower end of the manifold45is configured to be airtightly sealed by a seal cap46when a boat elevator (not illustrated) rises. A sealing member46asuch as an O ring for airtightly sealing an interior of the process chamber42is provided between the lower end of the manifold45and the seal cap46.

Further, a first gas supply pipe47having a valve61for introducing a source gas into the process chamber42, a second gas supply pipe49having a valve62for introducing a reactant gas into the process chamber42, and an exhaust pipe48for exhausting a gas in the process chamber42are connected to the manifold45.

A first purge gas introduction pipe51having a valve64for introducing a purge gas or the like is connected to the first gas supply pipe, and a second purge gas introduction pipe52having a valve63for introducing a purge gas or the like is connected to the second gas supply pipe.

The exhaust pipe48is provided with a pressure sensor248as a pressure detector that detects a pressure in the process chamber42and an auto pressure control (APC) valve242as a pressure control valve that adjusts the pressure in the process chamber42.

A heater unit207as heating means (heating mechanism) is arranged concentrically with the reaction tube41on an outer periphery of the reaction tube41. The heater unit207is configured to heat the interior of the process chamber42so that the interior of the process chamber42has uniform or predetermined temperature distribution.

(3) Outline of Substrate Processing Process

Next, an operation procedure in a case of performing processing for the wafer14as one process of semiconductor device manufacturing using the substrate processing apparatus10according to the present embodiments will be described.

In a case where the substrate processing apparatus10performs processing for the wafer14, first, the substrate processing apparatus10places the pod16accommodating a plurality of the wafers14on the pod stage18. Then, the pod transfer device20transfers the pod16from the pod stage18to the rotary pod shelf22aor the stacked pod shelf22b.

Thereafter, the pod transfer device20transfers the pod16placed on the rotary pod shelf22aor the stacked pod shelf22bto the pod opener24. Then, the pod opener24opens the lid of the pod16and the substrate number detector detects the number of the wafers14accommodated in the pod16.

When the pod opener24opens the lid of the pod16, next, the substrate transfer machine28arranged in the transfer chamber50takes out the wafer14from the pod16. Then, the substrate transfer machine28transfers the unprocessed wafer14taken out from the pod16to the boat30located in the transfer chamber50as in the substrate transfer machine28. That is, the substrate transfer machine28performs a wafer charge operation of charging the unprocessed wafer14into the boat30before being loaded into the process chamber42in the transfer chamber50. By the wafer charge operation, the boat30holds the plurality of wafers14in a stacked state at intervals in the vertical direction. The number of wafers14that the boat30holds in a stacked state and collectively processes is, for example, 50 to 175.

After the wafer charge operation, the boat30holding the plurality of unprocessed wafers14is loaded into the process chamber42(boat loading) by a lifting and lowering operation of the boat elevator. That is, the boat30holding the unprocessed wafers14is loaded from the transfer chamber50into the process chamber42by operating the boat elevator. By the boat loading, the seal cap46is in a state of sealing the lower end of the manifold45via the sealing member46a.

After the boat loading, predetermined processing is performed for the unprocessed wafers14held by the boat30loaded into the process chamber42. For example, in the case of performing the film formation processing, the interior of the process chamber42is heated using the heater unit207, and the rotation mechanism43is operated to rotate the wafer14while rotating the boat30. The rotation of the wafer14continues until unloading of the wafer14to be described below. Then, the source gas, the purge gas, and the like are supplied to the process chamber42through the first gas supply pipe47. As a result, a thin film is formed on a surface of the unprocessed wafer14held by the boat30.

After the formation of the thin film on the surface of the wafer14, the heating by the heater unit207is stopped, and the temperature of the processed wafer14is lowered to a predetermined temperature. Then, when a preset time has elapsed, the supply of the gas into the process chamber42is stopped, and supply of an inert gas to the process chamber42is started. As a result, the process chamber42is replaced with the inert gas and the pressure in the process chamber42is restored to normal pressure.

Thereafter, the boat elevator lifts and lowers the seal cap46to open the lower end of the manifold45, and unloads the boat30holding the processed wafer14from the lower end of the manifold45to the outside of the process chamber42(boat unloading). That is, the boat elevator is operated to unload the boat30holding the processed wafer14from the process chamber42into the transfer chamber50.

After the wafer14of the waiting boat30is cooled to the predetermined temperature (for example, around room temperature), the substrate transfer machine28arranged in the transfer chamber50dismounts the wafer14from the boat30. Then, the processed wafer14dismounted from the boat30is transferred to and accommodated in the empty pod16placed at the pod opener24. That is, the substrate transfer machine28performs a wafer discharge operation of taking out, from the boat30, the processed wafer14held by the boat30unloaded from the process chamber42and transferring the wafer14to the pod16in the transfer chamber50.

After that, the pod transfer device20transfers the pod16accommodating the processed wafers14onto the rotary pod shelf22a, the stacked pod shelf22b, or the pod stage18. In this way, the series of processing operations of the substrate processing step by the substrate processing apparatus10according to the present embodiments is completed.

A control device240that controls transfer mechanisms respectively including the pod transfer device20, the substrate transfer machine28, and the boat elevator, which are mechanisms that transfer at least the wafer14, a gas supply mechanism that supplies the processing gas and the like to the process furnace40, a gas exhaust mechanism that evacuates the interior of the process furnace40, and the heating mechanism207that heats the process furnace40to the predetermined temperature will be described with reference toFIGS. 3 and 4.

As illustrated inFIG. 3, the device controller240as a control device includes a main controller201, a transfer system controller211as a transfer control module, and a process system controller212as a process control module. The transfer system controller211and the process system controller212are electrically connected to the main controller201by, for example, a local area network (LAN) such as 100BASE-T. The main controller201is connected to an external host computer (not illustrated) via a communication network, for example.

Operation screens for operating a substrate processing apparatus10are configured to be displayed on a display device218. Further, the display device218receives input data (input instruction) of an operator from the operation screen and transmits the input data to the main controller201.

Further, the display device218receives an instruction (control instruction) for executing a recipe expanded on a memory (RAM) described below or the like or an arbitrary substrate processing recipe (also referred to as process recipe) out of a plurality of recipes stored in a storage described below from the operation screen, and transmits the received recipe to the main controller201. Note that the operation screen of the display device218may be configured by a touch panel. In the present embodiments, the main controller201is configured to execute a process recipe for repeatedly executing a process of supplying a process gas to the process chamber42and a process of exhausting the process gas from the process chamber42. Here, the process recipe includes at least a process of supplying a source gas as a first process gas to the process chamber42, a process of exhausting the source gas from the process chamber42, a process of supplying a reactant gas as a second process gas for reacting with the source gas to the process chamber42, and the process of exhausting the reactant gas from the process chamber42.

Although partly omitted inFIG. 3, the transfer system controller211is connected to a substrate transfer system mainly configured by the rotary pod shelf, the boat elevator, the pod transfer device20, the substrate transfer machine28, the boat30, and the rotation mechanism43. Further, the transfer system controller211is configured to control transfer operations of the substrate transfer system.

The process system controller212includes a temperature controller212a, a pressure controller212bas a pressure control controller, a gas flowrate controller212c, and a sequencer212d, which constitute a sub controller. Since the sub controller is electrically connected to the process system controller212, transmission and reception of data, downloading and uploading of files, and the like can be performed. Although the process system controller212and the sub controller are separately illustrated, the process system controller212and the sub controller may be integrally configured.

The heating mechanism207mainly configured by a heater and a temperature sensor is connected to the temperature controller212a. The temperature controller212ais configured to control the temperature in the process furnace40by controlling the temperature of the heater of the processing furnace40.

The gas exhaust mechanism configured by the pressure sensor248, the APC valve242, and a vacuum pump is connected to the pressure controller212b. The pressure controller212bis configured to control the degree of opening of the APC valve242and switching (on and off) of the vacuum pump such that the pressure in the process chamber42becomes a desired pressure at desired timing on the basis of a pressure value detected by the pressure sensor248. As will be described in detail below, the pressure controller212bis provided with a memory region for storing various data including opening and closing times of the APC valve242, and is configured to report (transmit) data in the memory region in response to a data request from the process system controller212. Note that the memory region stores (holds) latest data of the various data after the data report.

The gas flowrate controller212cis configured by a mass flow controller (MFC). The sequencer212dis configured to control supply and stop of the gases from the first gas supply pipe47and the second gas supply pipe49by opening and closing the valves61,62,63, and64. Further, the process system controller212is configured to control the MFC212cand the valves61,62,63, and64such that a flowrate of the gas to be supplied to the process chamber42becomes a desired flowrate at desired timing.

Further,FIG. 3illustrates details of the process system controller212. Although not illustrated and described, the transfer system controller211has a similar configuration.

Further, as illustrated inFIG. 3, the process system controller212includes a CPU236as a processor, and includes at least a temporary storage including at least a read-only memory (ROM)250and a random-access memory (RAM)251, and an I/O communicator255that performs I/O communication with the temperature controller212a, the MFC212c, the pressure controller212b, the sequencer212d, and the like. The CPU236outputs, for example, control data (control instruction) for processing the substrate to the sub controller such as the temperature controller212aat a predetermined cycle on the basis of the recipe created or edited on the operation screen of the display device218or the like and stored in the RAM251or the like. Note that a data collection cycle of the process system controller212is one second.

The RAM251temporarily stores the input data (input instruction) input from the display device218and the like, commands of the recipes and history data of at the time of execution of the recipes, for example, monitor data generated from the above-described transfer mechanism or processing mechanism, and the like. These data in the RAM251are configured to be uploaded to a storage222described below of the main controller201at predetermined timing. Further, the ROM250may also be used as a storage that stores programs including the above-described process recipe. In this case, the data are downloaded from the storage222described below of the main controller201according to a storage instruction made on the operation screen displayed on the display device218or on an operation screen displayed on an external display device.

Note that the main controller201, the transfer system controller211, and the process system controller212according to the present embodiments can be realized using an ordinary computer, not by a special system. For example, controllers that execute predetermined processing by installing programs for executing the above-described processing from a record medium storing the programs to a general-purpose computer can be configured.

Then, means for supplying these programs are arbitrary. Besides being able to be supplied via a predetermined recording medium as described above, the programs may be supplied via a communication line, a communication network, a communication system, or the like, for example. In this case, for example, the programs may be posted on a bulletin board of the communication network, and the programs may be provided by being superimposed on carrier waves via the network. Then, the programs provided in this manner are activated and executed similarly to other application programs under control of the OS, whereby the predetermined processing can be executed.

Next,FIG. 4is a block configuration diagram of the main controller201included in the device controller240as a control device of the substrate processing apparatus10according to the present embodiments.

The main controller201as a main controller is configured as a computer including a central processing unit (CPU)224as a processor, a memory (RAM, ROM, and the like)226as a temporary storage, a hard disk (HDD)222as a storage, a transmission reception module228as a communicator, and a timer (not illustrated) having a timing function.

The hard disk222stores recipe files such as the process recipes in which processing conditions and processing procedures are defined, control program files for executing the recipe files, and the like. In the present embodiments, a program for acquiring various data including opening and closing times of the pressure control valve242is executed during execution of the process recipe. The main controller201causes the process control module212to execute the process recipe, thereby causing the substrate processing apparatus10to execute a procedure of processing the substrate. Then, in the procedure of processing the substrate, the main controller201causes the process control module212to execute a procedure of controlling the degree of opening of the pressure control valve242on the basis of a detection value of the pressure sensor248that detects the pressure in the processing furnace and maintaining the process chamber42to a predetermined pressure, a procedure of holding the data acquired from the pressure sensor248and the pressure control valve242in the memory region, a procedure of measuring a valve full close time (hereinafter also referred to as close time) to full close of the pressure control valve242and storing the close time in the memory region, and a procedure of reporting the close time. Further, the main controller201causes the process control module212to execute a procedure of confirming whether the close time falls within a predetermined threshold value or threshold range. Here, in the present embodiments, not only a time from full open (the degree of valve opening 100%) to full close (the degree of opening 0%) but also a time required to the full close (the degree of valve opening 0%) based on a valve close signal of the process control module212is defined as the close time.

Here, a switching hub or the like is connected to the transmission reception module228of the main controller201, and the main controller201is configured to transmit and receive data to and from an external computer or the like via a network. Therefore, even in a case where the substrate processing apparatus10is installed in a clean room, for example, a host controller connected to a plurality of the main controllers201in a data exchangeable manner as an external computer can be installed in an office or the like outside the clean room. Note that the external computer located at a separated position and connected to the substrate processing apparatus10is not limited to the host controller and may be an ordinary general-purpose computer so-called personal computer (PC) or may be a dedicated terminal.

Note that, as illustrated inFIG. 4, the main controller201may include a user interface (UI) device218including a display device such as a liquid crystal display and pointing devices such as a keyboard and a mouse.

As illustrated inFIG. 5, according to the present embodiments, the process control module212that processes the substrate by executing the process recipe, and the pressure control controller212bthat controls the degree of opening of the pressure control valve242on the basis of the detection value of the pressure sensor248that detects the pressure in the process furnace40during execution of the process recipe and maintains the process chamber42to the predetermined pressure are provided, and the pressure control controller212bincludes the memory region as a storage that holds the various data acquired from the pressure sensor248and the pressure control valve242, and is configured to measure the close time to full close of the pressure control valve242, hold the full close time in the memory region, and report the close time in response to the request instruction from the process control module212. Then, the process control module212is configured to compare the acquired close time with the predetermined threshold value (or the threshold range) and detect an operation abnormality of the pressure control valve242. Further, the various data in the memory region is configured such that latest data of the various data is stored after the report of the data such as the close time to the process control module212.

The valve close signal (instruction to fully close the valve) is output from the process control module212to the pressure control module212b, and the pressure control module212bfully closes (full close) the pressure control valve242in response to the instruction. Then, since the pressure control module212bmeasures the data of the degree of valve opening of the pressure control valve242from the pressure control valve242at a shorter cycle than the process control module212, the pressure control module212bcan acquire an accurate close time to full close. Specifically, the data collection cycle of the pressure control module212bis 0.01 seconds and can collect detailed data, as compared with the cycle (one second) of the process control module212.

The pressure control controller212bconstantly stores the data of the degree of valve opening of the pressure control valve242in the memory region until the degree of valve opening becomes 0%, and stores all the data of the degree of valve opening in the memory region. Further, the pressure control controller212bmeasures the time (close time) to when the degree of valve opening becomes 0%, and stores time data of the close time in the memory region. Needless to say, in a case where the memory region is small, it is not necessary to store all the data of the degree of valve opening. Then, the pressure control controller212bstands by until a degree of valve opening monitor request instruction is given from the process control module212.

Note that the valve full close time held in the memory region by the pressure control controller212bis held until the next full close operation based on the valve full close time from the process control module212is given.

The process control module212is configured to output a data request instruction to the pressure control controller212b, and the pressure control controller212bis configured to report the close time together with all the data of the degree of valve opening to the process control module212when receiving the data request instruction. Then, the process control module212is configured to compare the acquired close time with the predetermined threshold value (or threshold range) and detect the operation abnormality of the pressure control valve242according to whether the close time falls within the threshold value (or threshold range). Furthermore, when detecting the operation abnormality, the process control module212is configured to notify the main controller201of occurrence of the abnormality in the pressure control valve242as abnormality information. The data collection cycle of the main controller201is one second.

Note that the process control module212is configured to hold the latest data of the degree of valve opening and the close time after the report. Although not specifically described, not only data regarding the pressure such as the pressure value (measured value) by the pressure sensor248but also data regarding the temperature and the gas flowrate are similarly reported as well as the latest data after the report is held.

Although not illustrated inFIG. 5, since the process control module212transmits various data including the acquired close time to the main controller201, the main controller201can similarly acquire the close time measured by the pressure control controller212b. That is, the main controller201can be configured to detect the operation abnormality of the APC valve242by comparing the acquired close time with the threshold value and provide notification of occurrence of the abnormality in the pressure control valve242as the abnormality information. In addition, the host controller can also be similarly configured to detect the operation abnormality of the APC valve242.

In the present embodiments, the process control module212can acquire the degree of opening data including the close time of the APC valve242, similarly to the pressure control controller212b. Further, the process control module212can detect the operation abnormality of the APC valve242by comparing the acquired close time with the threshold value and transmit the abnormality information of the APC valve242to the main controller201. Therefore, for example, the main controller201can monitor the close time of the APC valve242and confirm the state of the valve that affects the thickness of film like the APC valve242.

Further, in the present embodiments, since the process control module212acquires the close time measured by the pressure control controller212bas the time from the open state to the close state of the APC valve, the process control module212can detect the abnormality of the APC valve242without erroneous determination.

As illustrated inFIG. 6, in a comparative example, when data of the degree of valve opening of 0% is included in data of the degree of valve opening (not including a close time) when a pressure control controller212bresponds to a request instruction from a process control module212, the process control module212determines that an APC valve242is fully closed (full close).

Conventionally, the process control module212is configured to recognize a period when acquiring the data of the degree of valve opening of 0% as a time when the APC valve242is closed. Specifically, since the process control module212recognizes the time from when the process control module212outputs a valve close instruction to when the pressure control controller212bresponds with the data of the degree of valve opening of 0% as the close time, a time difference from the close time actually acquired by the pressure control controller212b(actual close time) has occurred.

However, in the present embodiments, the close time acquired by the pressure control controller212bis held, and the close time is included in response data to the request instruction data of the process control module212, whereby the process control module212can more accurately determine the full close time of the APC valve242. Further, the process control module212can also acquire the time from full open to full close of the APC valve242, which is the same as the close time acquired by the pressure control controller212b.

A communication system configuration of the device controller240in the present embodiments will be described with reference toFIG. 7. Here, description of contents that are the same asFIG. 5is omitted as needed, and here, configurations and contents different fromFIG. 5will be mainly described.

The main control module201receives an event set in advance in a step during execution of the process recipe or the valve close instruction from the display device218, and the main control module201outputs a full close (valve close) instruction of the APC valve242to the process control module212. The process control module212having received the instruction outputs the full close (valve close) instruction to the pressure control controller212b. Here, from when the process control module212outputs the full close (valve close) instruction to the pressure control controller212bto when the process control module212acquires the close time from the pressure control controller212bis omitted since it is as explained inFIG. 5. Hereinafter following steps will be described.

The process control module212reports the close time obtained from the pressure control controller212bto the main control module201. At this time, the pressure value by the pressure sensor248and the degree of opening data of the APC valve242may also be reported at intervals of one second.

Furthermore, the main control module201is configured to report the pressure value by the pressure sensor248and the close time and the degree of valve opening data of the APC valve242to the host controller connected via the network at intervals of one second.

The host controller or the main control module201is configured to accumulate the reported various data and graphically display numerical values of the various data on the screen. For example, by placing the accumulated close time on the vertical axis and displaying the close time in order of execution of the process recipes, changes with time of the APC valve242can be confirmed. As a result, wear and deterioration situations of the APC valve242can be visually observed.

Further, the host controller or the main controller201may be configured to compare the close time with the threshold value, and may be configured to, for example, detect the operation abnormality of the APC valve242by comparing the acquired close time with the threshold value, and display the abnormality information of the APC valve242on the display device218.

The film forming step of the process recipe is illustrated in a simplified configuration on the upper side inFIG. 8. Process A is a process of purging the process furnace40(or process chamber42) (also referred to as N2 gas flow process of supplying an N2 gas as an inert gas), and process B included in process C described below is a process of fully closing the APC valve242and step time301is one second. Process C is a process of supplying the process gas (for example, the source gas), and step time302is about several seconds. Then, at least process A and process C (including the process B) repeat the processes as one cycle is disclosed. A configuration in which process B is provided between process A and process C, and process A→process B→process C is repeated as one cycle may be adopted. Note that process C is set to about 2 to 5 seconds, particularly preferably 2 seconds.

The horizontal axis ofFIG. 8is time, and time relevancy between the degree of opening data (unit: %) indicating open and close states of the APC valve242at the time of both of normal time and occurrence of valve abnormality and process B below the upper film forming step configuration of the process recipe. At the normal time, close time311ends within the step time301of process B. Here, a time T indicates a threshold value (unit: time) of the close time311and is set to a time that does not affect the thickness of film. For example, the arrow303illustrated by the dotted line indicates a case where the time T is set to the minimum time for securing a necessary amount of the process gas (source gas) in one cycle.

Here, the point of the present embodiments is that the close time311at the normal time falls within the range of the step time (set to one second)301of the process B. That is, the point indicates that the data including the close time311collected by the pressure control controller212bcan be acquired by the process control module212and the main control module201. Therefore, the threshold value (time) T of the close time311can be set to a time as close the close time311as possible in a shorter time than the data collection cycle (one second) of the process control module212and the main control module201. Therefore, in the present embodiments it is configured to be able to detect the abnormality of the APC valve242during the film forming step.

According to the conventional valve abnormality occurrence time illustrated inFIG. 8, the valve operation time increases and close time312far exceeds the step time301of process B, and time304in which the process gas (source gas) is supplied to the process furnace40is shorter than the above-described minimum time303. This shows that the flowrate of the process gas (source gas) decreases and affects the thickness of film.

However, when the actual close time is between the close time311and the step time301of process B, the close time cannot be conventionally measured. Therefore, to actually detect the abnormality of the APC valve242, the thickness of film of a sample wafer needs to be measured after processing (after completion of process). In this case, there is a possibility that the wafer14is processed in the next batch without noticing the valve operation abnormality.

Meanwhile, in the present embodiments, as illustrated inFIG. 5, the pressure control controller212bis configured to report the acquired valve operation time (including the close time) of the APC valve242to the process control module212. The process control module212is configured to confirm whether the acquired close time of the APC valve242exceeds the threshold value (time) T illustrated inFIG. 8, thereby detecting the valve operation abnormality in real time.

As described above, the process control module212can compare the acquired close time with the threshold value (time) while repeatedly acquiring the accurate close time of the APC valve242in real time during execution of the process recipe, thereby monitoring chronological behavior of data indicating operation delay time of the APC valve242.

Further, since the threshold value T of the close time is set within the step time301of process B, for example, if the valve61for supplying the source gas is opened at the threshold value T, not only the process gas can be more efficiently filled in the process furnace40(process chamber42) but also supply of the process gas can be stopped if abnormality occurs in the APC valve242.

In the present embodiments, the degree of valve opening of the APC valve242is configured to maintain 0% during process C. However, the degree of valve opening of the APC valve242may be adjusted to keep a predetermined constant pressure in the interior of the process furnace40(process chamber42). With the configuration, even in a process of repeatedly opening and closing the valve in a short time and supplying the process gas, the flowrate of the process gas flowing in the process furnace40can be stabilized.

According to the present embodiments, the accurate close time of the APC valve242can be monitored during execution of the process recipe, and for example, whether the APC valve242is approaching the state of affecting the thickness of film can be confirmed according to the opening and closing times of the APC valve242(particularly, the close time to full close). With the confirmation, the APC valve abnormality can be detected.

According to the present embodiments, the close time of the APC valve242is accumulated in the storage222of the main control module201or the host controller and displayed, whereby tendency of changing of the close time of the APC valve242can be monitored. For example, even in a process of repeatedly opening and closing the APC valve242in a short time and supplying the process gas to the process chamber, the amount of the process gas flowing in the process furnace is not changed, the influence on the thickness of film to be formed can be reduced.

Further, according to the present embodiments, if the time from the full open state to the full close state of the APC valve242is changed, the abnormality can be detected during execution of the process recipe (during the cyclic film formation), and measurement of the thickness of film of the sample wafer after completion of the process recipe, as in the conventional case, is not necessary. Therefore, reduction of maintenance time from error processing to restoration can be expected. Further, prevention of the next batch processing without noticing the abnormality of the thickness of film of the substrate can be controlled.

Furthermore, according to the present embodiments, in the process of repeatedly executing the process of supplying the process gas to the process chamber and the process of exhausting unreacted process gas from the process chamber in a short time, abrupt fluctuation of the gas flowing in the process furnace can be suppressed and the influence on the thickness of film to be formed can be reduced.

Further, according to the present embodiments, the main control module201or the host controller may be configured to detect the operation abnormality of the APC valve242by comparing the acquired close time with the threshold value, and display the abnormality information of the APC valve242on the display device218. With such a configuration, even if abnormality occurs in the operation of the valve during the cyclic film formation, the valve operation abnormality in the film forming step (during execution of the recipe) can be detected. Therefore, performing the next batch processing without noticing the abnormality of the thickness of film of the substrate or measuring the thickness of film of the sample wafer after completion of the process recipe, as in the conventional case, are not performed and are not necessary. Therefore, reduction of maintenance time from error processing to restoration can be expected.

Further, the film forming step according to this present disclosure is not limited to the cyclic film formation of repeating process A and process C according to the thickness of film in the present embodiments, and can also be applied to cyclic film formation process of adding a process D of supplying the reactant gas into the process furnace40(process chamber42) and setting process A, process C, process A, and process D as one cycle, and repeating the one cycle according to a target thickness of film. Further, the film forming step can also be applied to cyclic film formation of simply setting process C and process D as one cycle and repeating the one cycle according to a target thickness of film. Note that process B may be performed before process D or process B may be included in process D, as appropriate.

Further, as described above, the process furnace40according to this present disclosure is configured as a batch type device that processes a large number of wafers14, for example. However, this present disclosure is not limited to the configuration and may be applied to a single sheet device that processes the wafers14sheet by sheet or to a multiple sheet device that processes the wafers14in every plurality of sheets.

For example, in the above-described embodiments, the case where the substrate to be processed is a semiconductor wafer substrate has been described as an example. However, this present disclosure is not limited to the example and can also be applied to a substrate processing apparatus that processes a glass substrate, such as a liquid crystal display (LCD) device.

Further, for example, in the above-described embodiments, this present disclosure is not limited to the embodiments. That is, another film forming processing may be processing of forming an oxide film and a nitride film or processing of forming a film containing metal may be adopted. Further, specific contents of the substrate processing are unmentioned, and furthermore, this present disclosure can also be suitably applied to other substrate processing apparatuses such as an oxidation processing apparatus, a nitriding processing apparatus, and a CVD apparatus using plasma.

According to this present disclosure, an accurate time to close a pressure control valve can be obtained.